description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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FIELD OF THE INVENTION
The field of the invention relates to imaging systems, and more particularly to systems and methods for pattern recognition.
BACKGROUND OF THE INVENTION
A fundamental step in image interpretation is pattern recognition, which essentially involves the process of analyzing one or more pixels of a given image and assigning one or more pixels to one of a limited number of pre-defined categories, or classes, based on the value(s) of the one or more pixels. One or more of the pre-defined categories are the patterns, or features, to be recognized and extracted. As is known in the art, the algorithm to determine which category to assign a pixel of an image may be established by providing a generic computational procedure a large number of sample images for each category and having the computational procedure determine the characteristics for each category that are unique compared to the other categories, such as color or brightness.
The accuracy of this approach is dependent upon the effectiveness of the determined unique characteristics. For example, turning to FIG. 1 a , an image is shown having a generally circular region 10 of gray points in the center of the image. In one pattern recognition system, it may be desirable to identify and locate this circular region 10 in the image. To develop such a system, small regions of pixels are evaluated throughout the picture. By evaluating the values and/or patterns of certain characteristics, such as brightness or color, of each pixel, or regions of pixels, and mapping or graphing the values, unique characteristics may become apparent. For example, turning to FIG. 1 d , the brightness of each region of pixels is evaluated, and a mean value of brightness for each region of pixels is calculated along with a corresponding standard deviation and graphed according to its mean and standard deviation. From such a graphing, two groups become apparent, regions of pixels 14 associated with areas of the image within the circular region 10 and regions of pixels 16 associated with areas of the image outside the circular region 10 . From this information, pre-defined categories may be established, and the pattern recognition algorithm may be configured to evaluate regions of pixels, assign them to the appropriate categories, and extract the desired patterns or features.
However, often times, imaging systems may introduce imperfections, such as blurring, into the images they produce, and thus, may generate images such as that shown in FIG. 1 b instead of that shown in FIG. 1 a . The desired pattern, shown in the circular region 10 of FIG. 1 a , cannot be visually detected in FIG. 1 b . A pattern recognition system that can detect a desired pattern from such an image would be desirable.
SUMMARY OF THE INVENTION
The invention is generally directed to imaging systems, and more particularly to systems and methods for pattern recognition. In one embodiment, a medical imaging system includes an imaging device and a computer-usable medium, electrically coupled to the imaging device, having a sequence of instructions which, when executed by a processor, causes said processor to execute a process including generating an image from signals received by the imaging device, deconvolving the image, and then extracting a desired pattern from the deconvolved image.
In another embodiment, a process for pattern recognition includes the steps of generating an image, deconvolving the image, and then extracting a desired pattern from the deconvolved image.
Other systems, methods, features and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to better appreciate how the above-recited and other advantages and objects of the inventions are obtained, a more particular description of the embodiments briefly described above will be rendered by reference to specific embodiments thereof, which are illustrated in the accompanying drawings. It should be noted that the components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views. However, like parts do not always have like reference numerals. Moreover, all illustrations are intended to convey concepts, where relative sizes, shapes and other detailed attributes may be illustrated schematically rather than literally or precisely.
FIG. 1 a is an image having a plurality of patterns or features to be extracted;
FIG. 1 b is the image of FIG. 1 a with blurring introduced into the image;
FIG. 1 c shows an image with blurring;
FIG. 1 d is an image of FIG. 1 c after a deconvolution algorithm as been applied;
FIG. 1 e is a graph of a plurality of regions of pixels shown in FIG. 1 a;
FIG. 2 is a diagram of a basic block diagram of a preferred embodiment of the invention; and
FIG. 3 is a diagram of a preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Described below is a new pattern recognition method and system that extracts patterns or features from an image generated by an imaging system 20 comprising an imaging device 22 and a processor 24 , as shown in FIG. 2 . The imaging system 20 may be a medical imaging system and the imaging device 22 may be an ultrasound transducer or an apparatus for obtaining images using a light source, such as through optical coherence tomography (OCT). Image acquisition using OCT is described in Huang et al., “Optical Coherence Tomography,” Science, 254, Nov. 22, 1991, pp 1178-1181, which is incorporated herein by reference. A type of OCT imaging device, called an optical coherence domain reflectometer (OCDR) is disclosed in Swanson U.S. Pat. No. 5,321,501, which is incorporated herein by reference. The OCDR is capable of electronically performing two- and three-dimensional image scans over an extended longitudinal or depth range with sharp focus and high resolution and sensitivity over the range.
As mentioned above, an imaging system 20 may introduce imperfections, such as blurring, into a generated image, as shown in FIG. 1 c . One common approach to remove the imperfection is to computationally reverse the imperfection in the generated image. This is particularly effective when the imperfection is predictable or known. This approach is known in the art as deconvolution. In one method known in the art to create a deconvolution algorithm, an additional image of a single bright point source, such as a dot, is generated by the imaging system 20 . When the imperfection is present in the image, an algorithm is created that reverses the blurred image to recreate the actual image with better precision.
Once this deconvolution algorithm is created, it may applied to all images created by the imaging system 20 . To deconvolve such images, each image is represented as a plurality of points, preferably infinitesimal points, and the algorithm is applied to each individual point. One of ordinary skill in the art can appreciate that such an algorithm is effective only for limited types of imperfections, such as those created by a linear shifting variant system. There are many types of imperfections that may remain unaffected by deconvolution. Thus, as an example, for the image shown in FIG. 1 c , a typical deconvolution system will produce the image shown in FIG. 1 d , which shows slight improvement but still lacks the quality of the image shown in FIG. 1 a . For instance, the desired pattern in the circular region 10 still cannot be visually detected in FIG. 1 d . Such images are still disregarded as unhelpful.
However, even though the image in FIG. 1 d does not provide any visual help, there is still useful information that may be obtained from the deconvolution process. Turning back to FIG. 1 e , small regions of pixels may be evaluated throughout the image in FIG. 1 d . By evaluating the values and/or patterns of certain characteristics, such as brightness or color, of each pixel, or regions of pixels, and mapping or graphing the values, unique characteristics may still become apparent from the graph, even though they may not be visually apparent. For example, turning to FIG. 1 e , the brightness of each region of pixels is evaluated, and a mean value of brightness for each region of pixels is calculated along with a corresponding standard deviation and graphed according to its mean and standard deviation. From such a graphing, two groups may become apparent, regions of pixels 14 associated with areas of the image within the circular region 10 and regions of pixels 16 associated with areas of the image outside the circular region 10 . From this information, pre-defined categories may be established, and the pattern recognition algorithm may still be effective in extracting the desired patterns or features.
In other words, the deconvolution of an image may function as a contrast enhancer, which causes a better separation between categories. Accordingly, pattern recognition applied to such a deconvolved image may generate more accurate results.
Turning to FIG. 3 , an example embodiment of a new pattern recognition method is shown as applied to an image generated by a processor 24 of an imaging system 20 based on data received by an imaging device 22 , such as a medical imaging device, electrically coupled to the processor 24 . After the image is generated (step 100 ), particular regions of interest may be selected and segmented for further analysis (step 200 ). Subsequently, the segmented image may be deconvolved (step 300 ), using any known deconvolution method. After the deconvolution (step 300 ), the pixels, or regions of pixels, of the image may be assigned to pre-defined categories, and then the desired feature(s) may be extracted (step 400 ) and further evaluated in search for a desired pattern (step 500 ).
In the foregoing specification, the invention has been described with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention. For example, the reader is to understand that the specific ordering and combination of process actions described herein is merely illustrative, and the invention may appropriately be performed using different or additional process actions, or a different combination or ordering of process actions. For example, this invention is particularly suited for applications involving medical imaging devices, but can be used on any design involving imaging devices in general. As a further example, each feature of one embodiment can be mixed and matched with other features shown in other embodiments. Additionally and obviously, features may be added or subtracted as desired. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents. | The invention is generally directed to imaging systems, and more particularly to systems and methods for pattern recognition. In one embodiment, a medical imaging system includes an imaging device and a computer-usable medium, electrically coupled to the imaging device, having a sequence of instructions which, when executed by a processor, causes said processor to execute a process including generating an image from signals received by the imaging device, deconvolving the image, and then extracting a desired pattern from the deconvolved image. | 6 |
BACKGROUND OF THE INVENTION
Various solar collector - skylight assemblies have been proposed wherein the assembly is constructed and arranged to function not only as a solar heater, but also as a skylight to illuminate the interior of a building upon which the assembly is mounted. Examples of such assemblies are disclosed in U.S. Pat. Nos. 4,144,931 dated Mar. 20, 1979; and 4,219,008 dated Aug. 26, 1980. These assemblies include shutters or vanes adapted for movement between a heat absorption position, wherein the assembly functions as a solar heater, to a second position allowing the sun rays to pass through the solar collector, whereby the assembly functions as a skylight.
The solar collector - skylight assembly of the present invention is an improvement over the prior art solar collector - skylight assemblies, in that, in lieu of vanes or shutters, parabolic reflectors are employed for not only focusing the sun rays on the collector during the solar heater phase, but also for focusing the sun rays through the collector during the skylight phase of operation. By this construction and arrangement, the fluid flowing through the solar collector is more efficiently heated, and more sunlight is directed into the interior of the building than provided heretofore.
The solar collector - skylight assembly of the present invention comprises essentially, a housing adapted to be mounted on the roof or wall of a building, the housing having a transparent top wall and a translucent bottom wall. A plurality of fluid circulating pipes, having heat absorbing plates secured thereto, are mounted within the housing, and a plurality of parabolic reflectors are slidably mounted within the housing in proximity to the fluid circulating pipes whereby the reflectors are shiftable from a heat absorbing position wherein the sun rays are focused on the pipe heat absorbing plates, to a skylight position wherein the sun's rays are focused into the interior of the building. A temperature responsive control mechanism is operatively connected to the reflectors for shifting the reflectors between full heat absorbing and skylight positions, and also to intermediate positions wherein simultaneous adjustment of the solar energy absorbed by the solar collector and amount of illumination in the building can be obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the solar collector-skylight assembly of the present invention;
FIG. 2 is a view taken along line 2--2 of FIG. 1;
FIG. 3 is a view taken along line 3--3 of FIG. 2;
FIG. 4 is a fragmentary, sectional, side elevational view of another embodiment of a collector tube employed in the solar collector-skylight assembly of the present invention;
FIG. 5 is a side elevational view of the solar collector-skylight assembly of the present invention;
FIG. 6 is a side elevational view of the motor assembly employed for moving the concentrators from the solar heater position to the skylight position;
FIG. 7 is a fragmentary, side elevational view of another embodiment of a drive arrangement for moving the concentrators, and
FIG. 8 is a schematic of the electrical circuit employed in the solar collector-skylight assembly of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings and more particularly to FIGS. 1, 2 and 3 thereof, the solar collector-skylight assembly 1 of the present invention comprises a rectangular housing formed by a pair of side channel members 2 and 3, and end channel members 4 and 5. The top of the housing is provided with a clear, transparent low-iron glass cover 6 secured to the top of the channel members, and the bottom of the housing is covered with a translucent light-diffusing or non-diffusing glazing material 7, such as Rohm Haas-Twinwall material or glass. A plurality of transversely extending fluid circulating pipes 8 are mounted within the housing, the pipes being connected at one end to an air or water inlet manifold 9 and at the other end to an outlet manifold 10.
Each pipe 8 has a dark coated heat absorbing plate 11 secured to the upper surface thereof in heat conducting relationship to the fluid flowing through the pipes 8, the remainder of each pipe having a suitable heat insulating material 12 such as fiberglass secured thereto. The outer surface of the insulation material is provided with a specular reflective or diffuse reflective material 13.
While the heat absorbers shown in FIG. 2 employ flat absorber plates 11 insulated on their back surfaces to prevent heat loss, the absorber shown in FIG. 4 can be employed wherein the pipe 8 and associated absorber plate 11 are positioned within an evacuated transparent tube 14.
In order to direct sun rays into the absorber plates 11 when the assembly of the present invention is being utilized as a solar heater, a parabolic reflector is provided for each plate. As will be seen in FIGS. 2 and 3, each reflector comprises a pair of parabolic segments 15 and 16, each segment 15 being integrally connected as at 17 to the next adjacent segment 16. The segments 15 and 16 are secured to a pair of longitudinally extending channels 18 forming a track engaged by rollers 19 secured to the housing channel members 4 and 5. By this construction and arrangement, when the segments 15 and 16 are in the solid line position, as shown in FIG. 2, the sun rays are focused on the absorber plate 11, to thereby heat the fluid flowing through the pipe 8. When the segments 15 and 16 are moved in the direction of the arrows shown in FIG. 2, to the dotted line position, the sun's rays are obstructed from the absorber plates 11 and focused through the bottom wall 7 of the housing into the interior of the building upon which the device is mounted, to thereby function as a skylight.
The parabolic reflectors are designed to have an acceptance angle α shown in FIG. 2, selected sufficient to accommodate the solar altitude or zenith angle for the desired range of hours of operation in the particular locality in which the solar collector - skylight assembly is to be located.
The mechanism for shifting or sliding the parabolic reflectors within the housing 1 is shown in FIGS. 5 and 6, wherein it will be seen that a tension spring 20 is connected between the end of each channel member 18 and the adjacent side channel 2 of the housing. A pull cable 21 is connected to the opposite end of one of the channels 18 and extends around a pulley 22 and secured as at 23 to the free end of a rocker arm 24, the opposite end of the arm 24 being pivotally mounted as at 25 to a fixed support 26 within a housing 27. The rocker arm 24 is provided with a longitudinally extending slot 28 through which the free end of a pin 29 extends, the opposite end of the pin being connected to a rotary disc 30 connected to the drive shaft of a motor 31 (FIG. 8). By this construction and arrangement, when the motor 31 is energized, the disc 30 is caused to rotate in a counterclockwise direction to move the rocker arm 24 to the dotted line position shown in FIG. 6. As the rocker arm 24 moves, the cable 21 pulls the channel 18, thereby shifting the position of the parabolic reflectors to the position shown and described hereinabove in connection with FIG. 2, while extending the spring 20. Continued rotation of the disc 30 will cause the rocker arm 24 to pivot in the opposite direction, thereby slackening the cable 21, whereby the parabolic reflectors are shifted back to their original position by the restoring force of the tension spring 20. In order to limit the movement of the rocker arm 24 during the slackening of the cable 21, a tension spring 32 is connected between the arm 24 and housing 27. While not shown, it will be understood that the pulley 22 and housing 27 are mounted on the side of the solar collector skylight housing 1.
Another embodiment for moving the channel 18 and associated parabolic reflectors is shown in FIG. 7, wherein a rack 33 is secured to the bottom of channel 18 and meshes with a pinion 34 secured to a shaft 35 journalled in the housing end wall 4. A pulley 36 is also secured to the shaft 35, and the cable 21, having one end secured to the side wall of the housing, extends around the pulley and is connected to the rocker arm mechanism shown in FIG. 6.
The circuit for controlling the operation of the solar collector - skylight assembly 1 is shown schematically in FIG. 8 wherein a control mechanism 37 is electrically connected between a main switch 38 and a relay 39 to a pump 40 for circulating fluid to be heated through the pipes 8, the motor 31, a dipole, double throw switch 41, and a manual limit switch 42. The control mechanism 37 is also connected to suitable sensors 43 which sense not only the temperature of the fluid flowing through the collector and the temperature in the interior of the building upon which the solar collector - skylight assembly is mounted, but also the light intensity within the building, whereby the information obtained by the control mechanism 37 is employed to control the pump 40 and motor 31, to thereby move the parabolic reflectors to full heat absorption position, to full light transmission position, or to a desired intermediate position.
It is to be understood that the form of the invention herewith shown and described is to be taken as a preferred example of the same, and that various changes in the shape, size and arrangement of parts may be resorted to, without departing from the spirit of the invention or scope of the subjoined claims. | A solar collector-skylight assembly having movable parabolic concentrators wherein, in one position the parabolic concentrators direct solar energy to a collector to heat fluid circulating therethrough to thereby provide a solar heater; and when the concentrators are moved to another position, the assembly functions as a skylight wherein the solar energy is allowed to pass through the collector, to thereby illuminate the interior of a building upon which the solar collector-skylight assembly is mounted. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. provisional patent application Ser. No. 60/968,844, filed on Aug. 29, 2007 and entitled “Portable Light Source Shade,” which is incorporated by reference herein in its entirety.
FIELD
[0002] The subject matter disclosed herein relates to shade devices for use with portable light sources.
BACKGROUND
[0003] Military units, such as for example special forces or other troops who are active at night, can use small, lightweight, inexpensive portable light sources such as chemiluminescent light sticks as light sources to provide lighting needs. These light sources can also be used in other applications, such as for example by hunters, law enforcement personnel, campers, and the like; as well as in any other situation requiring inexpensive, lightweight, long-lasting light. In some situations, emission of stray light from such devices could present a danger, for example by betraying a military unit's position to enemy forces, or an inconvenience, for example by ruining a hunter's night vision in directions away from the light source. Additionally, these portable light sources tend to be omni-directional while tasks that require lighting might be better served with a more directed beam from the light source.
SUMMARY
[0004] In a first aspect, an apparatus includes a flexible device that has a first side, a second side shaped substantially similarly to the first side, an outer edge, a first joining edge, and a second joining edge. The flexible device is approximately flat with the first and the second sides disposed opposite one another such that the outer edge joins the first side and the second side along a substantial portion of a perimeter of the first side and the second side. The first joining edge and the second joining edge define a gap such that the outer edge does not continue uninterrupted around the entire perimeter of the flexible device. The flexible device flexes to form an assembled structure in which the first joining edge is disposed proximate to the second joining edge. The assembled structure encloses an inner volume with a first opening that is defined by the outer edge and an apex disposed opposite the first opening. The apex has a smaller cross sectional area than the first opening. The first side forms an inner surface of the assembled structure and the second side forms an outer surface of the assembled structure. The apparatus also includes joining means for connecting the first joining edge and the second joining edge and attaching means for securing a portable light source to the assembled structure to direct light from the portable light source in a desired manner. The portable light source has an elongated shape along a first axis and emits light both in the directions of the first axis and perpendicular to the first axis.
[0005] In an interrelated aspect, a method includes curving a flexible device such as those described herein into an assembled structure, securably connecting the first joining edge and the second joining edge of the flexible device; and attaching a portable light source to the assembled structure to direct light from the portable light source in a desired manner. The portable light source can have an elongated shape along a first axis and emit light both in the directions of the first axis and perpendicular to the first axis.
[0006] In optional variations, one or more of the following additional features can be included. The first side can include a reflective surface. The second side can include a dark colored and opaque surface. The attaching means can include a strap that wraps around the portable light source around the axis of the portable light source, thereby securing the portable light source to the assembled device. The flexible device can include a notch disposed approximately near a center of the flexible device. The notch can form a second opening that is opposite and smaller than the first opening when the flexible device forms the assembled structure.
[0007] The attaching means can include a strap disposed near the notch. The strap can wrap around the portable light source around the axis of the portable light source thereby securing the portable light source to the assembled structure with at least part of the portable light source extending out of the second hole to outside of the assembled structure. A remainder of the portable light source length along the axis can extend into the inner volume of the assembled device toward or out through the first opening. Alternatively, the portable light source can be secured to the assembled structure with at least part of the portable light source extending into the second hole to the inner volume of the assembled structure such that a remainder of the portable light source length along the axis extends outside the assembled device in a direction opposite the first opening so that the portable light source is supported by the assembled structure to form a free standing lantern device. The second side of the flexible device can include a reflective material and be oriented facing outward away from the inner volume in the assembled structure to reflect light from the portable light source outward and upward in the free standing lantern device.
[0008] The attaching means can include a light source affixing device that includes a socket side with a socket that accepts an end of the portable light source and an attachment side that can further include a tapered portion and a head with a larger cross section than the tapered portion. The head can be disposed at an opposite end of the tapered portion from the socket side. The socket can include a flexible or semi-flexible material that resiliently expands at least slightly to accept the end of the portable light source. The apex of the assembled structure can include a gap or opening that is large enough to accept the tapered portion but not to allow the head or the socket section to pass. The light source affixing device can be oriented in the assembled structure such that the socket section is disposed outside of the assembled structure so that the socket faces away from the first opening such that the portable light source affixed in the socket is supported by the assembled structure to form a free standing lantern device. The second side of the flexible device can include a reflective material and be oriented facing outward in the assembled structure to reflect light from the portable light source outward and upward in the free standing lantern device.
[0009] The apparatus can further include the portable light source, which can be a chemiluminescent light stick. The outer edge can define a substantial portion of a circle and the first joining edge and the second joining edges can each be perpendicular to the outer edge and each define a substantial portion of a diameter of the circle such that the first and the second sides are each circular with a fraction of the circle missing as defined by a gap between the first joining edge and the second joining edge. The assembled structure can include an approximately 45 degree cone-shaped shade with an approximately ⅝″ diameter second opening at the apex. An adjustable carrying strap can also be include at the apex.
[0010] The current subject matter can provide, among other potential benefits and advantages, a portable, adaptable device for shading and/or directing light from a portable light source. The subject matter can also provide a portable base for a light source. Among other potential benefits of the subject matter described herein, a rugged, lightweight, and versatile shade can be provided that directs light from a portable light source, such as for example a chemiluminescent light stick in a desired direction while minimizing light emission in other directions. This capability can be very useful in applications in which light is needed to perform various tasks but in which emission of the light outside of a controlled area can be undesirable. For example. The current subject matter provides a lightweight, inexpensive device that can be used in one example to direct the majority of the lighting power from a portable light source in one direction and to prevent light from escaping in other directions.
[0011] The details of one or more variations of the subject matter described herein are set forth in the accompanying drawings and the description below. Other features and advantages of the subject matter described herein will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0012] The accompanying drawings, which are incorporated in and constitute a part of this specification, show certain aspects of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed embodiments. In the drawings,
[0013] FIG. 1 is a schematic diagram showing a first side of a light shade device in a disassembled state;
[0014] FIG. 2 is a schematic diagram showing a second side of a light shade device in a disassembled state;
[0015] FIG. 3 is a schematic diagram showing a first isometric view of a light shade device in an unassembled state;
[0016] FIG. 4 is a schematic diagram showing a second isometric view of a light shade device in an unassembled state;
[0017] FIG. 5 is a schematic diagram showing a first isometric view of a light shade device in an assembled state;
[0018] FIG. 6 is a schematic diagram showing a first isometric view of an assembled light shade coupled to a portable light source;
[0019] FIG. 7 is a schematic diagram showing a second isometric view of an assembled light shade coupled to a portable light source;
[0020] FIG. 8 is a schematic diagram showing an isometric view of a light shade device in an assembled state;
[0021] FIG. 9 is a schematic diagram showing an isometric view of a light shade device in an assembled state with a portable light source installed to form a self-supporting lantern configuration;
[0022] FIG. 10 is a schematic diagram showing an example of an alternative portable light source affixing device; and
[0023] FIG. 11 is a process flow diagram describing a method according to the current subject matter.
DETAILED DESCRIPTION
[0024] The current subject matter can be implemented in a variety of configurations that each provide one or more of the aforementioned beneficial features. The following descriptions are addressed to an example implementation that include a device that is shaped approximately like a substantial portion of a flexible, circular disk having a central hole and means for connecting two joining edges of the disk to form a cone with a first opening near its apex and a larger second opening opposite the apex. A portable light source, perhaps having an elongated shape, can be secured within the first hole or otherwise near the apex of the cone such that the body of the light source is directed toward and possibly beyond the extent of the larger second opening. In this manner, the material forming the cone can prevent light from the light source from being projected outside of the device in the general direction of the apex of the cone. The interior surface of the assembled device can include a reflective coating that increases the intensity of light being projected out of the second opening of the device and in a general direction away from the apex. It will be readily understood that other geometrical shapes besides a circular disk and a cone are within the scope of the currently disclosed subject matter.
[0025] FIG. 1 and FIG. 2 are diagrams of opposite sides of a such a flexible device 100 . The first side 102 of the flexible device 100 is shown in FIG. 1 and the second side 202 is shown in FIG. 2 . The view of the flexible device 100 in FIG. 2 represents the results of a rotation of the flexible device 100 about the axis 101 . The first side 102 includes a circular shaped piece of semi-rigid or flexible material such as for example plastic, cardstock, or the like. The flexible device 100 can in some examples be opaque or approximately opaque and can further be optionally covered on the first side by a material that is durable to environmental conditions, such as for example nylon cloth, canvas, or the like. The first side 102 of the flexible device 100 can optionally be colored black or some other dark color to cut down on visibility and/or pass-through of light when the flexible device 100 is assembled and mated with a portable light source as further described below. The flexible device 100 further includes an outer edge 104 that extends, in the example shown, for some fraction (in the example shown, about 75%) of the arc of a complete circle. In the example shown, in which the flexible device 100 is approximately circular, the outer edge 104 is curved and smooth. Neither the curvedness nor the smoothness of the outer edge 104 are necessary features in all possible implementations. The outer edge 104 is disposed between a first joining edge 106 and a second joining edge 110 .
[0026] A notch 112 can also be provided approximately in the center of the flexible device 100 . In the example shown, the notch 112 is curved in the shape of an arc describing about 75% of a circle. Other shapes of the notch 112 are possible as well. In some implementations, the notch 112 and the outer edge can define approximately congruent shapes to give the device 100 some degree of rotational and/or axial or planar symmetry when it is fully assembled. The notch 112 can also optionally be shaped to be compatible with the shape of a portable light source. A curved, circular notch 112 as shown in FIG. 1 and FIG. 2 can be used for a cylindrical light source. Other shapes of the notch 112 can be used for, for example rectangular or triangular cross sections of the portable light source. The notch 112 can also be encircled by a collar 114 that can have a securing flap 116 . The collar 114 and the securing strap 116 can include a fastener or attaching segment such as for example a hook and loop connector like Velcro™ that allow the collar to be wrapped and secured with some snugness around a portable light source that is inserted into the notch 112 .
[0027] The flexible device 100 can also include a connection means, such as for example a fastener device or devices or other means of affixing the first joining edge 106 and the second joining edge 110 . In one example, as shown in FIG. 1 and FIG. 2 , a first strip 120 of a hook and loop fastener system is attached near the second joining edge 110 on the first side and a second strip 220 of a hook and loop fastener system is attached near the first joining edge 106 on the second side 202 . The fastener system can be a hook and loop system as described, or can alternatively be one or more adhesive strips that can be either removable and reusable (such as the adhesive found on Post-It™ notes available from 3M of Minneapolis) or permanent. A piece of adhesive tape can alternatively be provided, and this can be a double-sided adhesive adhered to one side of either the first joining edge 106 or the second joining edge 110 . Alternatively, the tape can extend from one of the first joining edge 106 or the second joining edge 110 such that it can extend onto the same side of the device 100 over the opposite joining edge when the joining edges are brought together. The fastening system can also be of a mechanical design, such as for example a tab and slit or hook and slit design. The second side 202 of the device 100 can include silvering or some other reflective surface or surface treatment that can reflect light from the portable light source.
[0028] Additional perspective views of a flexible device 100 that is consistent with the current subject matter are shown in the isometric diagrams of FIG. 3 and FIG. 4 . FIG. 3 and FIG. 4 , which provide two additional views of the first side of the device 100 , show the collar 114 and securing flap 116 as well as an additional attachment loop 302 that extends above the collar 114 and can be used, for example to hang the device from an elevated support or to secure the device to clothing, equipment, etc. Other shapes and sizes of such an attachment loop 302 can be used with the current subject matter depending on the desired application of the flexible device 100 .
[0029] FIG. 1 through FIG. 4 show the flexible device 100 in a configuration appropriate for storage, sale, or transport. FIG. 5 through FIG. 8 show the flexible device in an assembled configuration 500 in which it is ready for or actually in use. In these figures, the flexible device has been wrapped around itself to form a cone-shaped shade 500 with the first side 102 facing outward and the second side 202 facing inward. The second joining edge 106 overlaps the first joining edge such that the first strip 120 and the second strip 220 (not shown in FIG. 5 ) of the fastener system mate and secure to one another. The outer edge 104 of the flexible device 100 forms a first, larger opening 502 at the base of the assembled device 500 , which in this example resembles a cone. The collar 114 and the securing strap ( 116 but not shown in FIG. 5 ) are wrapped around a second opening 504 formed by the notch ( 112 but not shown in FIG. 5 ). In one example, when the first joining edge 104 and the second joining edge are affixed, a 45 degree cone-shaped shade 500 with an approximately ⅝″ diameter second opening 504 at the top is formed. Other sizes and shapes of the second opening 504 and the assembled device 500 can be used depending on the specific application.
[0030] The second opening 504 can accept a portable light source 602 , such as for example a chemiluminescent stick or similar sized light source as shown in FIG. 6 . The portable light source 602 can optionally be secured in place by the collar 114 and the securing flap 116 . As noted above, the surface of the second side 202 of the flexible device 100 can include a silvered or other reflective material as shown in FIG. 5 and FIG. 6 , thereby allowing the assembled device 500 to reflect light emitted from the portable light source and focus it out the first, larger opening 502 at the base to create a narrower, more concentrated and directional light source than the portable light source 602 would create absent the assembled device 500 . Because the material that makes up the flexible device 100 can be completely opaque, when the assembled device 500 is held facing outward (in other words, facing the exterior of the assembled device 500 ), the material of the device can completely or nearly completely shield a user's eyes from the portable light source 602 , thereby greatly increasing the usefulness of the projected light.
[0031] The flexible device 100 can also in some implementations be constructed so as to be capable of being assembled in a reversible configuration as shown in FIG. 9 . In this example, the reversed assembled device 900 can stand inverted and unassisted and thereby support a portable light source 602 in a vertical or approximately vertical orientation. If the flexible device 100 includes a reflective surface 202 as discussed above, this surface can be oriented facing outward to reflect light from the portable light source 602 in an outward and/or upward direction, thereby forming a portable, lightweight, and inexpensive lantern 900 that could be used on a table or other surface.
[0032] The current subject matter also includes portable light source shade designs that include neither a notch 112 in the unassembled device nor a second hole 504 near the apex of the assembled device 500 . In such implementations, an inner collar or other comparable means for affixing a portable light source 602 can be included on the second side 202 of the flexible device 100 . An example of such a device is shown in FIG. 10 . A portable light source affixing device 1000 can be included with the flexible device 100 described above. Such a portable light source affixing device 1000 can include a socket side 1002 and an attachment side 1004 . The socket side 1002 of the portable light source affixing device 1000 can include a socket 1003 made of a flexible or semi-flexible material that can resiliently expand at least slightly to accept the end of a portable light source 602 . The attachment side 1004 of the portable light source affixing device 1000 can include a tapered portion 1006 with an at least slightly larger head 1010 . When a flexible device 100 that does not include a notch 112 is formed into the assembled device 500 , the tapered portion 1006 can be fitted at the apex of the assembled device such that the larger head extends above the apex of the assembled device to the outside of the cone or other shape formed by the assembled device. When the first and second connecting edges 106 , 110 are connected as described above, this configuration can effectively trap the portable light source affixing device 1000 with the socket side 1002 and socket 1003 directed toward the first, larger opening 502 of the assembled device 500 . A portable light source 602 can then be fitted into the socket 1003 such that the assembled device functions as described above. The portable light source affixing device 1000 can alternatively be reversed in the assembled device 500 such that the socket side 1002 is on the outside of the assembled device 500 to create a lantern device similar to that shown in FIG. 9 . As in FIG. 9 , in this configuration, the flexible device 100 can be reversed in forming the lantern 900 such that the reflective second side 202 faces outward.
[0033] FIG. 11 shows a process flow diagram 1100 that illustrates an exemplary method consistent with the currently disclosed subject matter. At 1102 , a flexible device is formed into an assembled shade device structure, such as is described above. At 1104 , the first joining edge and the second joining edge of the flexible device are securably connected using an attaching means. At 1106 , a portable light source is attached to the assembled structure to direct light from the portable light source in a desired manner, the portable light source having an elongated shape along a first axis and emitting light both in the directions of the first axis and perpendicular to the first axis.
[0034] Although a few variations have been described in detail above, other modifications are possible. For example, the logic flow depicted in the accompanying figures and described herein do not require the particular order shown, or sequential order, to achieve desirable results. Other embodiments may be within the scope of the following claims. | A low cost, lightweight device that can be coupled with a portable light source such as a chemiluminescent light stick to create a small, focused and directional source of light. The device can be readily dismantled into a portable flat configuration and then reassembled with minimal effort as needed. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to using indexes to retrieve stored information.
Information in a relational database 10 (FIG. 1 ), for example, is stored as records 14 a , 14 b , . . . in tables 12 a , 12 b , . . . Each record contains data values for one or more fields 16 a , 16 b, . . . .
In a database of financial accounts, a table called ACCOUNTS may have a record for each financial account. The fields of the ACCOUNTS table could include an account identifying number (ACCT_ID) and a tax reporting number (TRN). The database may have other tables, and relationships may be defined between fields of different tables.
One simple, but often inefficient way to find a record that pertains to a given ACCT_ID is to search through the table, record by record, for the one that has that ACCT_ID.
To avoid having to do a full record-by-record search, a database system typically allows a user to define an index 20 for the table. The index has a field 22 a that contains values of a “key” field of the table, e.g., field 16 a . The entries of the index may be organized in a way that makes it easy to find an index entry that has a certain key value. For example, the index entries may be sorted in the numerical order of the values in the key field.
Each index entry contains a key value and an associated locator 24 that points to the location of the table record that corresponds to the key value of the record. Once a desired field value is found in the index, the table record can be accessed quickly using the locator.
Although an index consumes additional storage space without adding any more information to what is already in the tables of the database, the use of an index for retrieval saves other computer resources because the index is faster to search. On the other hand, additional computer resources are required to deal with the index when new records are inserted or records are deleted in the table and may be required when records are updated. These operations on records may require changing the corresponding entry in one or more indexes.
As an example of an index search, if the index key field 22 a corresponds to ACCT_ID numbers in field 16 a of the table then a desired TRN in field 16 b corresponding to a known ACCT_ID value can be quickly retrieved by searching the index for the entry that has the known ACCT_ID value and then accessing the table record that is identified by the locator found in that index record. Yet even this simple process can use a lot of computer resources if there is a high rate of database queries in which an index is searched for an ACCT_ID and the records are accessed to get the corresponding TRN.
Database systems allow a user to create a special kind of index, called a composite index, in which (in our example) the TRNs from the table appear in a second field of the index, as part of a composite key, together with the corresponding ACCT_ID key field. (Composite keys are also known as concatenated keys, compound keys, and multi-field keys.) This permits a simplified search process, called index-only searching, in which a TRN is retrieved directly from the index without having to access an underlying table record.
If the key value in each entry of an index is unique, it is possible to locate unambiguously a single record associated with a given value of the key. Database systems therefore allow a user to specify that an index have a key that is unique. The database system is capable of enforcing the uniqueness of the key but doing so costs computer resources.
In unique indexes, all fields of the index taken together determine uniqueness. In our example, if there were a unique index on the ACCT_ID and TRN fields, the entire combination would be analyzed in determining uniqueness.
SUMMARY OF THE INVENTION
The computer resources that must be expended to perform an index search of a database table may be reduced by storing, in the index, additional information (extra data) from, e.g., the associated table and refraining from using the extra data when searching. Such an index may be called an augmented index. Although the extra data, e.g., is not used for searching, it can be used to return data for an index-only search. The key and/or the extra data in an augmented index can contain more than one field.
A useful kind of augmented index has a unique key and is called a unique augmented index. In a unique augmented index, the uniqueness constraint is not enforced on the extra data but only on the unique keys portion of the index entry.
The invention is also useful with a conventional composite unique index which is redundant with a “smaller” unique index (i.e., the key fields of the smaller index are a proper subset of the key fields of the larger index). In earlier systems, the uniqueness constraint would be enforced on the composite index. Using the invention, the uniqueness constraint need only be enforced on the “smaller” unique index, which saves computer resources.
Thus, in general, in one aspect, the invention features a method for use in retrieving information from computer-stored records. An index of entries is provided that contains values that are keys for respective the stored records, the keys being used to reduce the time required to locate records. Additional information, included in the index of entries, is used for a purpose other than to reduce the time required to locate records. In connection with computer operations associated with the index, the additional information is treated in a manner different from the manner in which the keys are treated.
Implementations of the invention may include one or more of the following features. The index may be an index to a single table of a database or a join index to at least two tables. The index may be unique or non-unique. The keys may be used for locating records or checking uniqueness. The additional information may be derived from the records of the database (or other stored records) and may be used as data. The additional information may be stored in the index in a compressed form and may be of at least two different types.
In general, in another aspect, the invention features a method of forming an index for use in retrieving information from computer-stored records. As before, the entries contain values that are keys for respective ones of the stored records. At least some of the entries also contain additional information. Data is also stored that identifies the additional information as information that need not be treated as unique during computer operations associated with the index. In implementations of the invention, the data that is also stored may include a bit map pointing to fields that contain additional information or may include a value that indicates a number of fields that contain additional information.
In general, in another aspect the invention features providing a composite unique index of entries that contain values that are keys for respective ones of the stored records, the keys being used to reduce the time required to locate records, the key fields including a proper subset of key fields that are a smaller unique index of the entries. In connection with computer operations associated with the index, the key fields that are not part of the proper subset are treated in a manner different from the manner in which the key fields in the proper subset are treated.
Among the advantages of the invention are one or more of the following.
A unique augmented index has essentially the same size and can be maintained (after an insert, update, or delete) in essentially the same way and at essentially the same cost as a single corresponding conventional unique index. One augmented index can provide the functionality and performance of two (or more) conventional indexes. Thus the augmented index can render some conventional indexes superfluous, making it unnecessary to create or maintain them. Database operations are improved because less main memory is used. Fewer index entries are read during index-only access. Better query optimization is achieved because there are fewer indexes to consider. Database administration is easier because there are fewer indexes to create and manage. A unique augmented index can both enforce uniqueness and provide the improved performance of an index-only access. Less secondary memory (disk space) is used by one augmented index compared with multiple conventional indexes. Most database systems keep a main memory cache of frequently used database blocks to avoid reading them from secondary memory each time they are needed. Eliminating the superfluous index saves space in the cache.
Other advantages and features will become apparent from the following description and from the claims.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1 through 5 show database tables and indices.
FIGS. 6 and 7 are flowcharts.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An index can be modified to reduce the computational resources needed to use and maintain it, by augmenting the index with additional information in the index entries. As seen in FIG. 2, in the resulting “augmented index” 50 we call the additional information “extra data” 52 . Typically the extra data 52 in an index entry 54 consists of values 56 from one or more fields 60 from the data record 62 (in a table 64 ) to which the locator 58 points. In some sense this makes the entry resemble a composite index. However, in the augmented index 50 the extra data is distinct from the key 59 . The database has been instructed to know which part of the index entries is the augmented index and which part is the extra data.
Because of the conceptual distinction between the key and the extra data, it is possible to create a particularly useful kind of augmented index called a “unique augmented index” in which the uniqueness constraint is enforced on the key 59 , but not on the extra data 52 . The unique augmented index can provide the functionality and performance of two (or more) conventional indexes. As seen in FIG. 3, the key or the extra data may each have more than one field 70 or 72 .
A conventional index is either unique or not in its entirety. If the index is a unique index, all the fields in the key are part of the unique key and the uniqueness constraint is enforced with respect to the entire unique key.
By contrast, as suggested in FIG. 4, a unique augmented index 80 may be viewed as a set of fields 82 , 84 , 86 , 88 , in which the uniqueness constraint is based on a subset of the fields 82 , 84 , and is not based on others of the fields 86 , 88 . The fields on which the uniqueness constraint is based are the key fields. If the index of FIG. 4 were a composite index, all of the fields would be associated with the uniqueness constraint and all would comprise the key.
To enforce the uniqueness, the unique augmented index 80 could include as few as one bit 90 of control data for each field 82 . . . 88 to indicate whether that field is part of the uniqueness constraint. All of the bits 90 may be held in a data structure 92 . In the example of FIG. 4, one-valued bits indicate fields that are included in the uniqueness constraint (i.e., are part of the key) and zero-valued bits indicate fields that are not included in the uniqueness constraint (i.e., are extra data). The algorithms used for inserting new entries into or deleting entries from index 80 enforce the uniqueness constraint with respect to the fields flagged with one-bits and ignore the fields flagged with zero-bits. By contrast, a conventional index includes (in essence) a single bit that indicates whether the index as a whole is unique.
In the example of FIG. 4, the data structure 92 contains one bit for each field and is therefore general enough to control an index in which the key and extra data fields appear in any order. In indexes in which the order of fields is constrained so that key fields all appear adjacent to each other, e.g., first, and extra data fields all appear elsewhere, the data structure could simply record the number of key fields. Using a single 8-bit byte, for example, would support up to 255 fields in the key.
A unique augmented index uses essentially the same amount of computer resources as the corresponding unique conventional composite index. But because the augmented unique index permits both index-only access and enforcement of the uniqueness constraint, it permits the physical database design to have only one index, whereas using conventional indexes would have required two. The elimination of one or more conventional indexes yields the benefits described above.
A possible syntax of a statement that could be provided in SQL to enable a user to create an augmented index would be:
CREATE [UNIQUE] INDEX I ON T (K 1 [,K 2 . . . ])AND (E 3 [,E 4 . . . ])
Square brackets mean that the syntactic construct is optional, and ellipses mean that the item may be repeated.
For example, The key (K) and/or the extra data (E) may have one or more fields. If the keyword UNIQUE appears, as in the case of a unique augmented index, the uniqueness constraint is enforced but only on the key portion, K 1 , K 2 . . . . We now consider a specific example that illustrates differences between conventional and augmented indexes.
Referring to FIG. 5, in a table 100 of records 102 containing data about customers, each customer is identified by an account number in a field named ACCT_ID 104 , which is the “primary key”. Each account record also stores a tax reporting number in a field named TRN 106 . Suppose that a frequent query is “Given a value for ACCT_ID, return the associated TRN”.
If only conventional indexes are available, the database designer would define a unique index 108 (called U for “unique”) needed to enforce integrity, using a standard SQL statement:
CREATE UNIQUE INDEX U ON ACCT (ACCT_ID)
If the benefit of index-only access to TRN is worth the cost in computer resources, the designer could also define a composite index 110 (called C for “composite”), using a standard SQL statement:
CREATE UNIQUE INDEX C ON ACCT (ACCT_ID, TRN)
These two conventional indexes could be replaced by a single unique augmented index 112 (called A for “augmented”) that would be created using a new type of SQL statement:
CREATE UNIQUE INDEX A ON ACCT (ACCT_ID) AND (TRN)
This statement would indicate to the database system that only the key field ACCT_ID should be checked for uniqueness. Because ACCT_ID alone is a unique key, the value for field TRN can be treated as extra data and is not needed to enforce uniqueness. The syntax of the new type of SQL statement would take advantage of the already existing reserved word AND. Other syntaxes that the same semantics could be substituted.
Augmented index A could be implemented using any data structure suitable for the corresponding conventional composite index C and would occupy essentially the same amount of space. It would also require slightly less computer resources to maintain than index C.
Index A would be larger than index U because of the addition of the TRN data (and its overhead). But the computer resources required to maintain index A should be nearly the same as for index U though slightly higher because of the need to maintain the extra data. Yet the cost of an extra field, or even a few, is generally small relative to the maintenance cost of the insert, update, or delete of an index entry.
Because index C was defined as UNIQUE, the database system will enforce the uniqueness constraint when index entries are inserted or updated. This enforcement of uniqueness for index C is not necessary given the existence of index U. The index entries in index C will certainly be unique, because they contain the ACCT_ID field, whose uniqueness is already being enforced with respect to the U index.
To prevent the database system from doing needless extra work in maintaining both indexes C and U, the database designer might be tempted to create a non-unique index C 2 using the statement:
CREATE INDEX C 2 ON ACCT (ACCT_ID, TRN)
Index C 2 would use the same amount of space as index C. But its maintenance costs will be slightly lower, as there will be no requirement to enforce uniqueness. However the designer would have lost the benefits of defining an index C 2 as UNIQUE, for example, the benefit that the query optimizer would have more knowledge about the index's properties, which may lead it to choose a better execution plan.
Thus, if only conventional indexes are available, the database designer must either (redundantly) define index C as UNIQUE, and pay a slight penalty in maintenance costs, or else not define it as UNIQUE, and risk getting a worse execution plan. The unique augmented index resolves this tradeoff by providing low maintenance costs, small required space, and a high level of information for the optimizer. If only conventional indexes are available, the physical database design uses either U and C, or U and C 2 , either of which uses more space and more maintenance time than for a single unique augmented index A.
An augmented index on key K and extra data E corresponds to a conventional index with key K+E. The exact meaning of + depends on the implementation of the index. In the usual case of a B-tree the order of fields in the key matters, and so + must be a kind of concatenation. In a hash table based index the order of fields does not matter and so + can be implemented as a kind of union.
Operations on an augmented index are performed in a manner similar to the way they are performed on a composite index. Four basic operations on indexes are insert, delete, update, and read. An intended index entry is always found on the basis of the values of key K and extra data E in the corresponding data record in the table to which the index applies. We consider each of the operations in turn.
Insert—As shown in FIG. 6, when a new record (including K and E fields) is proposed to be inserted in the table ( 120 ), if A is a UNIQUE index ( 124 ) and an entry with a duplicate value for key K already exists in the index ( 126 ), then the insert is rejected. If A is not a unique index, or if there is no duplicate value for key “K”, then the new record is added to the table and the index entry is added to the index 122 , including the key value K and any additional information E. When testing for uniqueness, E is ignored, in contrast to a conventional unique index in which uniqueness of E would also be checked.
Delete—When a record in the table is deleted, its index entry is removed.
Update—Referring to FIG. 7, when a is proposed to be updated record (including possible changes in K and E fields) in the table ( 130 ), if A is a UNIQUE index ( 132 ) and an entry with a duplicate value for key K already exists in the index ( 134 ), then the update is rejected. If A is not a unique index, or if there is no duplicate value for key “K”, then the record is updated in the table and the index entry is updated in the index 136 , including changes in the key value K and any additional information E. When testing for uniqueness, E is ignored, in contrast to a conventional index in which uniqueness of E would also be checked. As with conventional indexes, the database system is free to optimize the change in the index entry to reflect only what changed in the data record. For example, if E has two fields E 1 and E 2 and only E 2 changes, not E 1 or K, the entry must be updated, but only E 2 must be changed.
Read—When queried, the index can return any of the data in K, E, or in the data record referred to by the index entry's locator.
An augmented unique index performs better than the corresponding conventional index for index-only access. For example, a query SELECT E FROM T WHERE K=‘k’ may be performed with respect to a table that has a record (there will be at most one) with key value ‘k’. For a conventional composite index on K and E, whether unique or not, the database system will first read the index entry for ‘k’, and then must read another index entry for E, because it does not know that there cannot be another entry with K=‘k’. By contrast, using a unique augmented index, the database will only read one index entry, because it knows that K alone is a unique key. This reduction from two index entry reads to one is a significant improvement in performance.
Given an existing implementation of a conventional composite index, the size and time cost of an augmented index may be estimated. The size of index A is essentially the same as either C or C 2 above (assuming that only a small number of bits are used in the index's control data structure). The time to maintain the unique augmented index cannot be greater than the time needed to maintain the unique conventional composite index C, because there are fewer fields to check for uniqueness, i.e., fewer bytes to compare. The time to maintain the index A will be no less than for a conventional index without the uniqueness constraint, e.g., C 2 above.
The cost and time for index A may also be compared to index U which is defined only on K. Index A will be larger than index U based on the average size of the extra data in each entry (plus any overhead in the index entry control bits). Its maintenance time will be slightly greater because of the extra data.
An index is useful if it may improve performance on a query. (We say “may” because query optimizers can make decisions that in hindsight are not optimal, e.g., because of skew in the data, or old statistics.) If the index is useful for an access, it may be used. (We say “may” because this depends on the execution plan adopted, e.g., there may be another index that is even more useful). The database system determines if the index is useful based on data provided in the query statement and on the implementation details of the index. For a typical tree structured composite index, the order of fields matters. In this case, an index is useful if the leading edge of the key (i.e., the first one or more fields in the key) was provided. For example, an index on K and E may be useful if only K (or a leading edge of K) is provided. For other indexes, e.g., hash table based indexes, all of the key must be provided.
Although augmented indexes yield benefits, using them in all cases and for many fields may not be desirable. Storing the extra data takes up space in the index entry. Consequently, fewer index entries may be stored in a block, the overall fanout of the index is reduced, and the height of the index tends to increase.
Whether to use an augmented index depends on some of the same factors as whether to use a corresponding conventional composite index. Factors that favor defining an augmented index A on table T with key K and extra data E include (a) queries to retrieve E given a value for K are frequent (the query need only provide a useful subset of K);
(b) changes to table T that affect index entries in A are infrequent; and (c) the ratio of the size of K to the size of E is large.
The invention can be implemented in software and/or hardware using conventional database systems modified to include the appropriate statement types to permit creation of augmented indexes, including unique augmented indexes, and the appropriate routines for executing searches and maintenance in a way that enforces uniqueness in the key fields of the augmented index and disregards uniqueness for the extra data.
Other embodiments are within the scope of the following claims.
For example, the invention can be used with indexes that are applied not only to relational databases but also to any other system that applies indexes to information. The other system may include a storage and retrieval system, a file system, or another kind of database system (hierarchical, network, inverted file, multi-dimensional, hybrid, object-oriented).
Other data structures that can be used to organize the data include B-trees (and variants such as B+-trees and B*-trees), hash tables, distributed schemes such as RP*and LH* data structures, multi-dimensional trees including grid files, R-trees, holey brick trees, and other kinds of trees.
The invention can be applied to any index that stores extra data record information beyond what is needed to achieve a unique key. The extra data may consist of, or can be derived from, data in the data record. The extra data need not be stored as a separate item in the index record. The extra data could, for example, be combined into the locator.
The invention is not limited to unique augmented indexes but also applies to other indexes that provide for a distinction between data used as a key and extra data. The key part of an augmented index entry may be stored uncompressed, to improve search speed, while the extra data portion may be stored compressed. The extra data need not be limited to a single kind but could include two or more types of data so that the index record is, for example, of the form “key, extra data 1 , extra 2 , . . . ”.
There may be more than one different kind of extra data using, for example, the following syntax:
CREATE INDEX I ON T 0 AND (C 1 , C 2 ) AND (C 3 , C 4 )
The zero indicates that there are no fields in the key.
The invention may apply to indexes in which the user has not explicitly requested the storage of the extra data.
For example, if the database system is adaptive to the historical mixture of queries and updates, it could decide to create an augmented index without user intervention. A system may also determine that an explicitly created augmented index is redundant with another and may avoid the redundancy. In other systems, the augmented index may be created as a combination of information from the user and the system.
The invention is not limited in terms of the kinds of access that may be accomplished using the augmented index. An online transaction processing (OLTP) could access the augmented index using its key. Alternatively, the augmented index could be scanned for particular values in the key, in the locator, or in the extra data as is done with conventional indexes in Decision Support Systems (DSS) applications.
Two indexes could be combined into one unique augmented index. If an account record contained a current balance in addition to an account identifying number and an account name, a single unique augmented index with the key based on the account identifying number could have both the account name and the current balance as additional data.
The additional data need not be drawn from the table record to which the locator points. If an account record in one table and an address record in a second table share an account identifying number and the address record also contains a ZIP field, the value of the ZIP may be stored in the index record that is keyed on the account identifying number of the account table. This could be seen as a kind of pre-computed join.
Storing extra data from another table is useful when the index is one that already maintains a referential integrity (RI) constraint with another table, because the referred to table will need to be accessed anyway to check the RI constraint. A useful variation applies when a referred-to table uses an augmented index to maintain its own unique index. In this case, the RI constraint in the first index can get the foreign data from the other index yielding another form of index-only access. In the previous example, suppose (a) there is an RI constraint that each ACCT_ID in the account table must match an ACCT_ID in the address table; (b) the address table has a unique index on the ACCT_ID; (c) the value of ZIP is stored as extra data in that unique index; and (d) the augmented index on the account table uses the ACCT_ID as its key and stores the ZIP as extra data. Then, for an any account that is inserted or updated, its account ACCT_ID and its address ID are known. The address identification number is used to enforce RI, and assuming one matching record is found, the value of ZIP is returned from the address index and stored in the account index. (If the value of ZIP in an address record can change, the extra data ZIP will need to be updated in both indexes. This could be done using conventional indexes, e.g. an index on the address identification number for the account table. But it can also be done by storing the value of the ACCT_ID as extra data in the address index. Here we see that extra data can actually be a set of values, not necessarily a single value.) | Information is retrieved from computer-stored records. An index of entries is provided that contains values that are keys for respective ones of the stored records, the keys being used to reduce the time required to locate records. Additional information, included in the index of entries, is used for a purpose other than to reduce the time required to locate records. In connection with computer operations associated with the index, the additional information is treated in a manner different from the manner in which the keys are treated. | 8 |
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0001] This invention was made, at least in part, with funding from the National Science Foundation under contract CHE-314344 and from the National Institutes of Health under contract GM067655. Accordingly, the U.S. government may have certain rights in this invention.
BACKGROUND OF THE INVENTION
[0002] Fluorescent molecules are widely used in chemistry and biochemistry. Fluorophores are used to tag various molecular objects for detection in a number of assays, providing a sensitive means to follow molecular distributions and interactions, especially in the biologically-relevant context. Most of the existing assays use static tagging of a species of interest with a fluorophore, allowing for detection of the species of interest, and visualization with fluorescence microscopy. Static tagging with a fluorophore that is always “on” is suitable for many biological processes exhibiting slow molecular dynamics. In cases when molecular dynamics are fast, one approach is to create an instantaneous local concentration of, for example, a biological effector via photoinduced release with a pulsed source of light. There are several photochemically labile groups available to carry out such an instantaneous release [reviewed in: Dynamic studies in biology. M. Goeldner, R. Givens, Eds., Wiley-VCH, 2005]. These photolabile groups, however, are lacking the fluorescence reporting function. It is critical in many fields not only to be able to release molecules of interest instantaneously, but at the same time be able to observe, quantify and follow the spatial distribution, localization and/or depletion of the released molecular objects. Two approaches are found in the literature, which attempt to combine the functionality of photolabile protecting groups with benefits of fluorescent labeling. One approach is to tether a fluorophore to a quencher through a photolabile linker. In this approach, most of the fluorescence of the tethered fluorophore is quenched. Photoinduced fragmentation in the photolabile linker separates the fluorophore and the quencher and fluorescence recovers. Examples of the quenching approach are described in: Veldhuyzen, W. F.; Nguyen, Q.; McMaster, G.; Lawrence, D. S. J. Am. Chem. Soc. 2003, 125, 13358; Vazquez, M. E.; Nitz, M.; Stehn, J.; Yaffe, M. B.; Imperiali, B. ibid., 2003, 125, 10150; Pellois, J.-P.; Hahn, M. E.; Muir, T. W. J. Am. Chem. Soc. 2004, 126, 7170. A second approach is to “cage” a peripheral hydroxy group of a generic fluorophore (for example, phenolic group of fluoresceine) with a generic photolabile group such as an o-nitrobenzyl. Examples of the caging of an existing fluorophore with existing photolabile groups are described in: Krafft, G. A.; Sutton, W. R.; Cummings, R. T. J. Am. Chem. Soc. 1988, 110, 301; Zhao, Y.; Zheng, Q.; Dakin, K.; Xu, K.; Martinez, M.; Li, W.-H. J. Am. Chem. Soc. 2004, 126, 4653. Such caging normally reduces fluorescence intensity of the fluorophore, however, the UV-Vis absorption of the caged fluorophore is often higher than the photoremovable group, which inevitably reduces the quantum efficiency of release and may cause other complications. The same problems apply to the approaches based on fluorescence quenching—even thought the fluorescence is quenched, the fluorophore is still absorbing photons to a much greater extent than the photolabile linker.
[0003] An improved system to quantify and image molecules of interest is needed.
SUMMARY OF THE INVENTION
[0004] A method of photofragmentation is provided comprising: providing a masked fluorescent molecule having a masking group bonded to a fluorescent molecule through a photolabile covalent bond which disrupts the conjugation of the fluorescent molecule; exposing the masked fluorescent molecule to cleaving photoradiation, producing an unmasked fluorescent molecule; detecting the fluorescence of the unmasked fluorescent molecule. In embodiments of the invention, either the unmasked fluorescent molecule or the masking group, or both, are attached to a molecule of interest. The molecule of interest is any molecule or structure which is able to be attached to either the unmasked fluorescent molecule or masking group, with any desired or required linkages between the molecule of interest and the unmasked fluorescent molecule or masking group. In one embodiment, the molecule of interest is a biological effector. In one embodiment, either the unmasked fluorescent molecule or the masking group, or both, are attached to a support. Examples of supports are dendrimers, particles including nanoparticles (having average size of below about 10 −8 meters) and microparticles (having average size below about 10 −6 meters), surfaces or liposomes. In one embodiment, the unmasked fluorescent molecule bonds to the masking group through a carbonyl group or a double bond. The photolabile covalent bond disrupts the conjugation of the fluorescent molecule, causing the fluorescence to be masked. When the photolabile covalent bond is broken, the conjugation is restored, resulting in an increase in fluorescence of the fluorescent molecule as compared to the masked fluorescent molecule.
[0005] Also provided is a photolabile molecule of formula: F-M, wherein F is a latent fluorescent molecule; M is a masking group which is bonded to the latent fluorescent molecule through a photolabile covalent bond which disrupts the conjugation of the fluorescent molecule. As discussed above, either F or M or both can be attached to a molecule of interest and/or a support.
[0006] Also provided is a plurality of photolabile molecules attached to a support. In this embodiment, a library of photolabile molecules can be formed. Also provided is a method of forming a plurality of support bound photolabile molecules, each molecule occupying a separate predefined region of the support, comprising: (a) binding a photolabile molecule to a first region of the support; (b) repeating step (a) on other predefined regions of the support, whereby each of the other regions has bound thereto another photolabile molecule, and wherein each other molecule may be the same or different from that used in step (a). This method may further comprise: (c) exposing the photolabile molecule(s) to cleaving photoradiation, producing unmasked fluorescent molecule(s); (d) detecting the fluorescence of the unmasked fluorescent molecule(s). In this embodiment, the photolabile molecule comprises the structure described above.
[0007] As used herein, “masking group” is a group, which when bound to a fluorescent molecule creating a masked fluorescent molecule, causes the masked fluorescent molecule to be non-fluorescent or have lower fluorescence intensity than the non-masked fluorescent molecule by disrupting the conjugation of the fluorescent molecule. Examples of masking groups include: dithiane, trithiane, dithiazine, tert-alkyl including tertiary butyl, carbonitriles, α-carbonyl, carboxamides, and other groups that are good radical leaving groups, as known in the art. As used herein, “photolabile covalent bond” is a covalent bond which can be broken by exposure to cleaving photoradiation. As used herein, “cleaving photoradiation” is light having the appropriate energy (wavelength) to break a photolabile covalent bond, as known in the art. One method of determining an appropriate wavelength of cleaving photoradiation is by measuring the absorbance spectrum of the masked fluorescent molecule, as known in the art. Examples of cleaving photoradiation include wavelengths in the ultraviolet spectrum, visible and infrared spectrum (between about 180 nm and 1.5 μm, for example) and all individual values and ranges therein, including UV-A (between about 320 and about 400 nm); UV-B (between about 280 and about 320 nm); and UV-C (between about 200 and about 280 nm). Other useful ranges include the radiation from visible, near-IR and IR lasers (about 500 nm to about 1.5 μm). Cleaving photoradiation is supplied using a variety of sources known in the art. As used herein, “latent fluorescent molecule” is a molecule where the conjugation has been disrupted by the attachment of a masking group, so that the fluorescence of the latent fluorescent molecule is lower than the fluorescence of the fluorescent molecule without the masking group attached. The fluorescence of a latent fluorescent molecule is increased when the photolabile covalent bond between the masking group and latent fluorescent molecule is broken. As used herein, “unmasked fluorescent molecule” is a fluorescent molecule from which a masking group has been released. As used herein, “fluorescence” includes phosphorescence. As used herein, “support” or “surface” indicates a material to which a molecule of the invention can be configured to attach. “Support” or “surface” does not necessarily indicate a substantially flat surface. The support or surface can have any of a number of shapes, such as strip, rod, particle, including bead, and the like. Examples of surfaces include conductive, semi-conductive, and non-conductive, including metal, silicon, ITO, glass and quartz. Conductive surfaces include metal surfaces and non-metal substrates with at least a partially electrically conductive layer or portion thereof attached thereto. Examples of electrically conductive materials include metals, such as copper, silver, gold, platinum, palladium, and aluminum; metal oxides, such as platinum oxide, palladium oxide, aluminum oxide, magnesium oxide, titanium oxide, tin oxide, indium tin oxide, molybdenum oxide, tungsten oxide, and ruthenium oxide; and electrically conductive polymeric materials, and mixtures thereof. For certain applications, an electrically conductive material can be deposited on or otherwise applied to a substrate to form a conductive surface. For example, an electrically conductive material can be deposited on a glass substrate or a silicon wafer or a plastic substrate to form a conductive surface. The substrate can be flexible. In other applications, the substrate is itself conductive such as a metal substrate. In some instances, a conductive layer can have a substantially uniform thickness and a substantially flat outer surface. In other instances, a conductive layer can have a variable thickness and a curved, stepped, or jagged outer surface. As used herein, “outer” means the side of the layer that is away from the substrate.
[0008] As used herein, “carbonyl group” contains the following structure:
[0000]
[0000] As used herein, a “dendrimer” is a structure formed from regular, highly branched monomers leading to a monodisperse, tree-like or generational structure. Dendrimers are built one monomer layer, or “generation,” at a time. A dendrimer comprises a multifunctional core molecule with a dendritic wedge attached to each functional site. The core molecule is referred to as “generation 0.” Each successive repeat unit along all branches forms the next generation, “generation 1,” “generation 2,” and so on until the terminating generation. An example of a dendrimer is the commercially available PAMAM dendrimer (Aldrich Chemical Co. As used herein, a “particle” is a discrete support that can be coated with a variety of materials, such as groups having functional groups allowing attachment of molecules. Examples of particles include commercially available particles such as TentaGel beads (Fluka Chemical Co.). As used herein, “liposome” is a fluid-filled structure whose walls are made of layers of phosopholipids. As used herein, “layer” does not necessarily indicate a complete monolayer is formed. There may be one or more gaps or defects in the layer, and there may be more than one monolayer with or without gaps or defects.
[0009] As used herein, “biological effector” is a molecule which is involved in any biological interaction, in vitro or in vivo, and which can be attached to a masked fluorescent molecule and/or masking group as described herein. Biological effectors includes proteins, peptides and nucleic acids and any small or large organic or inorganic molecules. One class of biological effectors includes those molecules having a carbonyl group or a nitrogen heterocycle which can hydrogen-bond to a nitrogen functionalities, for example, a NH (amide). As used herein, “molecule” refers to a collection of chemically bound atoms with a characteristic composition. As used herein, a molecule can be neutral or can be electrically charged. The term molecule includes biomolecules, which are molecules that are produced by an organism or are important to a living organism, including, but not limited to, proteins, peptides, lipids, DNA molecules, RNA molecules, oligonucleotides, carbohydrates, polysaccharides; glycoproteins, lipoproteins, sugars and derivatives, variants and complexes and labeled analogs of these. As used herein, “substantially” means more of the given structures have the listed property than do not have the listed property. As used herein, “about” is intended to indicate the value given is not necessarily exact, either as a result of the inherent uncertainty in measurement, or because the values surrounding the value given function in the same way as the value given. As used herein, “attach” refers to a coupling or joining of two or more chemical or physical elements. Examples of attachment includes chemical bonds such as chemisorptive bonds, covalent bonds, ionic bonds, van der Waals bonds, and hydrogen bonds. Various organic solvents and aqueous solutions, and mixtures thereof can be used in the reactions described herein, as known in the art. Additives such as buffers can be used as long as the additives do not prevent the desired reactions from occurring.
[0010] The photocleavage reaction can occur as a result of a single photon absorption or two photon absorption, as known in the art. The actual wavelength used for photocleavage depends on the UV/vis or near-IR absorption maximum of the masked fluorophore and is generally shorter than the absorption maximum for the unmasked fluorophore. This allows for monitoring the steady state fluorescence and at the same time irradiating with the wavelength causing fragmentation, conveniently avoiding “beam crossing” where the wavelength used to monitor the steady state fluorescence also causes fragmentation.
[0011] It is noted that derivatives of fluorescent molecules can be made that allow bonding of the desired masking group(s) in view of the disclosure herein and using methods of organic synthesis known in the art. These derivatives are apparent to one of ordinary skill in the art in view of the disclosure and these derivatives can be made using art known methods without undue experimentation. The formation of the photolabile covalent bond between the masking group and fluorescent molecule can be before, after, or during attachment of any portion thereof to a support. Unless otherwise specified, all groups described herein, including fluorescent molecules, masking groups, and unmasked fluorescent molecules can be optionally substituted with various groups, such as groups that allow attachment to another group, groups that allow attachment to a surface, allow alteration of the optical properties of the group, or groups that are present in commercially available analogues of groups or are as a result of synthesis methods used, as long as the substitution does not interfere with the desired use. Ring structures can be optionally substituted with one or more halogens, such as fluorine or chlorine, for example. Ring structures can also be substituted with one or more heteroatoms in the ring, for example. Other substituents can be added to various groups, such as alkyl groups, alkylene groups, alkenyl groups, alkenylene groups, alkynyl groups, alkynylene groups, aryl groups, arylene groups, iminyl groups, iminylene groups, hydride groups, halo groups, hydroxy groups, alkoxy groups, carboxy groups, thio groups, alkylthio groups, disulfide groups, cyano groups, nitro groups, amino groups, alkylamino groups, dialkylamino groups, silyl groups, and siloxy groups.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows fluorescence monitoring of the release from TentaGel beads.
[0013] FIG. 2 shows ketone 1 d : (a) single- and two-photon LIF spectra exited at 355 nm (empty) and 532 nm (filled diamonds) respectively; (b) quadratic dependence of the LIF intensity on the power of the 532 nm laser pulses.
[0014] FIG. 3 shows the two-photon induced fragmentation of compound 2 d at 532 nm.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The invention is further described by the following non-limiting description.
[0016] The general scheme describing the invention is shown below:
[0000]
[0000] where F is a fluorescent molecule and M is a masking group. The masking group is bonded to the fluorescent molecule through a photolabile covalent bond which disrupts the conjugation of the fluorescent molecule, producing a masked fluorescent molecule. This disruption of the conjugation results in a shifting of the absorbance spectrum of the masked fluorescent molecule to shorter wavelengths than the fluorescent molecule. Cleaving photoradiation is applied to the masked fluorescent molecule, cleaving the photolabile covalent bond and reforming the fluorescence of the fluorescent molecule.
[0017] Substituents that are not involved in bonding the masking group to the fluorescent molecule may be attached to either or both of the fluorescent molecule or masking group and are useful for purposes such as adjusting the wavelength of fluorescence or absorbance or binding to a molecule of interest, for example a biological effector, and/or a support such as a dendrimer, particle, surface or liposome. Such substituents are known in the art and are generally shown as “X” or “Y” in the schemes below. The “X” and “Y” substituents may be the same or different and are attached using methods described herein and methods known to one of ordinary skill in the art without undue experimentation.
[0000]
[0018] The unmasked fluorescent molecules may be monitored using techniques known in the art such as fluorescence microscopy or other types of spectroscopy, such as UV-vis absorption.
[0019] Fluorescent molecules which are useful in the invention include any molecule which has decreased fluorescence when one or more masking groups are attached, and increased fluorescence when at least one masking group is removed. Preferably, the molecule is non-fluorescent when one or more masking groups are attached and fluorescent when all the masking groups are removed. Fluorescent molecules useful in the invention contain, or can be modified to contain, at least one conjugated bond system that is disrupted by covalent bonding of the masking group(s).
[0020] A two photon process can also be used with the present invention. In a two photon process, radiation (such as laser radiation) in the near-IR or IR wavelength range is typically used for photocleavage. Absorption of two or more near-IR or IR photons having a combined energy equivalent to one UV photon pump the molecule to excited states. Use of a two photon process is useful when studying biological systems to minimize absorption of light by cells, and to minimize cell damage by higher energy radiation. The excitation volume for the two photon process is very small (typically a few femtoliters) because excitation is most probable only at the focal point of the focused laser beam. This provides additional spatial control for biological imaging experiments. Efficiency of two-photon photolysis is measured as the two-photon absorption cross section, as known in the art. Thioxanthones are examples of molecules having large two-photon absorption cross sections which are useful in the invention.
[0021] The photolabile molecules of the invention are especially useful in assays that require monitoring of fast dynamic processes in vivo or in vitro. Pulsed laser excitation allows for a high degree of temporal and spatial control. A high concentration of a biological effector or other molecular object of interest can be instantaneously created in a very small volume, and the dynamics of its distribution and localization in the surrounding medium can be monitored in real time by fluorescence microscopy or other spectroscopic techniques.
[0022] The intensity of the fluorescence from the fluorescent molecule provides information regarding the concentration of triggers present in the system. Attachment of a biological group of interest to the fluorescent molecule or masking group provides a method to monitor the biological group of interest in a variety of applications, as known in the art. Other applications of the invention are known and will be readily apparent to one of ordinary skill in the art in view of the disclosure provided herewith.
[0023] Several examples of molecules useful in the invention are included in Scheme 1 , where structures 1 a - f are fluorescent molecules and the remainder of the structures are masked fluorescent molecules. Molecules 2 a - f are 2-methyldithiane adducts; molecules 3 c , 3 d are dithiane adducts; molecules 4 c , 4 d are dithiazine adducts and molecules 5 a , 5 c , and 5 d are isobutyronitrile adducts.
[0000]
[0024] Some examples of useful masking groups are shown below:
[0000]
[0025] In the groups above, the wavy line indicates bonding to the remainder of the molecule, and the R, R′ and R″ substitutents may be the same or different. Exemplary R, R′ and R″ substituents include hydrogen, optionally-substituted straight chain, branched and cyclic C1-20 alkyl, alkenyl, or alkynyl groups where one or more of the C atoms can be substituted, or wherein one or more of the C, CH or CH 2 moieties can be replaced with O atoms, —CO— groups, —OCO— groups, N atoms, amine groups, S atoms or a ring structure, which ring structure can optionally contain one or more heteroatoms and which ring structure can be optionally substituted; and optionally substituted aromatic and nonaromatic ring structures, including rings that are fused to one or more other rings.
[0026] It is desired that the fluorescent molecules used in the invention have a high fluorescence quantum yield, preferably above 60-70%. One class of fluorescent molecules useful in the present invention include molecules useful as fluorescent dyes. One class of fluorescent dyes are those that contain a ketone functional group, such as fluorescein and fluorescein derivatives including fluorescein isothiocyanate derivatives; rhodamine and rhodamine derivatives including texas red and texas red derivatives; flavins and flavin derivatives; eosins and erythrosins; alizarin and alizarin derivatives; coumarin and coumarin derivatives; quinacrine and quinacrine derivatives. Another class of fluorescent dyes are those that do not contain a ketone functional group, and yet their conjugated system can be disrupted by addition to a double bond, for example, coumarine and coumarine derivatives, fluoresceine and other xanthene derivatives; and acridines and acridine derivatives.
[0027] Other examples of useful fluorescent molecules include those below:
[0000]
[0000] where at least one of R and R′ is a group which is conjugated with the carbonyl group and where R and R′ may be the same or different and are any useful groups, such as those disclosed herein. Examples of molecules having the structure above include:
[0000]
[0000] and substituted versions of the above, including those with heteroatoms in position 2 . The photocleavage described herein does not require an external electron transfer sensitizer.
[0028] Characterization Experiments
[0029] Nucleophilic additions to the carbonyl groups of ketones 1 a - f of Scheme 1 reduced their fluorescence by two orders of magnitude. The remaining p-amidodiphenyl sulfide moiety has tailing absorption well above 300 nm, allowing for photo deprotection in a wide spectral area. The relative quantum yield of fragmentation was highest for the 2-methyldithiane adducts 2 . Adducts of dithiane ( 3 ), dithiazine ( 4 ) and isobutyronitrile ( 5 ) cleaved with about 30-60% relative quantum efficiency of the methyldithiane adducts.
[0030] Laser flash photolysis of 2 d (355 nm Nd:YAG) showed a weak transient absorption band below 400 nm, which was assigned by analogy to the 2-amidothioxanthenol radical. The lifetime of these species was 1.7 μs and no further processes were detected, which puts an upper bound on the estimated time scale of this fragmentation.
[0031] Bulk photo reaction of 2 d at 320 nm (0.49 mW cm −2 ) in acetonitrile solution was monitored by fluorescence of the product, i.e. ketone 1 d . Within less then two minutes 90% conversion was achieved at this wavelength. Irradiation with the U-360 broad bandpass filter produced the same result in 10 min. Adduct 2 d had very weak fluorescence; the overall emission at 458 nm had increased by more than two orders of magnitude.
EXAMPLE OF IMMOBILIZATION TO A DENDRIMER OF TENTAGEL BEADS
[0032] As described above, the methods of the invention can be used to study the release of a biological effector. In this example, the fluorescent molecule is attached to a dendrimer, and the masking group is attached to the biological effector. Cleaving the photolabile covalent bond between the fluorescent molecule and the masking group produces fluorescence which reveals the initial location of the released biological effector and allows quantification of the concentration of the biological effector. One synthetic procedure is outlined in Scheme 2 . 2-Aminothioxanthone 6 was acylated with glutaric anhydride and reacted with excess of a nucleophile (lithiated dithiane is used in this example) to furnish 2 f , which was converted into the N-hydroxysuccinimide ester, 2f-NHS, and incubated in an orbital shaker with either 90 μm TentaGel-NH 2 beads or PAMAM-NH 2 dendrimer. According to NMR and elemental analysis, approximately 115 out of 128 surface amino groups of the fifth generation dendrimer were actually immobilized after 60 hour gentle shaking.
[0000]
[0000] 10 mg of the 2f-TentaGel beads were irradiated with a U-360 broadband filter and the total fluorescence was monitored ( FIG. 1 , arbitrary units). The resulting beads were mixed with the original 2f-TentaGel beads and the blank TentaGel beads as a control for comparison. In a comparison, using 405 nm excitation, the blank beads had a mean fluorescence intensity of 61.9, the original 2f-TentaGel beads had a mean fluorescence intensity of 78.3, and the irradiated beads had a mean fluorescence intensity of 111.0 (data not shown).
[0033] Irradiation of 2f-PAMAM produced a 17-fold increase in fluorescence intensity. Using multiple dilutions in glycerol (used to slow diffusion), a brightly lit dendrimer molecule was seen (data not shown). The calculated diffusion path in glycerol during 0.2 s ccd camera exposure time is 140 nm, which is in keeping with an observed approx. 200 nm bright inner spot in the fluorescent image. Stokes' hydrodynamic radius of the 1f-dendrimer is 3.2 nm as calculated from the PFG NMR diffusion coefficient of 3.42×10 −7 cm 2 /s measured in DMSO-d 6 . According to the Einstein equation, during the 200 ms exposure time of the CCD camera, the dendrimer of this size would travel about 9 μm in acetonitrile, which necessitated the use of a more viscous solvent, glycerol, for fluorescence imaging.
[0034] A complementary approach is to release the effector, tagged with 2-amidothioxanthone, for example, while immobilizing the radical leaving group (shown in Scheme 3 ). In an analogous process to that described above, photocleavage of the photolabile covalent bond produces biological effectors labeled with a fluorophore, allowing monitoring movement and accumulation/localization of the biological effectors.
[0000]
[0035] In the system discussed above, photoreleased fragments tagged by amidothioxanthone were monitored and quantified by two-photon fluorescence microscopy. Laser flash photolysis of ketone 1 d at 532 nm showed strong laser induced fluorescence (LIF) with emission closely matching the spectrum generated at 355 nm, see FIG. 2 a . The quadratic dependence of the LIF intensity on the relative laser power is shown in FIG. 2 b . The two-photon induced fluorescence lifetime was also the same, approx. 4.5-4.8 ns.
[0036] Adduct 2 d itself possesses a considerable two-photon absorption cross section, allowing for the two-photon excitation to be used not only for fluorescence monitoring of the released ketone, but also to affect the actual photocleaving. FIG. 3 shows fragmentation of 2 d , 1 mM solution in acetonitrile, being monitored by steady-state fluorescence of the generated ketone 1 d as a function of laser pulses. After 10K shots fluorescence increased 5-fold.
[0037] Photo bleaching of the reporter ketone was tested with a 405 nm-filtered, focused output of a medium pressure mercury lamp (13 mW cm −2 , approx. 9.5×10 19 photons per hour). After 4 hours continuous irradiation of the 10 −4 M solution, fluorescence intensity decreased only by 7.1%.
[0038] Other modifications of the above system include using discrete oligomer supports having two, three, four or more attachment sites. Alternatively, a payload (e.g., biological effector) and support are linked through the photolabile bond between masking group and fluorescent molecule. In this embodiment, photocleavage of the photolabile bond disengages the carrier and support. A benzophenone adduct of “a tripod” oligomer having three dithiane molecules at the ends of its legs was synthesized:
[0000]
[0039] In this embodiment, three detachable groups (X) are tagged with masked fluorescent molecules that may be the same or different. If the masked fluorescent molecules are different, different wavelengths of cleaving photoradiation can be used to photocleave the photocleavable bond, giving a method to monitor multiple different events simultaneously.
EXAMPLE OF SURFACE MODIFICATION
[0040] The methyldithiane adduct of 2-amidothioxanthone was immobilized on the self-assembled monolayer of 11-mercaptoundecanoic acid on gold (150 nm thin gold layer was thermally deposited on a 18 mm diameter microscope glass). It was estimated that about 1.7 nanomoles of the material was immobilized (Scheme 4 ). After photoinduced deprotection using a medium pressure 200 W mercury-xenon ozone-free lamp, an increase in fluorescence, concomitant with detection of methyldithiane in solution was observed. The fluorescence spectrum of the surface, obtained with a generic PMT at 1 kV and a grating monochromator was very similar to the fluorescence spectrum of 1 d in free solution.
[0041] The strength of the signal attests to the feasibility of miniaturization and fabrication of chips for photoinduced drug release or release of biological effectors (linked via the dithiane moiety), with the possibility of instantaneous quantification.
[0000]
[0042] As with the previous examples, the fluorescent molecule can be permanently attached to the released molecule, while the masking group is attached to the surface. In this case the departing molecule (e.g. a biological effector) is released carrying the fluorescent tag for easy monitoring of the dynamics of its spatial distribution.
EXAMPLE OF 2D OR 3D INFORMATION STORAGE
[0043] The masked fluorophore is embedded in a substantially transparent (for example, methyl acrylate or methacrylate) polymer, either by cross-polymerization or by dissolution of the masked fluorophore+ such polymer in an appropriate solvent, with subsequent evaporation of the solvent to form either a bulk transparent solid or a thin film. A focused laser beam of an appropriate wavelength, corresponding to the absorption of the masked fluorophore can then be used to “write” information in a form of fluorescing 2D or 3D dots. The reading of this information is done with a focused laser beam of a different wavelength, corresponding to the excitation of the free fluorophore. This mode is especially suitable for two photon writing and reading.
[0044] In this example, 2 d was dissolved in a dichloromethane solution of poly methyl methacrylate (transparent down to 290 nm) and spin coated onto a glass slide to furnish a thin transparent film. The film was dried in vacuum, a non-transparent mask was applied and the film was irradiated with medium pressure mercury-xenon ozone-free lamp. Visual inspection of the film through a 458 nm narrow bandpass filter in the dark room under 365 nm excitation showed a clear fluorescent image of the mask.
[0045] Synthesis
[0046] Common reagents were purchased from the Sigma-Aldrich Chemical Co. and used without further purification. THF was refluxed over and distilled from potassium benzophenone ketyl prior to use. PAMAM dendrimer (5 th generation) was purchased from Aldrich Chemical Co. and TentaGel S—NH 2 beads were purchased from Fluka Chemical Co. The 1 H and 13 C NMR spectra were recorded at 25° C. on a Varian Mercury 400 MHz instrument, CDCl 3 , DMSO-d 6 , CD 3 OD and CD 3 CN as solvents, and TMS was used as internal standard. The diffusion coefficients were measured with Varian Mercury's Performa I pulse field gradient module and 4 nucleus autoswitchable PFG probe. Elemental analyses were conducted at Huffman Laboratories Inc., Denver. Column chromatography was performed on Silica Gel, 70-230 mesh ASTM. UV-vis spectra were recorded on a Beckman DU-640 Spectrophotometer, and fluorescence spectra were recorded on SPEX-Fluorolog instrument and Hitachi, F-1050, Fluorescence Spectrophotometer. The irradiations were carried out in a carousel Rayonet photo reactor (RPR-3500 or RPR-3000 lamps), or with Oriel Photomax housing with a 200 W medium pressure ozone free mercury lamp and a grating monochromator or different wavelength bandpass filters, such as a U-360 nm broad bandpass (360 nm±45 nm) or 405 nm±5 nm narrow bandpass interference filter.
[0047] Synthetic Procedures:
[0048] N-(9-Oxo-9H-thioxanthene-2-yl)-butyramide:
[0000]
[0049] 2-Aminothioxanthen-9-one (1 g, 4.4 mmol) was dissolved in 15 ml of dichloromethane, and butyryl chloride (0.7 g. 6.6 mmol) and cat. amount of triethyl amine was added to this solution under stirring. The reaction mixture was stirred at room temperature overnight. The resulting solid was filtered, washed with water, dried to furnish yellow powder (1.18 g, 90%).
[0050] 1 H NMR (DMSO-d 6 , 400 MHz): δ 10.25 (s, 1H), 8.71 (d, J=2.35 Hz, 1H), 8.45 (d, J=8.17 Hz, 1H), 8.04 (dd, J 1 =2.36 Hz, J 2 =8.76 Hz, 1H), 7.83-7.73 (m, 3H), 7.58-7.54 (m, 1H), 2.30 (t, J=7.28 Hz, 2H), 1.65-1.60 (m, 2H), 0.90 (t, J=7.35 Hz, 2H).
[0051] 13 C NMR (DMSO-d 6 , 400 MHz): δ 179.31, 172.22, 138.91, 137.35, 133.49, 129.81, 129.47, 128.65, 127.75, 127.29, 127.22, 125.27, 118.65, 118.63, 39.02, 19.16, 14.31.
[0052] UV-Vis: λmax: 395 nm
[0053] Fluo: λex: 395 nm, λem: 460 nm, φ fluo =0.646 (10 −5 M, Acetonitrile)
[0054] N-[9-Hydroxy-9-(2-methyl-[1,3]dithiane-2-yl)-9H-thioxanthene-2-yl]-butyramide:
[0000]
[0055] Methyldithiane (902 mg, 6.73 mmol) was dissolved in 15 mL of freshly distilled THF under nitrogen atmosphere. To this solution 2.52 mL of butyl lithium (1.6M solution in hexanes, 4 mmol) was added dropwise upon stirring at room temperature. The resulting mixture was stirred for 10 min at this temperature to generate the anion. N-(9-Oxo-9H-thioxanthene-2-yl)-butyramide, (400 mg, 1.35 mmol) in 10 mL of THF was added dropwise to the vigorously stirred solution of the methyldithianyl anion. The reaction mixture was stirred overnight at room temperature. The subsequent aqueous workup included quenching the reaction mixture with a 30 mL 1 M solution of ammonium chloride, extracting twice with ether, and drying the organic layer over sodium sulfate. The solvent was removed under vacuum, the crude reaction mixture was purified by silica gel column chromatography, hexane:EtOAc (9:1 & 3:2) as an eluent to afford pale yellow solid (380 mg, 65.2%).
[0056] 1 H NMR (CDCl 3 , 400 MHz): δ 8.03-8.02 (m, 2H), 7.72 (d, J=8.49 Hz, 1H), 7.35-7.26 (m, 4H), 4.03 (s, 1H), 2.91-2.86 (m, 2H), 2.73-2.66 (m, 2H), 2.27 (t, J=7.48 Hz, 2H), 1.91-1.86 (m, 4H), 1.74-1.64 (m, 2H), 1.49 (s, 3H), 0.95 (t, J=7.35 Hz, 3H).
[0057] 13 C NMR (CDCl 3 , 400 MHz): δ 171.5, 135.51, 134.47, 133.34, 132.42, 130.67, 128.21, 127.43, 126.45, 125.91, 125.219, 121.84, 120.24, 80.20, 76.92, 62.42, 39.86, 27.86, 25.77, 24.58, 19.20, 13.99.
[0058] N-(9-[1,3]Dithan-2-yl-9-hydroxy-9H-thioxanthene-2-yl)-butyramide:
[0000]
[0059] Dithiane (600 mg, 5 mmol) was dissolved in 15 mL of freshly distilled THF under nitrogen atmosphere, and 1.9 mL of butyl lithium (1.6M solution in hexanes, 3.03 mmol) was added to this solution dropwise upon stirring at room temperature. The resulting mixture was stirred for 10 min at this temperature to generate the anion. N-(9-Oxo-9H-thioxanthene-2-yl)-butyramide (300 mg, 1.01 mmol) in 10 mL of THF was added dropwise to the vigorously stirred solution of the dithiane anion. The reaction mixture was stirred overnight at room temperature. The subsequent aqueous workup included quenching the reaction mixture with a 30 mL 1 M solution of ammonium chloride, extracting twice with ether, and drying the organic layer over sodium sulfate. The solvent was removed under vacuum, the crude reaction mixture was purified by silica gel column chromatography, with hexane:EtOAc (9:1 & 3:2) as an eluent to afford pale yellow solid (300 mg, 71.8%).
[0060] 1 H NMR (CDCl 3 , 400 MHz): δ 7.85 (dd, J 1 =1.57 Hz, J 2 =7.70 Hz, 1H), 7.78 (d, J=8.29 Hz, 1H), 7.75 (d, J=2.26 Hz, 1H), 7.44 (dd, J 1 =1.44 Hz, J 2 =7.55 Hz, 1H), 7.38 (d, J=8.33 Hz, 1H), 7.36-7.26 (m, 2H), 7.22 (s, broad, 1H), 5.04 (s, 1H), 3.61 (s, broad, 1H), 2.81-2.68 (m, 2H), 2.67-2.61 (m, 2H), 2.30 (t, J=7.46 Hz, 2H), 1.98-1.93 (m, 1H), 1.79-1.68 (m, 3H), 0.98 (t, J=7.38 Hz, 3H).
[0061] 13 C NMR (CDCl 3 , 400 MHz): δ 171.61, 138.29, 137.26, 136.75, 130.91, 127.99, 127.76, 127.23, 127.17, 126.22, 125.58, 119.77, 118.52, 77.9, 50.12, 39.84, 30.41, 30.33, 25.48, 19.18, 14.
[0062] N-[9-Hydroxy-9-(5-methyl-[1, 3, 5]dithiazinan-2-yl)-9H-thioxanthene-2-yl-butyramide:
[0000]
[0063] 5-methyl-[1,3,5]dithiazine (909 mg, 6.72 mmol) was dissolved in 15 mL of freshly distilled THF under nitrogen atmosphere, and 2.6 mL of butyl lithium (1.6M solution in hexanes, 4.04 mmol) was added dropwise to this solution upon stirring at room temperature. The resulting mixture was stirred for 10 min at room temperature to generate the anion. N-(9-Oxo-9H-thioxanthene-2-yl)-butyramide (400 mg, 1.35 mmol) in 10 mL of THF was added dropwise to a vigorously stirred solution of the dithiazine anion. The reaction mixture was stirred overnight at room temperature. The subsequent aqueous workup included quenching the reaction mixture with a 30 mL 1 M solution of ammonium chloride, extracting twice with ether, and drying the organic layer over sodium sulfate. The solvent was removed under vacuum and the crude product was purified by silica gel column chromatography with hexane:EtOAc (9:1 & 1:1) as an eluent to afford yellow solid (320 mg, 54.9%).
[0064] 1 H NMR (DMSO-d 6 , 400 MHz): δ 10.01 (s, 1H), 7.94 (s, J=2.26 Hz, 1H), 7.77 (dd, J 1 =1.37 Hz, J 2 =7.84 Hz, 1H), 7.73 (dd, J 1 =2.21 Hz, J 2 =8.42 Hz, 1H), 7.40 (dd, J 1 =1.27 Hz, J 2 =7.56 Hz, 1H), 7.32-7.23 (m, 3H), 6.47 (s, 1H), 4.69 (s, 1H), 4.21 (d, J=13.24 Hz, 2H), 4.10 (d, J=11.69 Hz, 2H), 2.35 (s, 3H), 2.26 (t, J=7.31, 2H), 1.62-1.56 (m, 2H), 0.87 (t, J=7.34 Hz, 3H).
[0065] 13 C NMR (DMSO-d 6 , 400 MHz): δ 171.82, 139.55, 138.72, 138.27, 130.46, 128.98, 128.01, 127.12, 126.90, 126.02, 123.47, 119.80, 118.94, 78.66, 60.20, 39.59, 38.97, 37.43, 19.27, 14.35, 14.32.
[0066] 4-(9-Oxo-9H-thioxanthene-2-ylcarbamoyl)-butyric acid:
[0000]
[0067] 2-aminothioxanthen-9-one (0.6 g, 2.6 mmol) and glutaric anhydride (0.35 g, 2.9 mmol) were dissolved in 30 mL of DMF; the mixture was refluxed overnight, poured onto 200 g of crushed ice, resulting solid was filtered, thoroughly washed with dichloromethane and water, dried under vacuum to furnish yellow solid (620 mg, 71.6%).
[0068] 1 H NMR (DMSO-d 6 , 400 MHz): δ 12.05 (s, 1H), 10.28 (s, 1H), 8.71 (d, J=2.4 Hz, 1H), 8.44 (d, J=8.15 Hz, 1H), 8.01 (dd, J 1 =2.41 Hz, J 2 =8.72 Hz, 1H), 7.83-7.75 (m, 3H), 7.54 (m, 1H), 2.37 (t, J=7.29 Hz, 2H), 2.25 (t, J=7.24 Hz, 2H), 1.84-1.82 (m, 2H).
[0069] 13 C NMR (DMSO-d 6 , 400 MHz): δ 179.26, 174.82, 171.81, 138.82, 137.32, 133.39, 130.87, 129.77, 129.41, 128.62, 127.69, 127.21, 127.14, 125.23, 118.65, 36.10, 33.65, 21.03.
[0070] 4-(9-Oxo-9H-thioxanthene-2-ylcarbamoyl)-butyric acid 2,5-dioxopyrrolidin-1-yl-ester:
[0000]
[0071] A mixture of 4-(9-Oxo-9H-thioxanthene-2-ylcarbamoyl)butyric acid (0.25 g, 0.73 mmol), N-hydroxy succinimide (126 mg, 1.1 mmol) and EDC (168 mg, 0.87 mmol) were dissolved in THF (20 mL)) and stirred for 24 hrs at room temperature. The resulting solid was filtered, washed with water and sat. aq. NaHCO 3 , followed by 20 mL of brine; dried under vacuum to yield off yellow solid (260 mg, 81.25%).
[0072] 1 H NMR (CDCl 3 , 400 MHz): δ 10.36 (s, 1H), 8.9 (s, 1H), 8.44 (d, J=7.55 Hz, 1H), 8.02 (d, J=7.97 Hz, 1H), 7.83-7.75 (m, 3H), 7.54 (m, 1H), 2.83-2.75 (m, 6H), 2.52-2.45 (m, 2H), 1.99-1.92 (m, 2H)
[0073] 4-[9-Hydroxy-9-(2-methyl-[1,3]-dithan-2-yl)-9H-thioxanthene-2-ylcarbamoyl]butyric acid:
[0000]
[0074] Methyldithiane (700 mg, 5.27 mmol) was dissolved in 10 ml of freshly distilled THF under nitrogen atmosphere, and 2.2 mL of butyl lithium (1.6M solution in hexanes, 3.51 mmol) was added dropwise with stirring at room temperature. After stirring for 10 min at r.t. to generate the anion, 4-(9-Oxo-9H-thioxanthene-2-ylcarbamoyl)butyric acid (300 mg, 0.87 mmol in 10 ml of THF) was added dropwise to the vigorously stirred solution of the dithiane anion. The reaction mixture was stirred overnight at room temperature. The subsequent aqueous workup included quenching the reaction mixture with a 30 mL 1 M solution of ammonium chloride, extracting twice with ether, and drying the organic layer over sodium sulfate. The solvent was removed under vacuum, the reaction mixture was purified by silica gel column chromatography, with hexane:EtOAc as an eluent (9:1 & 2:3) to give yellow solid (220 mg, 52.7%).
[0075] 1 H NMR (CD 3 OD, 400 MHz): δ 8.24 (d, J=2.25 Hz, 1H), 8.18-8.15 (m, 1H), 7.64 (dd, J 1 =2.31 Hz, J 2 =8.47 Hz, 1H), 7.27-7.21 (m, 4H), 3.33-3.28 (m, 2H), 2.60-2.55 (m, 2H), 2.44-2.37 (m, 4H), 2.02-1.94 (m, 3H), 1.84-1.74 (m, 1H), 1.24 (s, 3H).
[0076] 13 C NMR (CD 3 OD, 400 MHz): δ 175.64, 172.59, 136.48, 135.74, 135.43, 131.94, 131.78, 127.41, 127.05, 124.94, 124.72, 124.38, 123.74, 119.99, 82.26, 59.43, 35.71, 32.94, 28.33, 25.076, 26.062, 24.40, 20.99
[0077] 4-[9-Hydroxy-9-(2-methyl-[1,3]-dithan-2-yl)-9H-thioxanthene-2-ylcarbamoyl]butyric acid 2-methylene-5-oxo-pyrrolidin-1-yl-ester:
[0000]
[0078] A mixture of 4-[9-Hydroxy-9-(2-methyl-[1,3]-dithan-2-yl)-9H-thioxanthene-2-ylcarbamoyl]butyric acid (170 mg, 0.35 mmol), N-hydroxysuccinimide (62 mg, 0.54 mmol) and EDC (75 mg, 0.39 mmol) was dissolved in DCM (20 mL) and stirred for 24 hrs at room temperature. After that it was washed with water, NaHCO 3 , and brine; the organic layer was separated and dried over Na 2 SO 4 , solvent was removed under vacuum to afford a pale yellow solid (184 mg, 90%).
[0079] 1 H NMR (CDCl 3 , 400 MHz): δ 8.07-8.01 (m, 3H), 7.70 (dd, J 1 =2.31 Hz, J 2 =8.43 Hz, 1H), 7.33-7.26 (m, 4H), 3.93 (m, 1H), 2.93-2.85 (m, 6H), 2.73-2.67 (m, 4H), 2.41 (t, J=6.96 Hz, 2H), 2.21-2.13 (m, 2H), 1.92-1.82 (m, 2H), 1.5 (s, 3H).
[0080] 13 C NMR (DMSO-d 6 , 400 MHz): δ 171, 170.92, 170.86, 169.47, 137.15, 136.82, 135.85, 132.67, 132.63, 128.14, 125.47, 125.31, 125.16, 124.96, 123.29, 119.57, 82.21, 60.24, 35.29, 30.34, 28.47, 28.36, 26.14, 25.88, 25.84, 24.64, 20.82.
[0081] 4-(9-Oxo-9H-thioxanthene-2-ylcarbamoyl)-butyric acid-functionalized PAMAM-NH 2 Dendrimer (Generation 5):
[0000]
[0082] 0.25 ml of a 5.5 wt % solution of the fifth generation PAMAM-NH 2 dendrimer in methyl alcohol was added to a 3 mL DCM solution of 4-(9-Oxo-9H-thioxanthene-2-ylcarbamoyl)butyric acid 2,5-dioxo-pyrrolidin-1-yl-ester (27 mg, 0.06 mmol) and the solution was stirred for 60 hrs. The solution was concentrated in vacuum, 20 mL of 1 N NaOH(aq) was added to this residue, and the suspension was stirred for 3 hrs. The suspension was filtered, and the solid was washed with 1 N NaOH(aq) and with distilled water. After being vacuum-dried, the product was obtained as yellow solid, 24 mg, 80%.
[0083] 4-[9-Hydroxy-9-(2-methyl-[1,3]-dithan-2-yl)-9H-thioxanthene-2-ylcarbamoyl]butyric acid Functionalized PAMAM Dendrimer (Generation 5):
[0000]
[0084] 0.25 ml of a 5.5 wt % solution of the fifth generation PAMAM-NH 2 dendrimer in methyl alcohol was added to a 3 mL DCM solution of 4-[9-Hydroxy-9-(2-methyl-[1,3]-dithan-2-yl)-9H-thioxanthene-2-ylcarbamoyl]-butyric acid 2-methylene-5-oxopyrrolidin-1-yl-ester (37 mg, 0.06 mmol) and the solution was stirred for 60 h. The solution was concentrated in vacuum and stirred for 3 hrs with 20 mL of 1 N NaOH(aq). The suspension was filtered, and the solid was washed with 1 N NaOH(aq) and with distilled water. After being vacuum-dried, the product was obtained as yellow solid, 30 mg, 81%.
[0085] 4-(9-Oxo-9H-thioxanthene-2-ylcarbamoyl)-butyric acid Functionalized TentaGel S—NH 2 :
[0000]
[0086] A mixture of the 90 μm TentaGel S—NH 2 beads (50 mg, 23 μmol) and 4-(9-Oxo-9H-thioxanthene-2-ylcarbamoyl)butyric acid 2,5-dioxp-pyrrolidin-1-yl-ester (9.8 mg, 23 μmol) in 2 mL of CH 2 Cl 2 was shaken in an orbital shaker at room temperature for 24 hrs. The beads were washed with ethyl acetate (4×2 mL), acetonitrile (2×2 mL), shaken with acetonitrile (2 mL) for 1 hr, decanted, washed with acetonitrile several times, and dried under vacuum at 50° C. overnight to afford yellow beads.
[0087] 4-[9-Hydroxy-9-(2-methyl-[1,3]-dithan-2-yl)-9H-thioxanthene-2-ylcarbamoyl]butyric acid Functionalized TentaGel S—NH 2 :
[0000]
[0088] A mixture of TentaGel S—NH 2 (100 mg, 45 μmol) and 4-[9-Hydroxy-9-(2-methyl-[1, 3]-dithan-2-yl)-9H-thioxanthene-2-ylcarbamoyl]-butyric acid 2-methylene-5-oxo-pyrrolidin-1-yl-ester (26 mg, 45 μmol) in 2 mL of CH 2 Cl 2 was shaken in a orbital shaker at room temperature for 24 hrs, washed with ethyl acetate (4×2 mL), acetonitrile (2×2 mL), shaken with acetonitrile (2 mL) for 1 hr, decanted, washed with acetonitrile several times, and dried under vacuum at 50° C. overnight to afford a pale yellow beads.
[0089] Determination of Quantum Yield of Fluorescence: Thioxanthone was used as a reference molecule for determining the quantum yield of fluorescence (φ flu =0.12 in methanol). The quantum yield of Fluorescence was determined using the following equation.
[0000] φ f =( A s ·F u /F s ·A u )×φ s
[0000] where:
[0090] A s =Absorbance of the standard
[0091] A u =Absorbance of the unknown
[0092] F s =Emission intensity of the standard
[0093] F u =Emission intensity of the unknown
[0094] φ s =quantum yield of the standard (0.12)
[0095] Fluorescence Microscopy
[0096] The images were obtained with a Zeiss Axiovert S100 inverted microscope equipped with a z-stepper motor, Sutter filter wheels and Cooke Sensicam CCD camera. The images were processed with Slidebook software (Intelligent Imaging Innovations, Denver, Colo.).
[0097] Laser Flash Photolysis
[0098] The system used: Applied Photophysics LKS.60/S Nanosecond Laser Photolysis Spectrometer with a digitizer from Agilent Technologies and a Laser System provided by OPOTEK.
[0099] One and two photon laser induced fluorescence of compound 1 d show matching lifetimes. For single photon LIF: exited at 355 nm; emission @ 460 nm; lifetime is 4.8 ns For two photon LIF: exited at 532 nm; emission @ 460 nm; lifetime is 4.5 ns (data not shown).
[0100] Although the description herein 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 invention. For example, fluorescent molecules, molecules of interest and masking groups other than those specifically exemplified herein may be used, as known to one of ordinary skill in the art without undue experimentation. Additional embodiments are within the scope of the invention and within the following claims. Chemical synthesis methods to attach masking groups to fluorescent molecules and molecules of interest to masking groups and/or fluorescent molecules are known to one of ordinary skill in the art. Other detection methods are known in the art. Additional embodiments are within the scope of the invention described in the specification and within the following exemplary claims.
[0101] When a group of substituents is disclosed herein, it is understood that all individual members of those groups and all subgroups, including any isomers and enantiomers of the group members, and classes of molecules that can be formed using the substituents are disclosed separately. When a molecule is claimed, it should be understood that molecules known in the art including the molecules disclosed in the references disclosed herein are not intended to be included. In particular, it should be understood that any molecule for which an enabling disclosure is provided in any reference cited in this specification is to be excluded from the claims herein if appropriate. When a Markush group or other grouping is used herein, all individual members of the group and all combinations and subcombinations possible of the group are intended to be individually included in the disclosure. Unless otherwise indicated, when a molecule is described and/or claimed herein, it is intended that any ionic forms of that molecule, particularly carboxylate anions and protonated forms of the molecule as well as any salts thereof are included in the disclosure. Counter anions for salts include among others halides, carboxylates, carboxylate derivatives, halogenated carboxylates, sulfates and phosphates. Counter cations include among others alkali metal cations, alkaline earth cations, and ammonium cations.
[0102] Every formulation or combination of components described or exemplified can be used to practice the invention, unless otherwise stated. Specific names of molecules are intended to be exemplary, as it is known that one of ordinary skill in the art can name the same molecules differently. When a molecule is described herein such that a particular isomer or enantiomer of the molecule is not specified, for example, in a formula or in a chemical name, that description is intended to include each isomer and enantiomer of the molecule described individually or in any combination. One of ordinary skill in the art will appreciate that methods, device elements, starting materials, synthetic methods, and detection methods other than those specifically exemplified can be employed in the practice of the invention without resort to undue experimentation. All art-known functional equivalents, of any such methods, starting materials, synthetic methods, and detection methods are intended to be included in this invention. Whenever a range is given in the specification, for example, a temperature range, a time range, or a composition range, all intermediate ranges and subranges, as well as all individual values included in the ranges given are intended to be included in the disclosure.
[0103] As used herein, “comprising” is synonymous with “including,” “containing,” or “characterized by,” and is inclusive or open-ended and does not exclude additional, unrecited elements or method steps. As used herein, “consisting of” excludes any element, step, or ingredient not specified in the claim element. As used herein, “consisting essentially of” does not exclude materials or steps that do not materially affect the basic and novel characteristics of the claim. Any recitation herein of the term “comprising”, particularly in a description of components of a composition or in a description of elements of a device, is understood to encompass those compositions and methods consisting essentially of and consisting of the recited components or elements. The invention illustratively described herein suitably may be practiced in the absence of any element or elements, limitation or limitations which is not specifically disclosed herein.
[0104] The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed. Thus, it should be understood that although the present invention has been specifically disclosed by preferred embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention. All photolabile systems known in the art to function in the identical method as those described herein are not intended to be included in this disclosure and should be construed as disclosed and not included individually and in combination.
[0105] In general the terms and phrases used herein have their art-recognized meaning, which can be found by reference to standard texts, journal references and contexts known to those skilled in the art. The specific definitions are provided to clarify their specific use in the context of the invention.
[0106] All patents and publications mentioned in the specification are indicative of the levels of skill of those skilled in the art to which the invention pertains.
[0107] One skilled in the art would readily appreciate that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. The molecules and methods and accessory methods described herein as presently representative of preferred embodiments are exemplary and are not intended as limitations on the scope of the invention. Changes therein and other uses will occur to those skilled in the art, which are encompassed within the spirit and scope of the invention.
[0108] All references cited herein are hereby incorporated by reference to the extent that there is no inconsistency with the disclosure of this specification. Some references provided herein are incorporated by reference herein to provide details concerning additional starting materials, additional methods of synthesis, additional methods of analysis and additional uses of the invention. U.S. provisional application 60/697,760, filed Jul. 8, 2005, from which this application claims priority, is incorporated by reference in its entirety.
REFERENCES
[0000]
Schoevaars, A. M.; Kruizing a, W.; Zijistra, R. W. J.; Veldman, N.; Spek, A. L.; Feringa, B. L. J. Org. Chem. 1997, 62, 4943.
Kurchan, A. N.; Kutateladze, A. G. Org. Lett., 2002, 4, 4129. | A method of photofragmentation is provided comprising: providing a masked fluorescent molecule having a masking group bonded to a fluorescent molecule through a photolabile covalent bond; exposing the masked fluorescent molecule to cleaving photoradiation, producing an unmasked fluorescent molecule; detecting the fluorescence of the unmasked fluorescent molecule. The photolabile covalent bond disrupts the conjugation of the fluorescent molecule, causing the fluorescence to be masked. When the photolabile covalent bond is broken, the conjugation is restored, resulting in an increase in fluorescence of the fluorescent molecule as compared to the masked fluorescent molecule. | 1 |
BACKGROUND
[0001] Whipstocks are well known to the hydrocarbon industry as devices providing a hardened diverter face useful to cause a milling tool run into the downhole environment either behind (single trip) or after (multiple trips) the whipstock to track through a wall of a borehole whether that hole be cased or open. The ability to cause such “side tracks” is important in that it is the basis for multilateral wellbore technology. Multilateral technology has dramatically enhanced the ability of operators to recover hydrocarbon materials from subsurface formations by accessing multiple reservoir areas from a single surface location. This reduces the cost involved with recovering the hydrocarbon materials and in addition, reduces the footprint of a well system at the surface.
[0002] Inherent in the milling of either a casing or the formation or both is the production of debris. Debris in the wellbore is undesirable because it tends to cause malfunctions in well equipment resulting in delays and additional costs in running the well operation. In order to avoid debris falling down the wellbore, debris barrier devices have been employed by the industry. Unfortunately, an effective debris barrier has eluded the art.
SUMMARY
[0003] A self adjusting debris excluder sub includes a cup; a cone configured to bias the cup to a sealed position; and a support having an end supporting the cup and an end mounted in the sub to allow lateral movement of the end that supports the cup.
[0004] A self adjusting excluder sub includes a first subassembly; a second subassembly with respect to which the first subassembly is axially movable; and a support disposed at the second subassembly and when actuated being resiliently disposed against the first subassembly while being laterally movable relative to the first and second subassemblies jointly.
[0005] A debris excluder includes a cup having a first perimetrical dimension smaller than a tubular member in which it is intended to be run; and a cone in operable communication with the cup to selectively increase the cup to a second perimetrical dimension.
[0006] A method for milling a window while excluding debris includes shifting a second subassembly relative to a first subassembly in a self adjusting excluder sub; and expanding a cup of the first subassembly with a cone of the second subassembly, the cone mounted on a support articulated from the second assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Referring now to the drawings wherein like elements are numbered alike in the several Figures:
[0008] FIG. 1 is a cross-sectional view of a debris catcher for use with a whipstock as disclosed herein.
DETAILED DESCRIPTION
[0009] It has been discovered by the inventors hereof that whipstock debris catchers of the prior art have been thwarted by properties inherent in the whipstock assembly. Because whipstock assemblies are pushed to a side of the primary borehole in which they are anchored opposite of the side of the borehole at which an exit is being milled by the milling tool, debris excluding devices of the prior art can fail to catch all the debris. Further, because the greatest concentration of debris is generated on the side of the whipstock that is being pushed away from the borehole wall, generally, therefore also being the side of the whipstock where a prior art debris catcher is most vulnerable, debris generally escapes capture.
[0010] Referring to FIG. 1 , a debris catcher arrangement 10 is illustrated that accommodates the lateral movement of the whipstock inherent in milling the casing or open hole wall. The arrangement 10 includes a bottom sub 12 that is configured to be received in an anchor of the prior art (not shown). The bottom sub 12 includes at least one, and as shown, a series of ports 14 to prevent a swabbing effect of the tool as it is tripped into or out of the hole. A downhole end of the bottom sub 12 is, as noted above, configured for receipt by a conventional anchor (not shown) in the wellbore. This, then, is also the pivot point about which the arrangement 10 and a whipstock (not shown) attached thereto (at a top sub introduced later herein) pivot when the whipstock is urged laterally during a milling operation as discussed above. The bottom sub 12 is attached at an uphole end 16 thereof to each of a collet 18 , a mandrel 20 and a spring retainer 22 . The collet and the spring retainer are fixedly attached to the bottom sub 12 at affixation 24 and 26 , respectively, while the mandrel 20 is axially slidably received at the bottom sub 12 . A torque transmissive coupling 28 is provided between the mandrel and the bottom sub for two specific reasons. The first is to allow torque generated as a byproduct of the milling operation to be borne through the arrangement to the anchor (not shown) so that the whipstock (not shown) will remain in the orientation in which it is intended to exist. The second is to provide a stroke length that is designed into the tool and ensures that a fluid bypass closing operation (discussed more fully hereunder) takes place reliably. In one embodiment, the stroke length is about 1.5 inches although it is to be appreciated that other lengths can be designed in for particular applications.
[0011] The collet 18 cooperates with the mandrel 20 through a resiliency of the collet occasioned by one or more slits 30 therein, a series of slits 30 being illustrated. The collet 18 includes a profile 32 thereon complementarily shaped to a recess 34 in the mandrel 20 . The profile 32 is disposed downhole of the recess 34 during run in and prior to actuation of the debris seal arrangement 10 and resides in the recess 34 after such actuation. It is to be appreciated that it is the mandrel that moves downhole rather than the collet moving uphole during actuation. The collet 18 is axially fixed. In one embodiment, the collet 18 is configured to provide a deflection force of about 20,000 pounds. This means that the collet can be snapped in for actuation and snapped out for deactivation of the arrangement 10 by using a set down weight of about 20,000 or a pull of about 20,000 pounds. Other amounts of force can be designed in. In the embodiment discussed, this rating is selected to be between the typical setting range of about 12,000 to about 15,000 pounds for the anchor (not shown) and about 40,000 pounds for the milling bit to whipstock release member (not shown but well known commercially available configuration). This will ensure that the arrangement 10 actuates at the appropriate time. In addition, it is to be appreciated that the collet as disclosed herein, in combination with the other components, disclosed results in an arrangement that does not utilize one time release members such as shear screws thereby enabling the arrangement to be snapped in/snapped out numerous times if necessary or desired for some reason. Debris excluding configurations of the prior art do not possess such capability.
[0012] Consequent movement of the mandrel 20 , at least one opening 36 or a series of openings 36 as illustrated, are blocked during the actuation phase of the arrangement 10 . The openings 36 are necessary to allow fluid to flow from an annular area of the wellbore 40 through the arrangement 10 and through ports 14 back to the annular area when the arrangement is being run in or retrieved from the hole, a fluid bypass arrangement. After the arrangement 10 is landed in the anchor (not shown), blocking the openings 36 closes a potential debris path. In order to ensure that the bypass is closed, the stroke of the mandrel must be a substantially fixed dimension. As noted above, in one embodiment, the length is 1.5 inches. Were the arrangement 10 to stop stroking the mandrel 20 prior to achieving the full design stroke (of for example 1.5 inches), the blocking of the bypass might well be ineffective leading to potential migration of debris through the arrangement 10 . As this would be contrary to the point of the arrangement 10 , it is undesirable. Therefore, it is important to achieve a full stroke. Potentially impeding the gratification of full stroke, however, is the relative unknown of the casing or open hole inside dimension. If the debris excluding arrangement encounters resistance to the stroke due to contact with the casing or open hole wall, the full stroke can be in jeopardy. To alleviate this potential occurrence, resiliency in the arrangement is also provided (discussed further hereunder).
[0013] Also, consequent movement of mandrel 20 , a debris catch system 42 of the arrangement 10 , is actuated. The debris catch system 10 comprises a cup thimble 44 (through which openings 36 extend) fixedly attached to the mandrel 20 . A cup 46 is nested within the cup thimble 44 and further anchored to the mandrel at shoulder 48 . Cup 46 may be constructed of a number of different materials providing they have a debris exclusionary effect. Materials include but are not limited to a resilient material such as rubber or plastic, a wire brush comprising metal or other material capable of withstanding the environment in which it is intended to be deployed, etc. The material is to act as a debris catch with the casing or open hole wall to exclude debris from falling downhole of the arrangement 10 when actuated. In one embodiment as illustrated, the cup 46 is a frustoconical structure that grows in diametrical dimension in a downhole direction. This provides an advantage for retrieval of the arrangement 10 because debris cannot collect in the concavity defined by the frustocone. Such debris would interfere with dimensional reduction of the cup 46 when retrieving the arrangement 10 , an undesirable occurrence. Prior to actuation (including during run in) the system 42 is a clearance fit within the borehole so that the cup 46 does not experience significant wear during the run in and so that the tool avoids “float” in the bore related to too small of an annular space around the cup 46 for fluid to easily pass during the run in.
[0014] Once the arrangement 10 is in place in the borehole, it is actuated whereby the cup 46 is radially displaced, to effect a debris catch. Displacement in one embodiment is by a cone 50 . The cone 50 is fixedly mounted upon a support 52 , for example, a sleeve as illustrated, which is itself disposed about the mandrel 20 but not in contact therewith. The cone 50 acts as a wedge against the cup 46 to cause the cup 46 to grow in outside dimension. The sleeve 52 is axially moveably mounted about the mandrel 20 with a clearance annulus 54 . Clearance annulus 54 is disposed between an inside dimension surface 56 of the sleeve 52 and an outside dimension surface 58 of the mandrel 20 . This annulus, provided within the arrangement 10 , is important in that it allows the cone 50 to remain relatively centralized in the borehole even when the whipstock (not shown) is urged off center thereby causing the arrangement 10 to pivot about the anchor point at a downhole end of the bottom sub 12 . The centralized position of the cone causes the cup 46 to be pushed into contact with the wall of the casing or open hole even though the whipstock is out of center. Because of the arrangement 10 , debris exclusion is enhanced. In one embodiment, the cone 50 is mounted at one axial end of the sleeve while the other axial end of the sleeve is mounted to the mandrel 20 allowing the end of the sleeve supporting the cone to move laterally relative to the arrangement 10 .
[0015] Further to the foregoing, the sleeve 52 includes at a downhole end thereof a radially thickened section 60 with a stop surface 62 . The stop surface 62 is cooperable with a stop flange 64 . Sleeve 52 further includes an end 66 that is limited in movement by a shoulder 68 of mandrel 20 . Total axial movement of the sleeve 52 and therefore cone 50 is limited to the illustrated distance between end 66 and shoulder 68 . Promoting articulation of the sleeve 52 about its thickened section 60 is a ridge 70 which spaces the thickened section 60 of the sleeve from the mandrel 20 providing an articulation point.
[0016] The cone 50 is biased by a resilient member 70 , such as a spring, as illustrated. The resilient member 70 is protected by a cover 72 . The bias drives the cone into the cup 46 in order to expand the same when the sleeve 52 is driven in a downhole direction by the movement of the arrangement 10 . Further, the member 70 serves another purpose for the arrangement 10 and that is to allow resiliency in the system 42 when the cup 46 contacts the borehole wall prior to the mandrel fully stroking the designed in distance. For example then, assuming the cup 46 contacts the borehole wall early in the stroke of the mandrel, the mandrel will not be prevented from achieving a full stroke because the member 70 deflects to facilitate full stroke of the mandrel. In other words, because after the cup 46 contacts the borehole wall, the cone cannot significantly more move into cup 46 , something has to give or the mandrel will stop its stroke. What gives in the illustrated embodiment is the member 70 to allow the rest of the stroke to occur. It is to further be appreciated that while no seal is shown at the bypass, one could easily be created by providing seals such as o-rings on the collet straddling the openings 36 . Because the arrangement is primarily a debris catcher, sealing is unnecessary. It is well to note, however, the sealing potential of the arrangement 10 if needed for a particular application.
[0017] Initial downhole movement of the arrangement comprises a downhole motion of a first sub assembly of the arrangement 10 comprising the mandrel 20 , cup 46 , cup thimble 44 , a top sub 62 (all of which are fixed relative to each other) and other components (not shown) attached uphole of the components illustrated relative to a second subassembly comprising the bottom sub 12 , the collet 18 , the spring retainer 22 , the sleeve 52 , the cone 50 and the resilient member 70 . When the mandrel moves downhole, the collet 18 deflects and moves the profile 32 into the recess 34 . Due to the retainer 22 being fixedly attached to bottom sub 12 , the resilient member 60 cannot move downhole but rather is compressed axially both facilitating stroke for the mandrel 20 , as noted above and resulting in a rebound force that is used to force the cup 46 to open. The rebound force facilitates the maintenance of the cup 46 in a position to effectively exclude debris even when the arrangement 10 is pivoted out of position due to the whipstock being urged off center into a wall of the borehole opposite the exit window being milled.
[0018] While preferred embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation. | A self adjusting excluder sub includes a first subassembly; a second subassembly with respect to which the first subassembly is axially movable; and a support disposed at the second subassembly and when actuated being resiliently disposed against the first subassembly while being laterally movable relative to the first and second subassemblies jointly and method. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[1] 1. This application is a continuation-in-part application of Ser. No. 09/259,019, filed Feb. 26, 1999, now U.S. Patent [ ].
FIELD AND BACKGROUND OF THE INVENTION
[2] 2. The present invention relates generally to the field of control systems for lighting devices and in particular to a new and useful electronically addressable device and DMX-512 protocol addressing system for the device.
[3] 3. Theater lighting systems used in stage productions are often elaborate and include many different lighting devices and effects devices to produce a desired lighting combination. In recent years, many different aspects of lighting systems have been computerized to improve the ease and speed with which a lighting program for a particular stage show can be set up. While many different control systems are available for this purpose, one protocol which is generally accepted for use in theater lighting in particular is the DMX-512 protocol. DMX-512 protocol refers to a protocol standard as defined by the United States Institute for Theatre Technology, Inc. (USITT).
[4] 4. Presently, a DMX-512 protocol controller has up to 512 channels transmitted serially to each of any number of connected lighting system devices. Known devices each contain a manually set address circuit which identifies the particular channel or channels that the device will take instructions from the DMX-512 controller. Each of the DMX-512 controller channels has multiple levels, or amplitude settings, to produce different conditions in the connected lighting devices, whether they be dimmers, color mixers, etc. The DMX-512 controller does not produce a digital signal; that is, a binary address cannot be programmed on any one of the DMX-512 controller channels.
[5] 5. A drawback to the known lighting devices used with DMX-512 protocol systems is that the addresses of the devices must be set manually using DIP switches by a person having physical contact with the device. In order to change the address of a particular device, the DIP switches must be reset in the proper configuration for the new address.
[6] 6. When the lighting devices have been mounted on fly rods many feet above a theater stage, this can present a problem. Either the entire fly rod must be lowered to the level of the stage or a stage hand must climb up to the position of the lighting device. When the lighting devices are not mounted on movable theater equipment, but rather in a fixed spot this difficulty is increased. The address switches may be obstructed by other objects as well, including the mounting brackets for the lighting device, further increasing the difficulty of changing the address of a device.
[7] 7. The DMX-512 protocol control system is discussed in connection with the lighting system taught by U.S. Pat. No. 4,947,302. The lighting system is programmable with intensity changes, movements, etc., but the addresses of the lamps and other devices are not programmable.
[8] 8. Other types of lighting systems with digitally addressable devices are known.
[9] 9. For example, a lighting system with programmable addressable dimmers is taught by U.S. Pat. No. 5,530,332, which discusses the problems associated with manually set addressable dimmers and teaches a dimmer which is addressed by first entering a program mode by depressing buttons. An address is then set in the dimmer memory by using a central controller to generate the address location data and send the address to the dimmer. The address location data is a binary word.
[10] 10. U.S. Pat. No. 5,059,871 teaches a lighting system in which individual lamp controllers may have their addresses programmed electronically from a central controller unit. When one of the lamp controllers is placed in a programming mode, a Master Control Unit (MCU) in the central controller unit is used to generate an identification (ID) for the lamp controller. The particular ID is set by incrementing or decrementing any channel on the central controller between 1 and 31. The ID value is shown in binary code on a LED display. The ID in the lamp controller is the address used to select the lamp(s) connected to the lamp controller. The lamp controller may be a dimmer or on/off switch, for example.
[11] 11. A control system with programmable receivers for controlling appliances is disclosed by U.S. Pat. No. 5,352,957. The receivers may control lights, for example. The original addresses for the controlling receivers are initially set manually, but may be changed electronically once the receivers are connected to the control system. The addresses of the receivers are set automatically based on their positioning within the system, rather than by a person on an arbitrary basis.
[12] 12. U.S. Pat. No. 5,245,705 discloses a memory addressing system in which a central control unit sends a message signal with an address code to several attached devices over a bus interface. Devices which are encoded to accept the address code respond to the message signal. At column 6, lines 3-8, this patent indicates that the functional addresses recognized by a device may be changed using a control message. The memory addressing system is not specifically for a lighting system, but rather, is for use in a general data processing system.
[13] 13. Lighting systems using addressable lamps controlled by computers are also known in the prior art.
[14] 14. U.S. Pat. No. 5,406,176 teaches a lighting system controlled by a personal computer. The computer can address individual lamps which have pre-programmed addresses. However, changing the addresses of the lamps using the computer is not taught.
[15] 15. U.S. Pat. No. 4,392,187 discloses a console-controlled lighting system having addressable lights of the manual set type. The electronic address of each light is set using manual thumb switches. The console sends instructions which are interpreted by the light to which they are addressed.
[16] 16. A series of lighting cues can be programmed and stored in memory in each lamp of the lighting system disclosed by U.S. Pat. No. 4,980,806. The different lighting cues, or setups, can be recalled by a signal sent from a central controller. The electronic addresses of the individual lamps are not changed using the controller.
[17] 17. U.S. Pat. No. 5,072,216 discloses a track lighting system having individual lights with manually set address switches contained in the light housings.
[18] 18. None of these prior systems provides a method or system for using a DMX-512 protocol controller to remotely change or set the address of devices connected to the controller.
SUMMARY OF THE INVENTION
[19] 19. It is an object of the present invention to provide an electronically addressable device that can be used with a serial network control system and the address of the device can be set remotely using a central controller.
[20] 20. It is a further object of the invention to provide a method for using a DMX-512 protocol or other serial network protocol controller to remotely set the addresses of any number of connected devices.
[21] 21. Yet another object of the invention is to provide a method for remotely setting threshold and other preset values in one or more devices connected to a central controller using DMX-512 or other serial network control protocols.
[22] 22. Accordingly, the invention has a central controller, or code generating, system having a fixed number of control channels with at least one channel connected to an addressable device to be controlled, such as an addressable light dimmer. Multiple devices can be controlled by a single central controller using the individual channels to send control signals to connected addressable devices having their addresses set to specific ones of the channels.
[23] 23. Each device being controlled by the central controller has an electronic circuit which can interpret control signals. Each light dimmer has an electronic address which is set and is preferably unique to that device. The electronic address setting determines which of the individual channels of control information the device will take instructions from, while ignoring instructions on other channels.
[24] 24. Previously, the electronic address of addressable light dimmers and devices has been set using manual DIP switches on an exterior panel. Thus, once the device is positioned or mounted on a stage set, its address may not be easily changed if access to the device is restricted.
[25] 25. According to the invention, the electronic address for each device can be set electronically using a combination of keypress commands and a control signal from the central controller. The keypress commands, which may be made manually on the controllable devices or with a remote control, instruct the selected devices to enter an address set, or programming, mode.
[26] 26. Then, all of the control channels except for the channel that will address the device are set to zero amplitude level. That is, to set the address of the device to 30, a central controller channel 30 is the only channel not set to zero. The lone non-zero channel level is set to any non-zero level, preferably at least above a threshold level, V t . The controller serially sends the signals for each channel to every connected controllable device. The device in address set mode decodes each channel signal and identifies the single non-zero level channel, which it then stores in a non-volatile memory, setting the address of the device to the non-zero level channel. Each device can then be returned to normal operation mode by operation of the remote or local keys on the device.
[27] 27. In a case where the addressable device uses more than one channel, the non-zero level channel sets the base address, and the additional channels used by the device are set as the next sequentially higher channel from the base address channel.
[28] 28. Alternatively, in addition to setting an address channel for the connected devices, peak and minimum limits, and other preset values, such as initial system states can be programmed with the address. The limits or preset values can be programmed using specific blocks of controller channels, or using channels following the non-zero channel setting the address. The addressable devices contain circuitry and software needed to store and interpret the signals received from the controller.
[29] 29. Thus, using the invention, several addressable devices can be positioned or mounted, as on a theater stage and using a combination of remote controls and the a controller, such as a DMX-512 controller, the addresses and preset limits of the devices may be set easily from a distance without disturbing their positioning.
[30] 30. The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[31] 31. In the drawings:
[32] 32.FIG. 1 is a schematic representation of the layout of a control system of the type used in the invention;
[33] 33.FIG. 2 is a graphical depiction of a signal generated by a DMX-512 protocol controller;
[34] 34.FIG. 3 is a perspective view of a remote control used with the invention;
[35] 35.FIG. 4 is a perspective view of one type of addressable control device used with the invention;
[36] 36.FIG. 5 is a graphical depiction of the output of a DMX-512 protocol controller when setting an address of one of the addressable control devices;
[37] 37.FIG. 6 is a graphical depiction of the output of a DMX-512 protocol controller used to set the address and a device feature limit;
[38] 38.FIG. 7 is a graphical depiction of an alternative output of a DMX-512 protocol controller used to set the address and a device feature limit; and
[39] 39.FIG. 8 is a schematic block diagram of an addressable device used with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[40] 40. Referring now to the drawings, in which like reference numerals are used to refer to the same or similar elements, FIG. 1 shows a schematic depiction of a lighting system using a central controller 200 , which may be a DMX-512 protocol controller, to coordinate and set the values of each of several addressable control devices 210 , 212 , 214 , 216 .
[41] 41. The DMX-512 protocol used in a DMX-512 protocol controller is described in a United States Theatre Technology, Inc. (USITT) publication entitled, “DMX512/1990 Digital Data Transmission Standard for Dimmers and Controllers.” The protocol is a network protocol having a central controller for creating stream of network data consisting of sequential data packets. Each packet initially contains a header for checking compliance with the standard and synchronizing the beginning of data transmission, which is then discarded. A stream of sequential data bytes representing data for sequentially addressed device follows the header. For example, if the data packet contains information for device number 31 , then the first 30 bytes after the header in the data stream will be discarded by device number 31 and byte 31 will be saved and used. When more than one byte of information is needed by a device, then its device number is its starting address and the number of required bytes after the starting address will be saved and used. The DMX-512 protocol uses a data stream of up to 512 bytes each having hexadecimal values corresponding to decimal numbers from 0-255.
[42] 42. Other serial control systems can be used for central controller 200 as well, such as a computer having a serial network link to each connected control device 210 - 216 to provide serial data commands. As used herein, it should be understood that such a serial controller could be substituted for a DMX-type controller.
[43] 43. The addressable control devices 210 - 216 each convert an information signal from one or more of the DMX-512 controller 200 channels into a usable signal for one or more attached lighting elements such as lamps 220 , color adjustors 225 or gobo wheels 230 , for example. Thus, the addressable control devices 210 - 216 could be dimmers or other types of control devices used in theatrical lighting. The addressable control devices 210 - 216 include circuits for setting the electronic address that determines which channel or base channel in the signal from the DMX-512 controller 200 is received and interpreted by the addressable control devices 210 - 216 .
[44] 44. As discussed above, known DMX-512 controllers have up to 512 channels, each of which can transmit a different amplitude level. The amplitude level on each channel can be set to one of up to 255 discrete levels, with zero as the lower bound. The present invention takes advantage of the fact that the amplitude signal of each channel can be set individually and independently of the other channels combined with the fact that the signal from each channel is always transmitted serially in the same order at a constant rate with constant period in a repeating manner. That is, all 512 channels are continuously broadcast from the controller in series starting with channel 1 , like a clock pulse train having different amplitudes.
[45] 45.FIG. 2 shows a sample output signal 108 from a DMX-512 protocol controller having 512 channels. Relative time is shown along the x-axis 105 and analog amplitude is shown on the y-axis 107 . The time at which the 512 th channel is broadcast is marked along the time axis 105 to show the repeating nature of the signal 108 . As can be seen, a fixed time period T passes between each broadcast of the 512 th channel. Each of the 512 channels is broadcast sequentially during the time t encompassed by the period T. Depending on the length of period T and changes made at the DMX-512 controller, the signal 108 may repeat several times before changing, or it may change in the next cycle.
[46] 46.FIGS. 3 and 4 illustrate generally an addressable control device 210 and a remote control unit 90 that can be used with the invention.
[47] 47. The addressable control device 210 has a button panel 50 with a series of control buttons 51 - 55 and an LED indicator 56 . The control buttons 51 - 55 are used to operate the device 210 to manually control a connected element, such as a lamp. For example, the buttons 51 - 55 may be part of a dimmer control circuit and include level up and level down buttons, preset level buttons and a power switch. For use with the invention, at least one combination of button presses can be used to switch an address circuit inside the device between an operating mode and a programming mode. For example, if both buttons 51 and 52 are held down simultaneously, the control device 210 will switch modes. The LED indicator 56 can be used to indicate when a button has been pressed and when the mode has been changed, such as by blinking repeatedly while in the programming mode.
[48] 48. A power connection 80 , control cable 70 and infrared sensor 60 are provided on the control device 210 . The control cable 70 is used to receive signals from the DMX-512 controller 200 . Power connection 80 can be used to connect a controlled lighting element. The lighting element can be controlled by varying the power output to the element. Infrared sensor 60 is used to receive signals from the remote control 90 .
[49] 49. The remote control 90 includes buttons 91 - 95 which correspond to the same functions as are found on the control device 210 . The remote control 90 can be used to change settings on the control device 210 from a distance, thereby eliminating the need to be in physical proximity to the control device 210 to switch to the programming mode from the operating mode, for example.
[50] 50. Additional infrared sensors can be provided on the control device 210 so that at least one sensor is capable of receiving signals from remote control 90 when the addressable control device 210 is positioned above a theater stage for use in a lighting arrangement. Preferably, the LED indicator 56 is visible to provide visual confirmation that signals sent from the remote control 90 are received by the addressable control device 210 .
[51] 51. The addressable control device 210 has the address circuit inside which is used to set and change the electronic address of the device. The electronic address of the control device 210 is the channel or base channel of the signal sent by the DMX-512 controller 200 that the control device 210 will take instructions on during operation. The control device 210 may have a base address when multiple channels are used to operate the control device 210 . In such a case, the electronic address is set to the lowest number channel that information will be broadcast on. The control device 210 will then take information from the signal broadcast by the DMX-512 controller on the base channel and each sequential channel after the base channel to obtain the full signal needed to operate the control device 210 . An example of how the electronic address of the control device 210 can be set is as follows.
[52] 52. All connected control devices 210 - 216 which will have the same electronic address are switched into the programming mode either using the buttons 51 - 55 on the control devices 210 - 216 themselves, or the remote control 90 . The DMX-512 controller 200 is set so that all of the channels have amplitude levels of zero, except for the channel which corresponds to the electronic address the control device 210 will be set to.
[53] 53.FIG. 5 is an illustration of one possible signal sent by a DMX-512 controller 200 to none or more addressable control devices 210 - 216 connected to the controller 200 to set the electronic address of whichever devices are in the programming mode. The amplitude level of the signal 108 is shown on the y-axis 107 versus time on the x-axis 103 . The graph shows the amplitude level 108 of each channel as the amplitude level of all 512 channels is sent sequentially in time t during period T. All of the channels 150 are set to zero level 110 , except for channel 9 , which is set to any non-zero amplitude level 100 greater than V t . The control signal 108 is then sent to the connected devices 210 - 216 , which receive the repeating signal of period T and interpret the amplitude level of each channel 150 . The electronic address of any control devices 21 - 216 in the programming mode will be set to the non-zero level channel.
[54] 54. Thus, in this example, the electronic addresses of any connected control devices 210 - 216 which are in the programming mode will be set to channel 9 . If the connected control device 210 - 216 in programming mode is a multi-channel device, the base address will be set to channel 9 , and channels 10 , 11 , 12 , etc. will be used in sequence for the remaining channels by the control device.
[55] 55. Once the DMX-512 control signal 108 has been sent while the control devices 210 - 216 are in the programming mode, the signal 108 can be terminated and the control devices 210 - 216 switched back to operating mode. A different electronic address can then be set for other control devices 210 - 216 .
[56] 56. Alternatively, the DMX-512 controller 200 amplitude levels for each channel can be set first, followed by placing the appropriate control devices 210 - 216 in programming mode. Clearly, the controller signal 108 for setting the electronic address should be terminated or the control devices 210 - 216 taken out of programming mode before changing settings during programming to avoid errors.
[57] 57. In a further embodiment of the addressing system, as shown in FIGS. 6 and 7, in addition to setting an address for a connected control device 210 - 216 , the controller 200 can be used to set peak and minimum limit or preset levels, collectively referred to as preset levels, in the control devices 210 - 216 .
[58] 58. The control devices 210 - 216 must be capable of interpreting a signal received on a predefined channel while in the programming mode as being a preset value for a particular function. As seen in FIG. 8, the control device 210 contains a micro-controller 300 having software or which is hardwired with logic programming for this purpose. To store information and facilitate the operation of the micro-controller 300 , RAM 330 , ROM 335 and non-volatile storage 340 are connected to the micro-controller via a bi-directional bus. Each of these components is powered by an internal power supply 350 connected to a wall outlet, a battery, a generator or other power source. A program mode switch 320 that is activated as described above is connected to the micro-controller 300 . A line receiver 310 connects the micro-controller 300 to the network cabling 70 delivering signals from the central controller 200 . Finally, a power stage 360 receives control signals from the micro-controller 300 and varies the power output to outlet 80 depending on the micro-controller 300 instructions.
[59] 59. In one embodiment of setting the address and preset levels, when a DMX-512 controller is used, for example, the channels from 502 - 512 may be set aside from use as a device address channel, and instead, are used to transmit preset values to control devices 210 - 216 at the same time as the address channel is set. A preset value transmitted on one of the channels in the upper-most 10-channel block is interpreted by the control device 210 - 216 as corresponding to a specific feature and is stored in programmable, non-volatile memory 340 . The specific feature having the preset value set could be a minimum or maximum dimming/brightness level, another feature depending on percent power output of the control device 210 - 216 , or a maximum shutdown temperature (control device turns off when operating temperature is higher).
[60] 60. As an example, the lighting system of the invention can be used in a large restaurant with several rooms each having different lighting requirements and thus requiring several control devices 210 - 216 . As the addresses for the control devices 210 - 216 in each room are set, a minimum brightness level of 20% could be programmed as well, so that the room can never be made entirely dark accidentally.
[61] 61.FIG. 6 illustrates the output signal from a DMX-512 controller 200 to produce this result. The minimum brightness level can be set by first designating a channel as the control device address, such as channel 35 , and transmitting a non-zero signal above V t , followed by transmitting an amplitude of “20” on channel 505 as the control signal 108 . The micro-controller 300 in the control device 210 is programmed to understand that the amplitude of the signal received on channel 505 corresponds to a minimum level of 20% and stores the value in a non-volatile memory 340 . The remaining channels receive a zero-level signal 110 which is below V t . When necessary to ensure that all intended signals are above V t , the preset instruction amplitudes may be scaled, such as by addition of a constant value, or by a multiplier.
[62] 62. Following programming, while it is in the operating mode, the micro-controller 300 in control device 210 will compare any brightness command received on channel 35 (the control channel) to the 20% preset level stored in memory. If the received command is for a lower brightness percentage, it will be ignored as it is below the preset limit.
[63] 63. As a second example, a theater using the lighting system with a DMX-512 controller might want to limit certain lights from ever being dimmer than 10% brightness, brighter than 80% and having a temperature shutoff at 200° F. The control devices 210 - 216 for the lights in this group are each placed in program mode, as described above.
[64] 64. An address channel is selected, for instance, channel 25 , and the channel amplitude is set to a non-zero value, while the remaining channels from 1 to 411 are all zero value amplitude. Channel 412 corresponding to minimum brightness is set to an amplitude of “10”, channel 452 corresponding to maximum brightness is set to an amplitude of “80”, and channel 502 corresponding to the shutoff temperature is set to an amplitude of “100”. The control devices 210 - 216 receive the non-zero signal on channel 25 and each sets the address for the device as channel 25 . Then the devices 210 - 216 receive the amplitude value of “10” on channel 412 and set a minimum brightness level of 10% in a programmable non-volatile memory 340 . A maximum brightness level of 80% is stored in the memory 340 after the signal on channel 452 is received. The amplitude of “100”received on channel 502 is scaled by a factor of two in accordance with programming in the control devices 210 - 216 to correspond to the shutoff temperature of 200° F. and the value is stored in memory 340 .
[65] 65. In a further alternative, illustrated by the control signal 108 shown in FIG. 7, the control devices 210 - 216 may contain software or other logic programming for understanding that the first non-zero level above V t received in the program mode is the base channel, and that any subsequent non-zero level sets one or more preset values for predefined features. For example, if channel 25 is the desired address for the control device 210 , then channels 1 - 24 will have a zero amplitude and channel 25 will have a non-zero amplitude of any level higher than V t to indicate it is the address channel. Then, any subsequent channel, from 26 - 512 in a DMX-512 system, can contain preset value information.
[66] 66. The preset values can be set based on the order in which they are received when more than one value will be set. The control devices 210 - 216 understand that the first value after the address channel corresponds to one feature, and then the next channel in sequence corresponds to a second feature, followed by the next channel containing information corresponding to a third feature and so on. The preset value setting channels could be spaced by any number of channels to make setting the values easier or reduce errors, if necessary. For example, the micro-controller 300 may contain programming which determines that after the address channel is set, five channels later (channel 30 in the example) contains a minimum brightness setting 120 , while another five channels later contains a maximum brightness setting signal 130 , five channels after than is an initial state (power on) brightness setting signal 140 and five channels later is an overheat shutdown temperature setting (channel 45 ) signal 140 . Thus, a value does not have to be preset for each feature as the amplitude value of the signal 108 on that channel could be left below V t , so that the micro-controller 300 will not interpret that channel as containing any information.
[67] 67. In each of the alternative programming situations described above, the control devices 210 - 216 require a micro-controller 300 or other logic device and software instructions used in the programming mode to evaluate the signals coming from the controller 200 . The software contains information either about which channels are blocked off and correspond to preset value settings, or understands that subsequent non-zero values are preset value settings.
[68] 68. Although the invention is described using a DMX-512 protocol controller to generate the address programming signal, it is possible to use another networking protocol controller having similar features. As noted above, a feature of the DMX-512 protocol which makes it usable for this purpose is the repeating, periodic nature of the serial output signal, which permits the addressable control devices to determine which channel has a non-zero amplitude level when in the programming mode. Thus, another serial transmitting controller having a plurality of channels could be used if the channel amplitude levels are transmitted sequentially in a periodic repeating pattern.
[69] 69. Further, the invention could be used with other types of control systems other than theater lighting systems. For example, the control system is easily adaptable to a variety of architectural lighting, such as for building interiors, building exteriors and home interior design. The control system and addressable devices are also very useful for lighted sign applications, where a complex sign display may require changing different settings to produce a display. The system can be used with neon, other gas discharge, incandescent, and fluorescent lighting schemes.
[70] 70. The invention is ideal for any situation where a central controller is used to operate individual control devices where rapid changing of addresses of the control devices is desired. A clear advantage of the invention over the prior art devices is the ease with which the address or other preset values for each control device connected to the controller can be changed without dismounting or removing the control device from its location.
[71] 71. While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. | An addressable lighting device and control system uses a DMX-512 protocol controller or other serial network protocol controller to selectively generate an electronic address for the addressable lighting device on which the device will respond to all future signals from the controller corresponding to that electronic address. The addressable device has a program mode for setting the address and a working mode for receiving control signals on the set address. The addressable device may have the address set and changed remotely using the DMX-512 protocol controller and a remote control to switch modes, thereby avoiding the problems associated with using DIP switches to set device electronic addresses. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to pellets incorporated with a carbonaceous material and a method of producing reduced iron using the same.
2. Description of the Related Art
As a method of producing reduced iron, a MIDREX method is well known, in which a reducing gas obtained by degenerating natural gas is blown into a shaft furnace through tuyeres, and moved upward in the shaft furnace so that iron ore or iron oxide pellets filled in the furnace are reduced to obtain reduced iron. However, this method requires the supply of a large amount of natural gas expensive as fuel.
Therefore, a process for producing reduced iron using relatively inexpensive coal as a reducing agent in place of natural gas has recently attracted attention. For example, U.S. Pat. No. 3,448,981 discloses a process for producing reduced iron comprising heating and reducing pellets incorporated with a carbonaceous material, which are obtained by pelletizing a mixture of fine ore and a carbonaceous material in an atmosphere of high temperature. This process has the advantages that coal is used as the reducing agent, fine ore can be used directly, high-rate reduction is possible, the carbon content in a product can be adjusted, etc.
In this process, the pellets incorporated with the carbonaceous material are heated by radiant heat from the upper side of a high-temperature reducing furnace, and thus the height of the pellet layer is limited. Therefore, in order to improve productivity, it is necessary to increase the reaction rate of reduction. However, since the reduction rate of the pellets is controlled by heat transfer within the pellets, when the temperature of the reducing furnace is increased to the heat transfer limit of the pellets or more in order to improve productivity, the pellets incorporated with the carbonaceous material are melted from the surfaces thereof to cause the problems of sticking in the furnace, and damage to the furnace body. The pellets incorporated with the carbonaceous material include pellets formed by pelletizing a mixture of raw materials such as fine ore, a carbonaceous material such as coal or the like serving as the reducing agent, and a binder, by using a pelletizer or a molding machine. In this case, the formed pellets incorporated with the carbonaceous material are porous, and have a small area of contact between the carbonaceous material and the fine ore, low thermal conductivity, and a low reduction rate.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide pellets incorporated with a carbonaceous material, which are capable of promoting reduction reaction of iron oxide, and which exhibit excellent strength after reduction, and a method of producing reduced iron using the pellets incorporated with a carbonaceous material with high productivity.
The pellets incorporated with a carbonaceous material of the present invention comprise a carbonaceous material and iron ore mainly composed of iron oxide, wherein combinations of the maximum fluidity of the carbonaceous material in softening and melting and the ratio of iron oxide particles of 10 μm or smaller in the iron ore are within the range above a line which connects points A, B and C shown in FIG. 1, including the line. Point A shown in FIG. 1 is a point where the maximum fluidity is 0, and the ratio of iron oxide particles of 10 μm or smaller in iron ore is 15% by mass; point B shown in FIG. 1 is a point where the maximum fluidity is 0.5, and the ratio of iron oxide particles of 10 μm or smaller in iron ore is 1% by mass; point C shown in FIG. 1 is a point where the maximum fluidity is 5, and the ratio of iron oxide particles of 10 μm or smaller in iron ore is 1% by mass.
In this case, it is possible to promote reduction reaction of iron oxide, and obtain the pellets incorporated with the carbonaceous material exhibiting excellent strength after reduction.
In the present invention, the maximum fluidity is a value which is represented by logDDPM, and obtained by measurement using a Gieseler Plastometer, as defined by JIS M8801. The iron oxide particles of 10 μm or smaller in iron ore are measured by a wet laser diffraction method.
In the present invention, the carbonaceous material represents a carbon-containing material such as coal, coke, petroleum coke, pitch, tar, or the like, and any carbonaceous material which satisfies the above-described relation between the maximum fluidity of the carbonaceous material in softening and melting, and the ratio of iron oxide particles of 10 μm or smaller in iron ore can be used. The carbonaceous material may be a single material or a mixture of a plurality of materials, and the iron ore may be a single type or a mixture of a plurality of types.
The pellets incorporated with the carbonaceous material have excellent thermal conductivity, and thus the use of the pellets can realize improvement in productivity of the production of reduced iron.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing a range of combinations of the maximum fluidity of a carbonaceous material in softening and melting and the ratio of iron oxide particles of 10 μm or smaller in iron ore in order that the ratio of fines of 6 mm or smaller in reduced iron is 10% by mass or less in accordance with the present invention;
FIG. 2 is a graph showing the relation between the ratio of iron oxide particles of 10 μm or smaller in iron ore and the ratio of fines of 6 mm or smaller in reduced iron with each fluidity of a carbonaceous material in softening and melting in Example 1;
FIG. 3 is a graph showing the relation between the reduction time and the ratio of fines of 6 mm or smaller in reduced iron with a reduction temperature of 1300° C. in Example 2; and
FIG. 4 is a graph showing the relation between the rate of temperature rising of the central portions of pellets and the ratio of iron oxide particles of 10 μm or smaller in iron ore.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A carbonaceous material as a reducing agent is softened and melted by the start of carbonization at 260° C. or more, and is solidified at 550° C. or more according to the type of carbon. In this temperature region, the melted carbonaceous material readily enters the spaces between iron oxide particles to strongly bond the iron oxide particles. This bonding structure of iron ore by the carbonaceous material increases the area of contact between the iron oxide particles and the carbonaceous material in pellets, improving the thermal conductivity in the pellets incorporated with the carbonaceous material.
Although the amount of the carbonaceous material mixed may be an amount necessary for reducing iron ore according to the type of the iron ore and the type of carbon used, the amount is generally about 10 to 30% by mass based on the raw material iron ore. The carbonaceous material may be single or a mixture of a plurality of materials. The maximum fluidity is a weight average.
In the present invention, with the carbonaceous material having a maximum fluidity in softening and melting of 0, the thermal conductivity in the pellets incorporated with the carbonaceous material can be improved by adjusting the ratio of iron oxide particles of 10 μm or smaller in iron ore. Namely, by decreasing the particle size of the iron ore, the number of contacts between the iron oxide particles is increased to increase the are of contact between the iron oxide particles, improving thermal conductivity in the pellets incorporated with carbonaceous material even when the maximum fluidity of the carbonaceous material is low in softening and melting. The iron oxide particles of 10 μm or smaller in the iron ore increase the number of bonding contacts between the iron oxide particles metallized by heating and reduction to promote sintering, thereby increasing strength after reduction, obtaining reduced iron with a low fines ratio represented by a ratio of fines of 6 mm or smaller.
An increase in the area of contact between the carbonaceous material and the iron ore also has the function to promote direct reduction with the carbonaceous material. Furthermore, since the iron oxide particles are strongly bonded, the CO partial pressure in the pellets can be increased, promoting gaseous reduction with CO of the iron ore.
In the present invention, the optimum particle size of iron ore according to the maximum fluidity of the carbonaceous material in softening and melting, particularly the amount of the iron ore particles of 10 μm or smaller, is defined so that even when coarse iron ore is used as a raw material, part of the iron ore is ground and the mixed, or a required amount of another fine iron ore is mixed to control the ratio of iron ore particles of 10 μm or smaller after mixing, permitting the achievement of the object of the invention.
FIG. 1 shows a range of combinations of the maximum fluidity of the carbonaceous material in softening and melting, and the ratio of iron oxide particles of 10 μm or smaller in iron ore in order that the ratio of fines of 6 mm or smaller in reduced iron is 10% by mass or less. In the range above a line which connects in turn points A, B and C shown in FIG. 1, including the line, the above object can be achieved.
In the use of coke or petroleum coke without fluidity as the carbonaceous material, the ratio of particles of 10 μm or smaller in the iron ore may be adjusted to 15% by mass or more (corresponding to point A shown in FIG. 1 ). In the present invention, even with the carbonaceous material having no fluidity in softening and melting, the thermal conductivity in the pellets incorporated with the carbonaceous material can be improved by adjusting the ratio of iron oxide particles of 10 μm or smaller in iron ore. Namely, by decreasing the particle size of iron ore, the number of contacts between the iron oxide particles is increased to increase the area of contact between the iron oxide particles, improving the thermal conductivity in the pellets incorporated with the carbonaceous material even when the maximum fluidity of the carbonaceous material in softening and melting is low. In addition, the iron oxide particles of 10 μm or smaller in iron ore increase the number of bonding contacts between the particles metallized by heat reduction to promote sintering, thereby increasing strength of reduced iron, obtaining reduced iron with a low fines ratio represented by the ratio of fines of 6 mm or smaller.
As the maximum fluidity of the carbonaceous material in softening and melting is increased, the ratio of iron oxide particles of 10 μm or smaller in iron ore can be linearly decreased. With the carbonaceous material having a maximum fluidity of 0.5 in softening and melting, the ratio of iron oxide particles of 10 μm or smaller may be 1% by mass or more (corresponding to point B shown in FIG. 1 ). Even with the carbonaceous material having a maximum fluidity of 0.5 or more in softening and melting, or a maximum fluidity of 5 (corresponding to point C shown in FIG. 1 ), the ratio of iron oxide particles of 10 μm or smaller is preferably 1% by mass or more. Because with substantially no particle of 10 μm or smaller in the iron ore, the iron ore particles are significantly coarsened to decrease the number of contacts between the respective iron oxide particles, decreasing the thermal conductivity in the pellets, and causing the danger of decreasing the strength of reduced iron after reduction.
The carbonaceous material having a maximum fluidity of 0.3 in softening and melting, and iron ore containing iron oxide particles of 10 μm or smaller at each of ratios of 1.7% by mass, 4.3% by mass, and 19.0% by mass were used to form three types of pellets incorporated with the carbonaceous material and having a diameter of 17 mm. The thus-formed pellets were charged in an atmosphere of 1300° C., and the rate of temperature rising in the central portions of the pellets was examined. The results are shown in FIG. 4 .
FIG. 4 indicates that as the ratio of iron oxide particles of 10 μm or smaller in iron ore increases, the time required until the central portions of the pellets reach 1300° C. decreases. This is due to the fact that as described above, a decrease in the particle size of iron ore increases the number of contacts between the respective iron oxide particles to secure bonding between the respective iron oxide particles even when the maximum fluidity of the carbonaceous material in softening and melting is low, thereby improving the thermal conductivity in the pellets incorporated with the carbonaceous material.
EXAMPLES
The present invention will be described below with reference to examples.
Example 1
Ten types (A to J) of coal having different maximum fluidities shown in Table 1 were used as carbonaceous materials, and ten types (a to j) of iron ore having different ratios of iron oxide particles of 10 μm or smaller shown in Table 2 were used to produce pellets incorporated with each of the carbonaceous materials and having a diameter of 17 mm. The composition of the thus-produced pellets incorporated with each of the carbonaceous materials comprised 100 parts of iron ore having an iron content of 67 to 70% by mass, 25 to 27 parts of single coal or a mixture of two types of coal, and 1 part of bentonite and 0.1 part of organic binder both of which were used as a binder.
More specifically, predetermined amounts of iron ore, carbonaceous material, and binder were taken out of respective raw material tanks, and then mixed by a raw material mixer. Then, water was added to the resultant mixture, followed by pelletization using a pelletizer. After pelletization, the pellets were passed through a drier to produce the pellets incorporated with a carbonaceous material. The pellets incorporated with a carbonaceous material were reduced under heating by a rotary hearth furnace at 1300° C. for 9 minutes, and the fines ratio of reduced iron after reduction was measured. The results are shown in FIGS. 1 and 2.
FIG. 1 indicates that in the range of combinations of the maximum fluidity of the carbonaceous material and the ratio of iron oxide particles of 10 μm or smaller in iron ore above the line which connects in turn points A, B and C shown in FIG. 1, including the line, the ratio of fines of 6 mm or smaller of reduced iron is as low as less than 10% by mass (marked with o in the drawing). On the other hand, beyond the above range, the ratio of fines of 6 mm or smaller in reduced iron is 10% by mass or more (marked with x in the drawing). FIG. 2 indicates that the fines ratio of reduced iron decreases as the maximum fluidity of the carbonaceous material increases, and the fines ratio of reduced iron also decreases as the ratio of iron oxide particles of 10 μm or smaller in iron ore increases. This is due to the fact that an increase in the maximum fluidity of the carbonaceous material, and an increase in the ratio of iron oxide particles of 10 μm or smaller in iron ore contribute to improvement in strength of the pellets incorporated with a carbonaceous material.
TABLE 1
Melting and
softening
property
Maximum
Chemical Composition (mass %)
fluidity
Fixed
Volatile
Sul-
Symbol
Type
(logDDPM)
carbon
matter
Ash
fur
A
Jelinbah
0.0
74.3
16.1
9.6
0.5
coal
B
Smoky River
0.3
74.4
15.9
9.8
0.4
coal
C
B: 90 mass %
0.4
74.2
16.1
9.8
0.4
F: 10 mass %
D
B: 60 mass %
0.8
73.7
16.6
9.8
0.3
F: 40 mass %
E
Norwich
1.2
72.2
17.3
10.5
0.5
coal
F
Yakut coal
1.6
72.7
17.6
9.7
0.2
G
Gregg River
1.7
69.4
21.3
9.3
0.4
coal
H
Oak Grove
2.6
72.4
18.7
8.9
0.5
coal
I
Blue Creek
3.7
65.2
25.8
9.0
0.8
coal
J
AMCl coal
4.2
57.4
35.0
7.5
0.9
TABLE 2
Particle
size
Chemical Composition (mass %)
−10 μm
Gangue
Sym-
Type
(mass
compo-
bol
Brand
Remarks
%)
T. Fe
FeO
nent
LD1
a
MBR
Fine
1.7
67.9
0.2
1.7
0.7
particles
were
removed
from b
by a
fluidized
bed.
b
MBR
Raw ore
4.3
67.9
0.2
1.7
0.7
c
MBR
b:
5.7
67.9
0.2
1.7
0.7
90 mass %
g:
10 mass %
d
Carajas
Raw ore
5.8
67.5
0.1
1.9
1.5
e
MBR
b:
7.2
67.9
0.2
1.7
0.7
80 mass %
g:
20 mass %
f
MBR
b:
8.6
67.9
0.2
1.7
0.7
70 mass %
g:
30 mass %
g
MBR
b was
18.6
67.9
0.2
1.7
0.7
wholly
ground
by a
ball mill
h
Romeral
Raw ore
19.0
69.5
30.2
2.7
0.4
i
Samarco
Raw ore
19.2
66.7
0.2
2.3
2.5
j
Peru
Raw ore
21.2
70.0
28.0
2.2
0.4
Example 2
Of the pellets incorporated with carbonaceous materials produced in Example 1, two types of pellets including a type (Comparative Example) in which the maximum fluidity of the carbonaceous material was 0.3, and the ratio of iron oxide particles of 10 μm or smaller in iron ore was 4% by mass, and a type (Example of this invention) in which the ratio of iron oxide particles of 10 μm or smaller in iron ore was 7% by mass, were reduced at a reduction temperature of 1300° C., and the reduction time and the fines ratio of reduced iron were measured. The results are shown in FIG. 3 .
FIG. 3 indicates that when the ratio of iron oxide particles of 10 μm or smaller in iron ore is 4% by mass, in order that the ratio of fines of 6 mm or smaller in reduced iron is 10% by mass or less, a reduction time of 9.2 minutes is required for promoting sintering of the metallized particles after reduction. On the other hand, when the ratio of iron oxide particles of 10 μm or smaller in iron ore is 7% by mass, a reduction time of 8.3 minutes are required for attaining the same fines ratio as the above. In this way, an increase in the ratio of iron oxide particles of 10 μm or smaller in iron ore improves the strength of reduced iron, and shortens the holding time in a reducing furnace required for sintering, thereby shortening the reduction time. Therefore, comparison between both types of pellets reveals that productivity of the example of this invention is improved by about 10% as compared with the comparative example. | Pellets incorporated with a carbonaceous material of the present invention contain a carbonaceous material and iron ore mainly composed of iron oxide. The maximum fluidity of the carbonaceous material in softening and melting, and the ratio of iron oxide particles of 10 μm or smaller in the iron ore are within the range above a line which connects in turn points A, B and C shown in FIG. 1 , including the line. This permits the production of pellets incorporated with a carbonaceous material having excellent thermal conductivity and high strength. Reduction of the pellets incorporated with a carbonaceous material produces reduced iron having high strength after reduction and a low fines ratio with improved productivity. | 2 |
[0001] This application hereby incorporates by reference U.S. patent application Ser. No. 10/055,800, filed Oct. 26, 2001, titled Electronically Controlled Vehicle Lift And Vehicle Service System and U.S. Provisional Application Serial No. 60/243,827, filed Oct. 27, 2000, titled Lift With Controls, both of which are commonly owned herewith.
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to vehicle lifts and their controls, and more particularly to a vehicle lift control adapted for maintaining multiple points of a lift system within the same horizontal plane during vertical movement of the lift superstructure by synchronizing the movement thereof. The invention is disclosed in conjunction with a hydraulic fluid control system, although equally applicable to an electrically actuated system.
[0003] There are a variety of vehicle lift types which have more than one independent vertically movable superstructure. Examples of such lifts are those commonly referred to as two post and four post lifts. Other examples of such lifts include parallelogram lifts, scissors lifts and portable lifts. The movement of the superstructure may be linear or non-linear, and may have a horizontal motion component in addition to the vertical movement component. As defined by the Automotive Lift Institute ALI ALCTV-1998 standards, the types of vehicle lift superstructures include frame engaging type, axle engaging type, roll on/drive on type and fork type. As used herein, superstructure includes all vehicle lifting interfaces between the lifting apparatus and the vehicle, of any configuration now known or later developed.
[0004] Such lifts include respective actuators for each independently moveable superstructure to effect the vertical movement. Although typically the actuators are hydraulic, electromechanical actuators, such as a screw type, are also used.
[0005] Various factors affect the vertical movement of superstructures, such as unequal loading, wear, and inherent differences in the actuators, such as hydraulic components for hydraulically actuated lifts. Differences in the respective vertical positions of the independently superstructures can pose significant problems. Synchronizing the vertical movement of each superstructure in order to maintain them in the same horizontal plane requires precisely controlling each respective actuator relative to the others to match the vertical movements, despite the differences which exist between each respective actuator.
BRIEF DESCRIPTION OF THE DRAWING
[0006] The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention. In the drawings:
[0007] [0007]FIG. 1 is a schematic diagram of an embodiment of a control in accordance with the present invention, embodied as a hydraulic fluid control system including the controller and hydraulic circuit.
[0008] [0008]FIG. 2 is a control diagram showing the complete raise control including the raise circuit and the position synchronization circuit for a pair of superstructures.
[0009] [0009]FIG. 3 is a control diagram showing the complete lower control including the lowering circuit and the position synchronization circuit for a pair of vertically superstructures
[0010] [0010]FIG. 4 is a control diagram showing the lift position synchronization circuit for two pairs of superstructures.
[0011] [0011]FIG. 5 is a control diagram illustrating the generation of movement control signals for raising each superstructure of each of two pairs.
[0012] [0012]FIG. 6 is a schematic diagram of another embodiment of a control in accordance with the present invention showing the controller and a different hydraulic circuit different from that of FIG. 1.
[0013] Reference will now be made in detail to the present preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Referring now to the drawings in detail, wherein like numerals indicate the same elements throughout the views, FIG. 1 illustrates a vehicle lift, generally indicated at 2 . Lift 2 is illustrated as a two post lift, including a pair of independently moveable actuators 4 and 6 which cause the respective superstructures (not shown) to move. In the depicted embodiment, first and second actuators 4 and 6 are illustrated as respective hydraulic cylinders, although they may be any actuator suitable for the control system. First and second actuators 4 and 6 are in fluid communication with a source of hydraulic fluid 8 . Pressurized hydraulic fluid is provided by pump 10 at discharge 10 a . Each actuator 4 and 6 has a respective proportional flow control valve 12 and 14 interposed between its actuator and source of hydraulic fluid 8 .
[0015] The hydraulic fluid flow is divided at 16 , with a portion of the flow going to (from, when lowered) each respective actuator 4 and 6 as controlled by first and second proportional flow control valves 12 and 14 . As illustrated, isolation check valve 18 is located in the hydraulic line of either actuator 4 or 6 (shown in FIG. 1 in hydraulic line 20 of actuator 6 ), between 16 and second flow control valve 14 to prevent potential leakage from either actuator 4 or 6 through the respective flow control valve 12 and 14 from affecting the position of the other actuator.
[0016] Isolation check valve 18 can be eliminated if significant leakage through first and second flow control valves 12 and 14 does not occur. In the embodiment depicted, equalizing the hydraulic losses between 16 and actuator 4 , and 16 and actuator 6 , makes it easier to set gain factors (described below). To achieve this, an additional restriction may be included in hydraulic line 20 a between 16 and actuator 4 to duplicate the hydraulic loss between 16 and actuator 6 , which includes isolation check valve 18 . This may be accomplished in many ways, such as through the addition of an orifice (not shown) or another isolation check valve (not shown) between 16 and actuator 4 .
[0017] The hydraulic circuit includes lowering control valve 22 which is closed except when the superstructures are being lowered.
[0018] Lift 2 includes position sensors 24 and 26 . Each position sensor 24 and 26 is operable to sense the vertical position of the respective superstructure. This may be done by directly sensing the moving component of the actuator, such as in the depicted embodiment a cylinder piston rod, sensing vertical position of the superstructure, or sensing any lift component whose position is related to the position of the superstructure. Recognizing that the position and movement of the superstructures may be determined without direct reference to the superstructures, as used herein, references to the position or movement of a superstructure are also references to the position or movement of any lift component whose position or movement is indicative of the position or movement of a superstructure, including for example the actuators.
[0019] Position sensors 24 and 26 are illustrated as string potentiometers, which generate analog signals that are converted to digital signals for processing. Any position measuring sensor having adequate resolution may be used in the teachings of this invention, including by way of non-limiting examples, optical encoders, LVDT, displacement laser, photo sensor, sonar displacement, radar, etc. Additionally, position may be sensed by other methods, such as by integrating velocity over time. As used herein, position sensor includes any structure or algorithm capable of generating a signal indicative of position.
[0020] Lift 2 includes controller 28 which includes an interface configured to receive position signals from position sensors 24 and 26 , and to generate movement control signals to control the movement of the superstructures. Movement control signals control the movement of the superstructures by controlling or directing the operation, directly or indirectly, of the lift components (in the depicted embodiment, the actuators) which effect the movement of the superstructure. Controller 28 is connected to first and second flow control valves 12 and 14 , isolation check valve 18 , lowering valve 22 and pump motor 30 , and includes the appropriate drivers on driver board 32 to actuate them. Controller 28 is illustrated as receiving input from other lift sensors (as detailed in copending application Ser. No. 10/055,800), controlling the entire lift operation. It is noted that controller 28 may be a stand alone controller (separate from the lift controller which controls the other lift functions) dedicated only to controlling the movement of the superstructures in response to a command from a lift controller.
[0021] In the depicted embodiment, controller 28 includes a computer processor which is configured to execute the software implemented control algorithms every 10 milliseconds. Controller 28 generates movement control signals which control the operation of first and second flow control valves 12 and 14 to allow the required flow volume to the respective actuators 4 and 6 to synchronize the vertical actuation of the pair of superstructures.
[0022] [0022]FIG. 2 is a control diagram showing the complete raise control, generally indicated at 34 , including raise circuit 36 and position synchronization circuit 38 for the pair of superstructures. When the lift is instructed to raise the superstructures, complete raise control 34 effects the controlled, synchronized movement of the superstructures based on input from position sensors 24 , 26 . Raise circuit 36 is a feed back control loop which is configured to command the pair of superstructures to an upward vertical trajectory. Raise circuit 36 compares the desired position of the superstructures indicated by vertical trajectory signal 40 (xd) to the actual positions indicated respectively by position signals 42 and 44 (x1 and x2) generated by position sensors 24 , 26 . The respective differences between each set of two signals, representing the error between the desired position and the actual position, is multiplied by a raise gain factor Kp, to generate first raise signal 46 for the first superstructure and second raise signal 48 for the second superstructure, respectively. Although in the depicted embodiment, Kp was the same for each superstructure, alternatively Kp could be unique for each.
[0023] In the embodiment depicted, vertical trajectory signal 40 is a linear function of time, wherein the desired position xd is incremented a predetermined distance for each predetermined time interval. It is noted that the vertical trajectory may be any suitable trajectory establishing the desired position of the superstructures (directly or indirectly) based on any relevant criteria. By way of non-limiting example, it may be linear or non-linear, it may be based on prior movement or position, or the passage of time. Alternatively, first and second raise signals 46 and 48 could be fixed signals, independent of the positions of the superstructures.
[0024] The vertical trajectory signal resets when the lift is stopped and restarted. Thus, if the upward motion of the lift is stopped at a time when the actual position of the lift lags behind the desired position as defined by the vertical trajectory signal 40 , upon restarting the upward motion, the vertical trajectory signal 40 starts from the actual position of the superstructures.
[0025] There are various ways to establish the starting position from which the vertical trajectory signal is initiated. In the depicted embodiment, one of the posts is considered a master and the other is considered slave. When the lift is instructed to raise, the actual position of the superstructures of the master post is used as the starting position from which the vertical trajectory signal starts. Of course, there are other ways in which to establish the starting position of the vertical trajectory signal, such as the average of the actual positions of the two posts.
[0026] In the embodiment depicted, vertical trajectory signal 40 is generated by controller 28 . Alternatively vertical trajectory signal 40 could be received as an input to controller 28 , being generated elsewhere.
[0027] Position synchronization circuit 38 , a differential feedback control loop, is configured to synchronize the vertical actuation/movement of the pair of superstructures during raising. In the depicted embodiment, position synchronization circuit 38 is a cross coupled proportional-integral controller which generates a single proportional-integral error signal relative to the respective vertical positions of the superstructures. As shown, position synchronization circuit 38 includes proportional control 38 a and integral control 38 b , both of which start with the error between the two positions, x1 and x2, indicated by 50 . Output 52 of proportional control 38 a is the error 50 multiplied by a raise gain factor Kpc 1 . Output 54 of integral control 38 b is the error 50 multiplied by a raise gain factor Kic1, summed with the integral output 54 a of integral control 38 b from the preceding execution of integral control 38 b . Output 52 and output 54 are summed to generate proportional-integral error signal 56 .
[0028] Controller 28 , in response to first raise signal 46 and proportional-integral error signal 56 , generates a first movement control signal 58 for the first superstructure. In the depicted embodiment, first movement control signal 58 is generated by subtracting proportional-integral error signal 56 from first raise signal 46 . First movement control signal 58 controls, in this embodiment, first flow control valve 12 so as to effect the volume of fluid flowing to and therefore the operation of first actuator 4 and, concomitantly, the first superstructure.
[0029] Controller 28 , in response to second raise signal 48 and proportional-integral error signal 56 , generates a second movement control signal 60 for the second superstructure. In the depicted embodiment, second movement control signal 60 is generated by adding proportional-integral error signal 56 to second raise signal 48 . Second movement control signal 60 controls, in this embodiment, second flow control valve 14 so as to effect the volume of fluid flowing to and therefore the operation of second actuator 6 and, concomitantly, the second superstructure.
[0030] [0030]FIG. 3 is a control diagram showing the complete lower control, generally indicated at 62 , including lowering circuit 64 , and position synchronization circuit 66 , a differential feedback control loop, for the pair of superstructures. When the lift is instructed to lower the superstructures, complete lower control 62 effects the controlled movement of the superstructures.
[0031] Lowering circuit 64 is configured to generate first lowering signal 68 for the first superstructure and to generate second lowering signal 70 for the second superstructure. In the depicted embodiment, lowering signals are constant, not varying in dependence with the positions of the superstructures or time. Although in the depicted embodiment, lowering signals 68 and 70 are equal, they could be unique for each superstructure. Lowering signals 68 and 70 may alternatively be respectively generated in response to the positions of the superstructures, such as based on the differences between a vertical trajectory and the actual positions.
[0032] Position synchronization circuit 66 is similar to position synchronization circuit 38 . Position synchronization circuit 66 is configured to synchronize the vertical actuation/movement of the pair of superstructures during lowering. In the depicted embodiment, position synchronization circuit 66 is a cross coupled proportional-integral controller which generates a single proportional-integral error signal relative to the respective vertical positions of the superstructures. As shown, position synchronization circuit 66 includes proportional control 66 a and integral control 66 b , both of which start with the error between the two positions, x1 and x2, indicated by 72 . Output 74 of proportional control 66 a is the error 72 multiplied by a lowering gain factor Kpc 2 . Output 76 of integral control 66 b is the error 72 multiplied by a lowering gain factor Kic2, summed with the integral output 76 a of integral control 66 b from the preceding execution of integral control 66 b . Output 74 and output 76 are summed to generate proportional-integral error signal 78 .
[0033] Controller 28 , in response to first lowering signal 68 and proportional-integral error signal 78 , generates a first movement control signal 80 for the first superstructure. In the depicted embodiment, first movement control signal 80 is generated by adding proportional-integral error signal 78 to first lowering signal 68 . First movement control signal 80 controls, in this embodiment, first flow control valve 12 so as to effect the volume of fluid flowing from and therefore the operation of first actuator 4 and, concomitantly, the first superstructure.
[0034] Controller 28 , in response to second lowering signal 70 and proportional-integral error signal 78 , generates a second movement control signal 82 for the second superstructure. In the depicted embodiment, second movement control signal 82 is generated by subtracting proportional-integral error signal 78 from second lowering signal 70 . Second movement control signal 82 controls, in this embodiment, second flow control valve 14 so as to effect the volume of fluid flowing from and therefore the operation of second actuator 6 and, concomitantly, the second superstructure.
[0035] The present invention is also applicable to lifts having more than one pair of superstructures. For example, this invention may be used on a four post lift which has two pairs of superstructures, each pair comprising a left and right side of a respective end of the lift or each pair comprising the left side and the right side of the lift. The invention may used with an odd number of superstructures, such as by treating one of the superstructures as being a pair “locked” together. More than two pairs may be used, with one of the pairs being the control or target pair.
[0036] For a four post lift, the controller includes an interface configured to receive first and second position signals of the first pair, and to receive third and fourth positions signals of the second pair. The complete up control and complete down control as described above are used for each pair (first and second superstructures; third and fourth superstructures). The respective gain factors between the pairs, or between any superstructures, may be different. Differences in the hydraulic circuits (such as due to different hydraulic hose lengths) can result in the need or use of different gain factors.
[0037] The controller is further configured to synchronize the first and second pairs relative to each other through a lift position synchronization control which in the depicted embodiment reduces the difference between the average of the positions of the first pair and the mean of the positions of the second pair.
[0038] [0038]FIG. 4 is a control diagram showing the lift position synchronization circuit, a differential feedback control loop, generally indicated at 84 , for synchronizing the two pairs during raising. As shown, lift position synchronization circuit 84 includes proportional control 84 a and integral control 84 b , both of which start with the error, indicated by 86 , between the first pair and the second pair by subtracting the positions of the second pair, x3 and x4, from the positions of the first pair, x1 and x2. Output 88 of proportional control 84 a is the error 86 multiplied by a raise gain factor Kpcc. Output 90 of integral control 84 b is the error 86 multiplied by a raise gain factor Kicc, summed with the integral output 90 a integral control 84 b from the preceding execution of integral control 84 b . Output 88 and output 90 are summed to generate lift proportional-integral error signal 92 .
[0039] [0039]FIG. 5 is a control diagram illustrating the generation of movement control signals for raising each superstructure of each of the two pairs. The controller, in response to first raise signal 94 , first pair proportional-integral error signal 96 and lift proportional-integral error signal 92 , generates a first movement control signal 98 for the first superstructure. In the depicted embodiment, first movement control signal 98 is generated by subtracting lift proportional-integral error signal 92 and first pair proportional-integral error signal 96 from first raise signal 94 . First movement control signal 98 controls, in this embodiment, first flow control valve 12 so as to effect the volume of fluid flowing to and therefore the operation of first actuator 4 and, concomitantly, the first superstructure.
[0040] The controller, in response to second raise signal 100 , first pair proportional-integral error signal 96 and lift proportional-integral error signal 92 , generates a second movement control signal 102 for the second superstructure. In the depicted embodiment, second movement control signal 102 is generated by adding subtracting lift proportional-integral error signal 92 from the sum of first pair proportional-integral error signal 96 and first raise signal 100 . Second movement control signal 102 controls, in this embodiment, second flow control valve 14 so as to effect the volume of fluid flowing to and therefore the operation of second actuator 6 and, concomitantly, the second superstructure.
[0041] Still referring to FIG. 5, the controller, in response to third raise signal 104 , second pair proportional-integral error signal 106 and lift proportional-integral error signal 92 , generates a third movement control signal 108 for the third superstructure. In the depicted embodiment, third movement control signal 108 is generated by subtracting second pair proportional-integral error signal 106 from the sum of lift proportional-integral error signal 92 and third raise signal 104 . Third movement control signal 108 controls, in this embodiment, third flow control valve 110 so as to effect the volume of fluid flowing to and therefore the operation of the third actuator (not shown) and, concomitantly, the third superstructure.
[0042] The controller, in response to fourth raise signal 112 , second pair proportional-integral error signal 106 lift proportional-integral error signal 92 , generates a fourth movement control signal 114 for the fourth superstructure. In the depicted embodiment, fourth movement control signal 114 is generated by summing fourth raise signal 112 , second pair proportional-integral error signal 106 and lift proportional-integral error signal 92 . Fourth movement control signal 114 controls, in this embodiment, fourth flow control valve 116 so as to effect the volume of fluid flowing to and therefore the operation of the fourth actuator (not shown) and, concomitantly, the fourth superstructure.
[0043] During lowering, the controller executes the lift position synchronization algorithm as shown in FIG. 4, except that the lowering gain factors are not necessarily the same as the raise gain factors. In the depicted embodiment, the lowering gain factors were different from the raise gain factors. During lowering, in the depicted embodiment, the arithmetic operations are reversed for the lift proportional-integral error signal: The lift proportional-integral error signal is added to generate the first and second movement signals (instead of subtracted as shown in FIG. 5) and subtracted to generate the third and fourth movement signals (instead of added as shown in FIG. 5).
[0044] The gain factors described above may be set using any appropriate method, such as the well known Zigler-Nichols tuning methods, or empirically. In determining the gain factors empirically, the integral control was disabled and multiple cycles of different loads were raised and lowered to find the optimum gain factor for the proportional control. The integral control was then enabled and those gain factors determined through multiple cycles of different loads.
[0045] The following table sets forth two examples of the gain factors and up rate:
Example 1 Example 2 Kp 1.0 6.0 Kpc1 0.5 6.0 Kic1 0.15 0.3 Kpc2 1.5 6.0 Kic2 0.25 0.25 Xdown1 65 50 Xdown2 175 175 up rate 2.0 in/sec 1.8 in/sec
[0046] It is noted, as seen above, that gain factors may be 1.
[0047] The controller preferably includes a calibration algorithm for the position sensors. In the depicted embodiment, whenever the lift is being commanded to move when it is near either end of its range of travel and the position sensors do not indicate movement for a predetermined period of time, the calibration algorithm is executed. In such a situation, it is assumed that the lift is at the end of its range of travel. The algorithm correlates the position sensor output as corresponding to the maximum or minimum position of the lift, as appropriate. The inclusion of a calibration algorithm allows a range of position sensor locations, reducing the manufacturing cost.
[0048] The present invention may be used with a variety of actuators and hydraulic circuits. FIG. 6 illustrates an alternate embodiment of the hydraulic circuit. In this vehicle lift, generally indicated at 118 , the difference in comparison to FIG. 1 lies in that control of the flow of hydraulic fluid to actuators 4 and 6 is accomplished through the use of individual motors 120 and 128 and pumps 122 and 130 for each superstructure, with each motor/pump being controlled by a respective variable frequency drive (VFD) motor controller 124 and 132 to effect raising the lift and through the use of respective proportioning flow control valves 126 and 134 to effect lowering the lift. Alternatively, individual motors 120 , 128 could drive a screw type actuator.
[0049] As illustrated, each motor/pump 120 / 122 and 128 / 130 has a respective associated source of hydraulic fluid 136 and 138 , although a single source could be associated with both motors and pumps. Each pump 122 and 130 has a respective discharge 122 a and 130 a which is in fluid communication with its respective actuator 4 and 6 .
[0050] Controller 140 includes the appropriate drivers for the VFD motor controllers 124 and 132 , and executes the control algorithms as described above to synchronize the vertical actuation of the superstructures. By varying the speed of the respective motors 120 and 132 , the hydraulic fluid flow rate to the respective actuators 4 and 6 varies for raising.
[0051] In summary, numerous benefits have been described which result from employing the concepts of the invention. The foregoing description of a preferred embodiment of the 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 form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment was chosen and described in order to best illustrate the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto. | A vehicle lift control maintains multiple points of a lift system within the same horizontal plane during vertical movement of the lift engagement structure by synchronizing the movement thereof. A vertical trajectory is compared to actual positions to generate a raise signal. A position synchronization circuit synchronizes the vertical actuation of the moveable lift components by determining a proportional-integral error signal. | 5 |
This patent application is a Continuation of U.S. Ser. No. 10/896,239 filed on Jul. 21, 2004.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates in general to a remote control decoy and, more specifically, to a radio controlled decoy with improved maneuverability and waterfowl attraction capabilities.
2. Description of the Prior Art
It is well known in the art to provide decoys of various types to attract game to a hunter. When hunting waterfowl, it is often desirable to utilize floating decoys. While such decoys are useful for attracting game, they have several important drawbacks. Drawbacks include the large number of decoys required, the difficulty in setting and retrieving the decoys, the disruption of the habitat during the critical period of time when the decoys are set, the unrealistic motion of the decoys, and the inability of such decoys to attract waterfowl from great distances.
It is known in the art to provide remote controlled decoys such as that shown in U.S. Pat. No. 5,377,439 to Roos, et al. Such remote control decoys avoid the disadvantages associated with setting and retrieving the decoys, and somewhat reduce the number of decoys needed. However, the disadvantages associated with using multiple transmitters, the requirement of additional units for different species of waterfowl, the difficulty in attracting waterfowl from large distances, and low maneuverability remain. It would, therefore, be desirable to provide a decoy which further reduced the number of decoys required, added more realistic maneuverability to the decoy, and was capable of drawing waterfowl from great distances. The difficulties encountered in the prior art discussed hereinabove are substantially eliminated by the present invention.
SUMMARY OF THE INVENTION
In an advantage provided by this invention, a remote control decoy is provided with improved maneuverability.
Advantageously, this invention provides a remote control decoy adaptable for different types of waterfowl.
Advantageously, this invention provides means for remotely controlling a plurality of decoys utilizing a single transmitter.
Advantageously, this invention provides a remote controlled decoy with forward, reverse and narrow radius turning capabilities.
Advantageously, this invention provides a remote controlled decoy with improved waterfowl attractant system.
Advantageously, this invention provides an improved method of laying and retrieving decoys.
Advantageously, in the preferred embodiment of this invention, a remote controlled decoy is provided with two propellers, each independently controlled by a different joystick of a transmitter. The transmitter is adjustable to allow the transmitter to control a plurality of different decoys, which may also be adapted to tow a non-powered decoy, to produce a realistic courting action. The decoy is also preferably provided with a strobe light to simulate the flapping of wings at great distances.
Advantageously this invention provides an improved waterfowl attracting system utilizing strobe lights to simulate wing action. The lights may be turned on when waterfowl are at a great distance, and turned off when the waterfowl comes closer.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described, by way of example, with reference to the accompanying drawings in which:
FIG. 1 illustrates a bottom perspective view of the remote controlled decoy of the present invention;
FIG. 2 illustrates a bottom perspective view of the transmitter associated with the remote controlled decoy of the present invention;
FIG. 3 illustrates a bottom perspective view in partial cutaway of the shell of the decoy being removed from the hull;
FIG. 4 illustrates a bottom perspective view of a supplemental shell representing a different waterfowl;
FIG. 5 illustrates a top perspective view of a hunting scenario, shown with multiple decoys being controlled by a single transmitter;
FIG. 6 illustrates a schematic of the electronics associated with the decoy of the present invention;
FIG. 7 illustrates a rear perspective view of an alternative embodiment of the present invention, shown in partial cutaway to reveal an alternative arrangement to mount the strobes in the decoy;
FIG. 8 illustrates another alternative embodiment of the present invention, utilizing a shell integrally formed with the hull.
FIG. 9 illustrates a bottom perspective view of the supplemental remote control decoy of the present invention; and
FIG. 10 illustrates a schematic of the electronics associated with the supplemental decoy of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A remote controlled decoy according to this invention is shown generally as ( 10 ) in FIG. 1 . The decoy includes a shell ( 12 ), preferably formed of any material known in the art for producing decoys, but is preferably resilient and colored to resemble the coloring of an actual waterfowl. As shown in FIG. 1 , the shell ( 12 ) is formed and colored to resemble a mallard hen. The shell is preferably provided with a hook ( 14 ), formed of metal or similarly strong material. As shown in FIG. 1 , the hook ( 14 ) overhangs and engages a lip ( 16 ) provided along a perimeter of a rigid plastic hull ( 18 ) to maintain the shell ( 12 ) in contact with the hull ( 18 ).
As shown, the hull ( 18 ) is provided with a first propeller ( 20 ) and a second propeller ( 22 ). The first propeller ( 20 ) is preferably provided within a first weed cage ( 24 ) and the second propeller ( 22 ) is provided within a second weed cage ( 26 ). The weed cages ( 24 ) and ( 26 ) may be constructed of any suitable material, but are preferably constructed of a rigid plastic material formed to define openings narrow enough to prevent the ingress of large weeds into contact with the propellers ( 20 ) and ( 22 ), yet large enough to limit a significant loss of power associated with reduced flow of water into contact with the propellers ( 20 ) and ( 22 ). Although the hull ( 18 ) may be of any desired shape, it is preferably injection molded of plastic to provide a first recess ( 28 ) and second recess ( 30 ), to accommodate the first propeller ( 20 ) and second propeller ( 22 ). As shown in FIG. 1 , the shell ( 12 ) is provided on its surface with a plurality of small strobe lights ( 32 ). The strobe lights ( 32 ) may be of any suitable type known in the art, but are preferably located near the wing ( 34 ) of the decoy ( 10 ).
Located on the hull ( 18 ) is an on/off switch ( 36 ), which may alternatively be located in any desired location. Provided on the shell ( 12 ) is an eyelet ( 38 ) for a purpose described below. Shown in FIG. 2 is a transmitter ( 40 ) utilized in association with the decoy ( 10 ) of the present invention. As shown in FIG. 2 , the transmitter ( 40 ) is of a standard type known in the art to produce radio frequency signals. The transmitter ( 40 ) is preferably provided with a housing ( 42 ) and an antenna ( 44 ). Coupled to the housing ( 42 ) is a first joystick ( 46 ) and a second joystick ( 48 ). Also provided on the transmitter ( 40 ) is an on/off switch ( 50 ), a radio frequency switch ( 52 ) and a strobe switch ( 54 ). Although the transmitter ( 40 ) may be constructed of any suitable type known in the art, it is preferably designed to operate on the frequencies 27 MHz and 49 MHz.
If it is desired to remove the shell ( 12 ) for replacement, or to access batteries ( 56 ) provided within the hull ( 18 ), the shell ( 12 ) may be removed from the hull ( 18 ). As shown in FIG. 3 , the shell ( 12 ) is preferably provided with a hollow interior ( 58 ), a first inwardly directed ear ( 60 ) and a second inwardly directed ear ( 62 ). Although the ears ( 60 ) and ( 62 ) may be constructed of metal, in the preferred embodiment they are constructed of a material similar to that used to construct the shell ( 12 ). The ears ( 60 ) and ( 62 ) are preferably provided with a latch and hook material ( 64 ) which fits into mating engagement with hook and latch material ( 66 ) coupled to the hull ( 18 ). While the hook ( 14 ) and ears ( 60 ) and ( 62 ) serve to secure the shell ( 12 ) to the hull ( 18 ), in the preferred embodiment, the coupling is not watertight but, instead, is merely overlapping to allow moisture contacting the back ( 68 ) of the shell ( 12 ) to roll downward across the shell ( 12 ) and away from the hull ( 18 ). Preferably, the hull ( 18 ) itself is substantially watertight, with the batteries ( 56 ) and other electrical components being protected from moisture, regardless of whether or not the shell ( 12 ) is attached to the hull ( 18 ).
Shown in FIG. 4 is a supplemental shell ( 70 ) similar in all respects to the shell ( 12 ), except that the shell ( 70 ) is configured in size, shape and coloring to resemble a teal, rather than a mallard hen. If it is desired to adjust the decoy ( 10 ) to resemble a teal, the hook ( 72 ) is provided over the lip ( 16 ) of the bare hull ( 18 ), and the supplemental shell ( 70 ) is rotated onto the hull ( 18 ) until the supplemental ears ( 74 ) and ( 76 ) contact the hook and latch material ( 66 ) of the hull ( 18 ), thereby securing the supplemental shell ( 70 ) to the hull ( 18 ). FIGS. 3-4 .
As shown in FIG. 5 , when it is desired to utilize the decoy ( 10 ) of the present invention, a hunter ( 78 ) merely actuates the on/off switch ( 36 ) of the decoy ( 10 ), and the on/off switch ( 50 ) of the transmitter ( 40 ), and sets the decoy ( 10 ) into the water ( 80 ). FIGS. 1 , 3 and 5 . The hunter ( 78 ) thereafter utilizes the joysticks ( 46 ) and ( 48 ) to control the speed of the propellers ( 20 ) and ( 22 ) to motivate the decoy ( 10 ) into a desirable position. As shown in FIG. 5 , the decoy ( 10 ) may be utilized in association with static decoys ( 82 ), such as those known in the art, which may be tethered utilizing an anchor line ( 84 ) in a manner such as that known in the art.
Alternatively, or additionally, a supplemental decoy ( 86 ) may be utilized and configured similarly to that described above in association with the decoy ( 10 ). As shown in FIG. 5 , the supplemental decoy ( 86 ) is provided with a mallard hen shell ( 88 ) and is coupled through an eyelet ( 90 ) via fishing line ( 92 ) or similar connection means to an eyelet ( 94 ) provided on a standard decoy ( 96 ), which is configured to resemble a mallard drake. Preferably, the supplemental decoy ( 86 ) is designed to operate in response to a 49 MHz signal, while the decoy ( 10 ) is designed to operate on a 27 MHz signal. Accordingly, the hunter ( 78 ) may utilize the radio frequency switch ( 52 ) on the transmitter ( 40 ) to toggle back and forth between controlling the supplemental decoy ( 86 ) and decoy ( 10 ), utilizing the joysticks ( 46 ) and ( 48 ) of the transmitter ( 40 ). In this manner, the hunter may control a single decoy or a double decoy combination configured to resemble a mating pair.
If it is desired to attract waterfowl from a long distance, the hunter ( 78 ) may actuate the strobe switch ( 54 ) which causes the strobe lights ( 32 ) to strobe at a predetermined frequency and intensity desired by the hunter ( 78 ), in accordance with the type of waterfowl being harvested and the specific conditions associated with the particular harvest. If desired, the strobe lights ( 32 ) may be configured to remain in either an actuated or deactuated state until specifically actuated or deactuated by the hunter ( 78 ). In this manner, the hunter ( 78 ) may actuate the strobe lights ( 98 ) of the supplemental decoy ( 86 ) simultaneously, utilizing the radio frequency switch ( 52 ) and strobe switch ( 42 ) of the transmitter ( 40 ). Preferably, the hunter actuates the strobe lights ( 32 ) and ( 98 ) when waterfowl ( 100 ) can be seen at a distance. The hunter ( 78 ) may maintain the strobe lights ( 32 ) and ( 98 ) actuating until the waterfowl ( 100 ) are close enough to be attracted by the realistic movement of the decoy ( 10 ) and supplemental decoy ( 86 ). At this point, the strobe lights ( 32 ) and ( 98 ) are preferably shut off to prevent the waterfowl ( 10 ) from flaring and exiting the area upon recognition of the strobe lights ( 32 ) and ( 98 ) not being actual feather movement of real waterfowl.
After the harvest has been completed, the hunter ( 78 ) merely utilizes the transmitter ( 42 ) to direct the decoy ( 10 ) and supplemental decoy ( 86 ) back to the hunter ( 78 ), where they may be retrieved. If static decoys ( 82 ) are utilized, the hunter ( 78 ) must still go retrieve these decoys in a manner such as that known in the art.
A schematic of the electronics provided within the hull ( 18 ) is shown generally as ( 102 ). As shown, an antenna ( 104 ) is coupled to a receiver ( 106 ), such as those well known in the art for use in association with remote control cars and boats. The receiver ( 106 ) in turn is coupled to a first motor controller ( 108 ), such as a throttle, and a second motor controller ( 110 ), such as a throttle. The motor controllers ( 108 ) and ( 110 ) are coupled to a battery ( 112 ) which is sufficiently powerful to motivate the motors ( 114 ) and ( 116 ) coupled to the motor controllers ( 108 ) and ( 110 ) and the propellers ( 20 ) and ( 22 ). FIGS. 1 and 6 . The motor controllers ( 108 ) and ( 110 ) are of a type known in the art to attenuate the supply of power from the battery ( 112 ) to the motors ( 114 ) and ( 116 ) in response to signals received from the receiver ( 106 ), which, in turn, are provided by the transmitter ( 40 ) in response to manipulation of the joysticks ( 46 ) and ( 48 ) by the hunter ( 78 ). The motors ( 114 ) and ( 116 ) are separately controlled to drive the propellers ( 20 ) and ( 22 ) at different speeds to cause the decoy to turn in response to differential movements of the joysticks ( 46 ) and ( 48 ). Also, as shown in FIG. 6 , the receiver ( 106 ) is coupled to a light controller ( 118 ) which, in turn, is coupled to the strobe lights ( 32 ) and to the battery ( 112 ) to actuate and deactuate the strobe lights ( 32 ) in response to signals received from the receiver ( 106 ). As shown in FIG. 6 , the battery ( 112 ) is coupled to the on/off switch ( 36 ). As noted above, the electronics associated with the receiver ( 106 ), except the strobe lights ( 32 ), are contained within the hull in a watertight manner.
An alternative embodiment of the present invention is shown generally as ( 120 ) in FIG. 7 . In this embodiment, a single, powerful strobe light ( 122 ) is in communication with a plurality of tapered bores ( 124 ) opening into holes ( 126 ) provided on the back ( 128 ) of the shell ( 130 ) of the alternative embodiment of the decoy ( 120 ). In this manner, a single strobe light ( 122 ) may be used to direct light to a plurality of holes ( 126 ) to give the illusion of a plurality of lights and, from a distance, wing movement.
Another alternative embodiment of the instant invention is shown generally as ( 132 ) in FIG. 8 . As shown, the shell ( 134 ) is integrally formed with the hull ( 136 ) to make the decoy ( 132 ) even more realistic and to provide the decoy with even greater protection against water seeping into the decoy ( 132 ). In this embodiment, the back ( 138 ) preferably lifts up to reveal the interior of the decoy ( 132 ) to allow for access to the propeller motors, batteries, switch (not shown), and strobe lights ( 140 ). The back ( 138 ) is preferably constructed of the same material as the shell ( 134 ). The back ( 138 ) may be easily lift and allowed to resiliently return to its former state when released.
The supplemental decoy is shown generally as ( 86 ) in FIG. 9 . The supplemental decoy ( 86 ) is provided with a shell ( 142 ) provided with a hook ( 144 ) that overhangs and engages a lip ( 146 ) provided along a perimeter of a rigid plastic hull ( 148 ) to maintain the shell ( 142 ) in contact with the hull ( 148 ). The hull ( 148 ) is provided with a first propeller ( 150 ) and a second propeller ( 152 ). Batteries ( 154 ) are provided within the hull ( 148 ) in a manner such as that described above in association with the decoy ( 10 ).
A schematic of the electronics provided within the hull ( 148 ) is shown generally as ( 156 ) in FIG. 10 . As shown, an antennae ( 158 ) is coupled to a receiver ( 160 ) in a manner such as that described above in association with the decoy ( 10 ). The receiver ( 160 ) is coupled to a third motor controller ( 162 ), such as a throttle, and a fourth motor controller ( 164 ), such as a throttle. The motor controllers ( 162 ) and ( 164 ) are coupled to a battery ( 166 ) which is sufficiently powerful to motivate the motors ( 168 ) and ( 170 ) coupled to the motor controllers ( 162 ) and ( 164 ) and the propellers ( 150 ) and ( 152 ). FIGS. 9-10 . The motor controllers ( 162 ) and ( 164 ) are the type known in the art to attenuate the supply of power from the battery ( 166 ) to the motors ( 168 ) and ( 170 ) in response to signals received from the receiver ( 106 ) which, in turn, are provided by the transmitter ( 40 ) in response to manipulation of the joysticks ( 46 ) and ( 48 ) by the hunter ( 78 ), when the hunter ( 78 ) uses the radio frequency switch ( 52 ) on the transmitter ( 10 ) to toggle the switch ( 52 ) to the 49 MHz signal. The motors ( 168 ) and ( 170 ) are separately controlled to drive the propellers ( 150 ) and ( 152 ) at different speeds to cause the supplemental decoy ( 86 ) to turn in response to different movements of the joysticks ( 46 ) and ( 48 ). Also, as shown in FIG. 10 , the receiver ( 160 ) is coupled to a light controller ( 172 ) which, in turn, is coupled to the strobe lights ( 174 ) and to the battery ( 166 ) to actuate and deactuate the strobe lights ( 174 ) in response to signals received from the receiver ( 160 ).
Although the invention has been described with respect to the preferred embodiment thereof, it is to be understood that it is not to be so limited, since changes and modifications can be made therein which are within the full, intended scope of this invention as defined by the appended claims. For example, it is anticipated that the hull ( 18 ) of the present invention may be utilized without the shell ( 12 ) for recreational use and may be modified to resemble a model watercraft. It is additionally anticipated that the decoy ( 10 ) may be programmed to follow a predetermined course or tethered to a line instead of, or in addition to, being remotely controlled by the transmitter ( 40 ). It is also anticipated that any number of decoys may be controlled with differing frequencies utilized by the transmitter ( 40 ). It is also anticipated that a plurality of decoys may be controlled simultaneously on a single frequency using the transmitter to cause the decoys to make simultaneous movements. | A remote controlled decoy is provided. The remote control decoy operates using two propellers secured to a hull and remotely controlled by a radio frequency transmitter. A shell resembling a particular waterfowl is releasably coupled to a hull which serves as a watertight compartment for the receiver and the electronics associated with the propulsion of the decoy. The decoy may also be provided with strobe lights to draw attention to the decoy from passing waterfowl. | 0 |
RELATED APPLICATIONS
[0001] This application claims priority from co-pending U.S. Provisional Application No. 60/424,486, filed Nov. 7th, 2002 , the full disclosure of which is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates generally to the field of oil and gas well services. More specifically the present invention relates to a connector assembly for a perforating gun that is quick, reliable, and simple to use.
[0004] 2. Description of Related Art
[0005] Perforating guns containing shaped charges are used for the purpose, among others, of making hydraulic communication passages, called perforations, in wellbores drilled through earth formations. These perforations hydraulically connect predetermined zones of the earth formations to the wellbore. Perforations are needed because wellbores are typically completed by coaxially inserting a pipe or casing into the wellbore where the casing is retained in the wellbore by pumping cement into the annular space between the wellbore and the casing. The cemented casing is provided in the wellbore for the specific purpose of hydraulically isolating from each other the various earth formations penetrated by the wellbore. Without perforations, the hydrocarbons entrained in the formations surrounding the wellbore could not flow into the wellbore.
[0006] Many different types of perforating guns exist, but most have the same basic components. Those components are, shaped charges, a gun tube, a gun body, a top sub or connector, a detonator, and a bottom sub. Typically the shaped charges are disposed within the gun tube, and the gun tube is inserted into the gun body. The top sub is attached to the upper portion of the gun body and connects the perforating gun to a means for raising and lowering the perforating gun into a wellbore. The bottom sub generally attaches to the lower end of the gun body. Often, the bottom sub houses the detonator within a recess located inside of its body.
[0007] When the perforating gun is situated in the portion of the wellbore where a perforation is desired, the shaped charges within the perforating gun are detonated. This in turn produces perforations through the cemented casing lining the wellbore and into the surrounding formation. As is well known in the art, each time a perforating gun is used to produce perforations inside of a wellbore, some of the components of the perforating gun are either expended or fully destroyed. Thus before perforating guns can be reused, they must be returned to the surface and refurbished to replace the parts destroyed or used up during the previous perforation. During its refurbishment the perforating gun usually must be disassembled and reassembled prior to its next deployment.
[0008] Part of the disassembly and reassembly process of the perforating gun involves disconnecting the perforating gun from its raising/lowering means; which is typically a wireline. The wireline is attachable to a cablehead, which provides the connection between the perforating gun and the wireline. Wirelines can also serve to provide a signal conduit from the surface to the perforating gun to actuate detonation of the shaped charges. Generally the wireline cablehead is affixed to the upper sub of the perforating gun and is detached during refurbishment of the perforating gun. Additionally, the upper sub is disconnected from the gun body when the expended portions of the perforating gun are replaced. Thus to help minimize the time and expense of refurbishing perforating guns between subsequent uses, it is important that disconnecting and reconnecting the upper sub to the gun body be quick, simple, and be capable of being done at or close to the wellbore.
[0009] Often, because of special or uniquely sized components used for a specific perforating application, the perforating gun must be transported to a central processing facility for refurbishment instead of the site where the perforations are performed, i.e. the field. Transportation to and from the field to a central processing facility can be financially expensive as well as costly from a lost time standpoint. On the other hand, if a perforating gun could be refurbished for reuse at a field location, the added expense and time of transportation to a central processing facility could be avoided.
[0010] Some examples of perforating guns having connection means can be found in Hromas et al., U.S. Pat. No. 6,098,716, Burleson et al. U.S. Pat. Nos. 5,778,979, 5,823,266, and 5,992,523, and Huber et al., U.S. Pat. No. 6,059,042. However each of these suffer from the drawbacks that they are complex and the connection mechanisms disclosed therein contain multiple moving parts. Additional components add complexity, which reduces reliability and adds capital and maintenance costs. Further, none of the above noted references appears to have the capability of being refurbished or modified in the field, which limits their application to single uses and reduces their flexibility of use.
[0011] Therefore, there exists a need for a device or system in connection with perforating guns that provides for a fast and simple method of connecting and disconnecting perforating guns from a wireline. Also the system should allow for the perforating guns to be prepared at a field site, provide for multiple gun lengths, minimize the time required to assemble the perforating gun assembly, and include a proven way of sealing the perforating guns from wellbore fluids.
BRIEF SUMMARY OF THE INVENTION
[0012] One embodiment of the present invention discloses a connection system for a perforating gun comprising a top sub formed to receive one end of the gun body of a perforating gun. Disposed on the outer surface of the gun body is a circumferential groove. A collet is securable to the top sub where the collet has at least one finger formed onto its body. The collet finger is produced to engage the gun body groove, which in turn connects the gun body to the top sub. Further included with the present invention is a cover sleeve that circumscribes the finger wedging the finger between the cover sleeve and the groove. Also included with the connection system of the present invention is a seal disposed between the top sub and the perforating gun.
[0013] A fastener, such as threaded bolt, screw, rivet, or pin, can be used to secure the collet and cover sleeve to the top sub. The cover sleeve should be freely slideable along the axis of the perforating gun and formed to simultaneously circumscribe the collet and the perforating gun. The magnitude of the inner diameter of the cover sleeve is substantially uniform along its axis up until it reaches a lip of the cover sleeve. The cover sleeve lip is located on the end opposite where the cover sleeve is attached to the collet. The lip protrudes inward toward the axis of the cover sleeve and axially contacts at least one finger.
[0014] An alternative embodiment of a connection system for a perforating gun comprises a top sub formed to receive one end of a gun body of a perforating gun. A groove is circumferentially disposed on the outer surface of the gun body. Also included is a cover sleeve attachably detachable to the top sub on one end and having an inwardly protruding lip on the other end. Mating threads on the cover sleeve and on the top sub can be used to secure the cover sleeve to the top sub. A ring is disposed within the groove having an outer diameter that is at least equal to the inner diameter of the lip. Thus upon attachment of the cover sleeve to the top sub, the lip engages the ring. The engagement of the lip to the ring secures the gun body to the top sub. The ring is comprised of at least two hemispherical sections.
[0015] One of the many features of the present invention involves providing a fast and simple method of connecting perforating guns. The present invention also provides for perforating guns to be assembled at field locations and allows for random length of gun hardware. Further, the time and expense required to assemble/reassemble perforating guns is reduced by utilization of the present invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0016] FIG. 1 illustrates a partial cross-sectional view of a perforating gun connection assembly having a split ring.
[0017] FIG. 2 depicts a cross-sectional view of a perforating gun connection assembly having a collet.
[0018] FIG. 3A illustrates a cross-sectional view of a collet.
[0019] FIG. 3B illustrates an axial view of a collet.
[0020] FIG. 4 illustrates a cross-sectional view of a gun body.
[0021] FIG. 5 illustrates a cross-sectional view of a cover sleeve.
[0022] FIG. 6A illustrates an axial view of a ring.
[0023] FIG. 6B illustrates a cross-sectional view of a ring.
DETAILED DESCRIPTION OF THE INVENTION
[0024] With reference to the drawings herein, a perforating gun quick disconnect system according to one embodiment of the present invention is illustrated in FIG. 1 . For purposes of reference, bottom or lower refers to portions of the perforating gun located closer to the bottom of the wellbore, whereas top or higher refers to portions of the perforating gun situated closer to the wellbore opening. In one embodiment of the invention as shown in FIG. 1 , a top sub 10 is secured to the upper end of a gun body 50 . Seals 16 are provided on the outer radius of the top sub 10 and contact the inner radius of the upper section of the gun body 50 .
[0025] In the embodiments illustrated in FIGS. 1 and 2 , the top sub 10 is substantially cylindrical with a varying diameter, and preferably with its diameter being largest at its mid-section. With regard to the embodiment of FIG. 2 , it is preferred that the diameter of the top sub 10 be substantially equal to the collet base 41 . Just below the top sub 10 mid-section, its diameter reduces to form a shoulder 12 on which the collet base 41 is secured. An annular retainer 25 is attachable to the lower portion of the top sub 10 . It is preferred that the outer radius of the upper section of the retainer 25 be substantially the same as the inner radius of the collet fingers 42 . However, the radius at the lower section of the retainer 25 should be smaller than the radius of the collet fingers 42 . The reduced diameter along the lower section of the retainer 25 creates an annular space between the collet fingers 42 and the retainer 25 . That annular space should be formed such that it is capable of accommodating the upper portion of the gun body 50 along a portion of its lenght.
[0026] In an embodiment of the invention of FIG. 1 , a ring 30 is shown situated inside of a groove formed on the outer radius of the upper section of the gun body 50 . The ring 30 is preferably comprised of at least two hemispherical sections that when placed into the groove on the gun body 50 , the ring 30 can circumscribe substantially the entire diameter of the gun body 50 . Alternatively the ring 30 can be comprised of a single section that is press fit into the groove, or be of three or more sections. A cover sleeve 20 is shown circumscribing a portion of the top sub 10 and a portion of the gun body 50 . A cover sleeve lip 21 is formed on the bottom of the cover sleeve 20 having a radius substantially similar to the radius of the ring 30 . The cover sleeve lip 21 protrudes inward toward the axis of the cover sleeve 20 . The presence of the cover sleeve lip 21 adjacent the ring 30 can prevent the ring 30 from axially moving downward past the cover sleeve lip 21 . Threads 22 on the top of the cover sleeve 20 at its inner diameter are formed to mate with corresponding threads located on the outer diameter of the top sub 10 , thus providing a threaded connection between the cover sleeve lip 21 and the top sub 10 . It is important that the cover sleeve 20 inner radius be formed to allow it to easily axially traverse the gun body 50 , and yet leave only a small clearance between it and the outer diameter of the ring 30 .
[0027] Also included with this embodiment of the invention are a shaped charge 54 , a gun tube 52 , and a detonator 56 . The form and type of the top sub 10 , lower sub 11 , seals 16 , detonating cord 57 , gun body 50 , and detonator 56 can vary from those illustrated here without departing from the spirit of the present invention.
[0028] Assembly of the perforating gun of FIG. 1 generally involves first loading the gun tube 52 with shaped charges 54 using approved ballistic procedures. The detonator cord 57 and associated electrical wire 58 is routed along the path of the ignition points of the charges. The gun tube 52 is then inserted into the gun body 50 . The cover sleeve 20 is slid over the gun body 50 and the top sub 10 is inserted into an opening on the upper portion of the gun body 50 . The ring 30 is placed into the groove 51 on the gun body 50 . The presence of the ring 30 prevents the cover sleeve lip 21 from sliding above the ring 30 . Due to the small clearance between the inner diameter of the cover sleeve 20 and the outer diameter of the ring 30 , the ring 30 is secured in place inside of the groove 51 . It is to be understood that one skilled in the art can determine the clearance between the ring 30 and the cover sleeve 20 necessary to secure the ring 30 within the groove 51 .
[0029] To complete the assembly process, the cover sleeve 20 is slid upwards toward the top sub 10 and screwed onto the top sub 10 by virtue of the threads 22 disposed on the cover sleeve 20 and the top sub 10 . It is important that the sub seals 16 mate up against the inner diameter of the opening of the gun body 50 to prevent fluid leakage from the wellbore to the inside of the gun body 50 . As is well known, if wellbore fluids enter the inside of the gun body 50 , the fluids can either damage the shaped charges 54 before detonation, or cause the gun body 50 to split upon detonation of the shaped charges 54 .
[0030] Another embodiment of the present invention is illustrated in FIG. 2 . In this embodiment, the ring 30 and threads 22 of the embodiment of FIG. 1 , are replaced by a collet 40 and a collet fastener 46 . The collet 40 is formed to fit over a portion of the top sub 10 and is securable to the top sub 10 . The features of the collet 40 include a collet finger 42 with a collet finger insert 44 . The collet finger insert 44 is fashioned to fit within the groove 51 formed on the upper portion of the top sub 10 . Also included with this embodiment is a cover sleeve 20 having inner diameter that is sufficiently large to easily slide over the collet finger 42 . While the present invention can be equipped with one or more collet fingers 42 , it is preferred that the number of collet fingers 42 be six. Further, it is also preferred that the collet fingers 42 be radially displaced around the collet 40 with an equal distance between each adjacent collet finger 42 .
[0031] Assembly of the embodiment of the invention shown in FIG. 2 is much the same as the embodiment of FIG. 1 . The difference lies in how the gun body is secured to the top sub 10 . In the embodiment of the invention illustrated in FIG. 2 , the collet 40 is secured to the top sub 10 before insertion of the gun body 50 into the top sub 10 . Insertion of the gun body 50 into the top sub 10 positions the collet finger insert(s) 44 adjacent the groove 51 on the gun body 50 where the collet finger insert(s) 44 can then fit into the groove 51 . As can readily be seen from FIG. 2 , upon assembly of the present invention, the axis of the collet 40 should be substantially aligned with the axis of the gun body 50 .
[0032] Because the collet finger insert(s) 44 is designed to mate inside of the groove 51 , the distance from the collet axis to the collet finger insert(s) 44 is equal to the distance from the groove 51 to the collet axis. Since the outer radius of the gun body 50 is greater than the distance from the groove 51 to the collet axis, the collet finger insert(s) 44 must be urged axially outward before the gun body 50 is inserted into the top sub 10 . Application of a sufficient upward axial force to the gun body 50 will temporarily bend the collet finger insert(s) 44 outward; thus out of the way of the gun tube 50 . Radial displacement of the collet finger insert(s) 44 allows the gun tub 50 to fit inside of the top sub 10 . To ensure ease of use and a quick turnaround time, the force required to insert the gun body 50 within the collet finger(s) 42 , or retract the gun body 50 from the grasp of the collet finger(s) 42 , should not exceed approximately 50 pounds force. Thus material selection of the collet finger(s) 42 as well as the size of the collet finger(s) 42 is dictated by this requirement. It is believed that one skilled in the art can choose the proper dimensions and material of a collet finger(s) 42 without undue experimentation.
[0033] Once the collet finger insert(s) 44 are within the groove 51 , the cover sleeve 20 can then be slid upward such that the body of the cover sleeve 20 surrounds the collet finger(s) 42 and collet finger insert(s) 44 . The inner diameter of the cover sleeve 20 retains the collet finger insert(s) 44 within the groove 51 on the gun body 50 . The cover sleeve 20 can be secured to the collet 40 by a threaded fastener 46 . However any number of other attachment devices can be employed, such as rivets, pins, or a series of mating threads on the inner diameter of the cover sleeve 20 and the outer diameter of the collet 40 . Firmly securing the collet finger insert(s) 44 inside the groove 51 provides a connection between the top sub 10 and the gun body 52 . This in effect connects the perforating gun to the wireline.
[0034] The present invention could employ a single cover sleeve 20 in conjunction with a single groove 51 formed on the upper or the lower portion of the gun body 50 . This would result in a quick disconnect system for either the top sub 10 or the bottom sub 11 , but not both subs simultaneously. However, a cover sleeve 20 and groove 51 on both ends of the gun body 50 allows for quick and simple removal, as well as attachment, of both the top sub 10 and the bottom sub 11 from the gun body 50 . Thus, it is preferred that the grooves 51 be provided on the gun body 50 at both its upper and its lower end.
[0035] Assembly of a perforating gun could be done with a groove 51 far from either end, but this would require a long collet finger(s) 41 and an elongated cover sleeve 20 . Since a long collet finger(s) 41 or a long cover sleeve 20 can increase the time and effort required to assemble and disassemble the perforating gun, it is preferred that the groove 51 be positioned close to its associated sub.
[0036] One of the many advantages of the present invention is realized during disassembly of the associated perforating gun. Just as the perforating gun having the present invention can be quickly and easily assembled, it can also be quickly and easily disassembled. Once the shaped charges 54 have discharged and the perforating gun is removed from the wellbore, the collet fastener 46 can be removed and the gun body 50 can be detached from the top sub 10 . Detaching the gun body 50 from the top sub 10 of the present invention does not involve the use of tools but instead can be performed manually—simply by pulling the gun body 50 away from the top sub 10 . More importantly, this function can be done in the field, thus eliminating the need to transport the perforating gun to a central processing facility. A loaded perforating gun can then be reattached to the top sub 10 and the perforating process can be repeated immediately.
[0037] The material selection of the gun body 50 , ring 30 , and collet 20 is important. Due to the large impulse forces encountered during use by each of these components, they should be constructed of a material that does not easily yield, either momentarily or permanently. Even small amounts of yield during use can cause the gun body 50 to bond to the collet finger insert(s) 44 . Which is highly undesirable since quick disassembly is important when refurbishing perforating guns. The proper material of the gun body 50 , ring 30 , and collet 20 can be determined by one skilled in the art and without undue experimentation.
[0038] The bottom sub 11 of the embodiment of the present invention of FIG. 2 can be attached to the gun body 50 in much the same fashion as the top sub 10 . However, because of the detonator 56 , safety procedures typically require that the detonator 56 be connected while the detonator 56 is in a blast shield outside of the gun assembly. The detonator 56 is then connected to the detonating cord 57 .
[0039] One of the many advantages of the present invention is the efficient manner in which the perforating gun can be assembled and disassembled, either for its initial use or for subsequent uses. The present invention enables the assembly/disassembly of the perforating guns to be done at either a primary manufacturing site, or in a remote field site. Thus use of the present invention eliminates time wasted to transport perforating guns to a primary manufacturing site for processing, saves money associated with transporting perforating guns, and reduces the time and effort required to assemble/disassemble perforating guns, either in the field, or at a manufacturing facility. For example, the present invention allows the user the flexibility of forming the groove 51 onto the gun body 50 in the field with a lathe or other machining device. The gun body 50 with its newly formed groove 51 can then be attached to the top sub 10 , while still in the field, inserted into a wellbore, and have the shaped charges within the gun body 50 detonated. After the perforating gun is raised up and out of the wellbore, a new gun body 50 , with a newly formed groove 51 can be switched into the present invention and the perforating process repeated. This provides one example of how use of the present invention allows many functions to take place in the field and reduces the need for machining at a manufacturing site, which in turn reduces costs, effort, and time associated with transportation and engineering coordination.
[0040] A further advantage of the present invention is that the top sub 10 can be disconnected from the perforating gun without the need to disconnect the wireline. This not only saves time, but can reduce possible infield anomalies caused by mistakes in the attachment/detachment during use of the perforating gun. In addition to a cost and time savings, the present invention also is flexible in its application. Use of the present invention is not limited to a single perforating gun of a single length. Instead the present invention can be implemented on perforating guns of any length.
[0041] The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes are possible in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims. | A connection system to be used in conjunction with a perforating gun comprising a top sub formed to receive one end of a gun body of a perforating gun, a circumferential groove disposed on the outer surface of the gun body, and a collet secured to the top sub. The collet has at least one finger that engages the groove. Engaging the groove with the at least one finger of the collect connects the gun body to the top sub. A cover sleeve is included that retains the finger in connective engagement with the groove. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/037,717, filed on Aug. 15, 2014. All information disclosed in that application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to the field of conveyors, and specifically to guide rail systems for guiding items moved by a conveyor defining a path with a straight or curved segment, and including equipment connected to such conveyors, as found in modern assembly, such as rinsers, fillers, cartoners, and case packers, to guide product into and out of such machines.
[0003] It is common for conveyors to need some type of guide rails alongside the conveying surface, so as to keep the items being conveyed from falling off the conveyor, or even just to keep the items upright and not falling over on the conveying surface, which could cause not only damage to the items being conveyed, but also jamming of the conveyor or the items being conveyed. It is desirable to be able to adjust the spacing between the guides, so as to accommodate different types and sizes of items to be conveyed. There have been prior systems where the spacing of the guides has been adjustable. But there is a need for simpler and quicker adjustments of the spacing.
[0004] The present invention relates to improvements over the apparatus described above and to solutions to some of the problems raised or not solved thereby.
SUMMARY OF THE INVENTION
[0005] The invention provides a guide rail system that is adjustable such that by engaging a single mechanism, the distance between a pair of rails (one rail on each side of the conveyor) is changed across multiple conveyor segments (straight and/or curved). The adjustable guide rail system is for use in connection with a conveying surface capable of moving with respect to the guide rail system. The guide rail system includes a guide rail positioned alongside the conveying surface. A guide rail support system is connected to the guide rail, the guide rail support system including a plurality of guide rail adjustment assemblies. Each guide rail adjustment assembly has a guide rail arm, to which the guide rail is mounted. The guide rail arm has an adjustment rack, and a guide rail pinion engaged with the adjustment rack and positioned such that a rotation of the guide rail pinion causes the adjustment rack, and consequently the guide rail arm and in turn the guide rail itself, to move generally linearly, closer to and further away from the center of the conveying surface. The guide rail support system further includes a synchronizing connector connected to the guide rail pinions of two guide rail adjustment assemblies. A rotator is connected to the synchronizing connector for rotating the synchronizing connector and thereby rotating the connected guide rail pinions.
[0006] Other objects and advantages of the invention will become apparent hereinafter.
DESCRIPTION OF THE DRAWING
[0007] FIG. 1 is a perspective view of a conveyor having an adjustable guide rail according to one embodiment of the invention.
[0008] FIG. 2 is an enlarged perspective view of a straight section of the conveyor shown in FIG. 1 .
[0009] FIG. 3 is an enlarged perspective view of a section of the conveyor shown in FIG. 2 , showing detail of the adjusters opposite each other.
[0010] FIG. 4 is an enlarged perspective view of a section of the conveyor shown in FIG. 3 , showing further detail of one of the adjusters.
[0011] FIG. 5 is a cross sectional view of the conveyor shown in FIG. 3 , taken along line 5 - 5 .
[0012] FIG. 5A is a cross sectional view of the conveyor shown in FIG. 2 , taken along line 5 A- 5 A.
[0013] FIG. 6 is an enlarged perspective view of a curved portion of the conveyor shown in FIG. 1 .
[0014] FIG. 7 is a perspective view of the curved portion of the conveyor shown in FIG. 6 , from the opposite side.
[0015] FIG. 8 is a cross sectional view of a portion of the conveyor shown in FIG. 8 , taking along line 8 - 8 .
[0016] FIGS. 9A and 9B are enlarged perspective views of an area of the curved portion of the conveyor and an adjacent area of the straight portion of the conveyor, showing the detail of the sliding support.
[0017] FIG. 10 is a perspective view of a portion of a conveyor constructed according to an alternative embodiment of the invention.
[0018] FIG. 11 is a perspective view of a portion of a conveyor constructed according to another alternative embodiment of the invention.
[0019] FIG. 12 is an enlarged perspective view of a section of the conveyor shown in FIG. 11 .
[0020] FIG. 13 is a cross sectional view of a conveyor constructed according to another alternative embodiment of the invention, wherein only one side of the guide rail is adjustable.
[0021] FIG. 14 is a cross sectional view of a conveyor constructed according to another alternative embodiment of the invention, wherein the guide rail is adjustable directly over the conveyor.
[0022] FIG. 15 is a cross sectional view of a conveyor constructed according to another alternative embodiment of the invention, including multiple adjustable guide rails on each side of the conveyor.
[0023] FIG. 16 is a cross sectional view of a conveyor constructed according to yet another alternative embodiment of the invention, including multiple adjustable guide rails sufficient to form multiple lanes on the conveyor.
DETAILED DESCRIPTION
[0024] Referring now to FIG. 1 , a conveyor 10 is generally shown, having a conveying surface 12 for conveying various items (not shown). The conveying surface 12 is supported on a frame 14 , and is capable of moving along the frame, by means of a conveyor motor (not shown) as is conventional and well known.
[0025] According to the invention, as shown in FIGS. 1-4 , a guide rail 16 is positioned along at least one side of the conveying surface 12 . In the embodiment shown there, there are two guide rails 16 , one positioned along each side of the conveying surface 12 , substantially along the entire length of the conveyor 10 . The invention provides for a guide rail support system, for supporting the guide rail 16 with respect to the conveying surface 12 . As will be explained below with respect to different embodiments of the invention, the guide rails 16 may be positioned at the side of the conveying surface, or over the conveying surface 12 , so as to guide the items with respect to a portion of the conveying surface, such as the center of the conveying surface.
[0026] As part of the guide rail support system, at certain spaced-apart locations along the conveyor 10 are positioned guide rail adjustment assemblies 18 . Each guide rail adjustment assembly 18 includes a guide rail arm 20 which is attached to and supports the portion of the guide rail 16 in the vicinity of the guide rail arm. Each guide rail arm 20 also has an adjustment rack 22 , which is shown integrally formed with the respective guide rail arm 20 , but which could also be formed as a separate item and assembled to the guide rail arm. Each adjustment rack 22 passes into a respective pinion block 24 to engage with a pinion gear or pinion 26 , shown in FIG. 5 . Each pinion block 24 is mounted to the frame 14 by means of pinion block mounting brackets 18 a . While the means of engagement between the pinion 26 and the adjustment rack 22 is shown to be pinion teeth 26 a engaging with openings 22 a formed for that purpose in the adjustment rack, any other suitably accurate and repeatable engagement between those two elements is also contemplated by the invention, including for example other gearing such as bevel gearing. The pinion block 24 and adjustment rack 22 are positioned and arranged so that, when pinion 26 is rotated in one direction, the guide rail arm 20 , and the respective portion of the guide rail 16 , is moved closer to the selected or desired area of conveying surface 12 , whereas when pinion 26 is rotated in the opposite direction, the guide rail arm 20 , and the respective portion of the guide rail 16 in the vicinity of the guide rail arm, is moved further away from the desired area of conveying surface 12 .
[0027] The invention further provides a synchronizing connector 28 connecting the respective pinions 26 of each pair of adjacent pinion blocks 24 on one side of the conveyor 10 , such that when one synchronizing connector 28 is rotated, the pinions 26 of each pair of adjacent pinion blocks 24 is rotated. Thus, when one synchronizing connector 28 is rotated, all the pinions 26 in all the pinion blocks 24 are rotated, thereby moving all the guide rail arms 20 , in turn moving the entire guide rail 16 on that side of the conveyor 10 . The synchronizing connector 28 shown in the drawing figures has a substantially square cross section. Synchronizing connectors with other cross sections could also be used, including rectangular, or oval. Even a round cross section could be used, but that would require the inclusion of a set collar or some other structure to connect the synchronizing connector to the respective pinions so as to pass on the torsional forces supplied by the synchronizing connectors.
[0028] The invention further provides a rotator 30 for rotating the synchronizing connectors 28 and pinions 26 , so as to move the guide rail a desired amount. In FIGS. 1 and 2 , the rotator 30 includes a crank handle 32 connected to a crankshaft 34 . As shown most clearly in FIG. 2 , in this embodiment the crankshaft 34 is oriented transverse to the synchronizing connectors 28 , and so this embodiment includes a gear box or other transfer case 36 , wherein the crankshaft 34 is the input shaft, and with the transfer case translating the rotational motion, the output shaft is connected to the nearest synchronizing connector(s) 28 . The rotator 30 may take other forms as well, as will be explained below.
[0029] It is common, though not required, for a conveyor 10 to have guide rails 16 on both sides. The present invention provides that the two guide rails 16 on the two opposite sides of the conveyor may have separate guide rail support systems, which could be separately adjustable, in the manner described above for a single side. The invention also provides for synchronizing the guide rail support systems of the two sides, if desired. According to the invention, as shown best in FIGS. 2 and 5A , the sides-synchronized version of the invention provides for an opposite transfer case 36 a on the side of the conveying surface 12 opposite the transfer case 36 . For this arrangement, transfer case 36 includes a second output shaft 38 , which acts as, or connects to, the input shaft 34 a of opposite transfer case 36 a . In FIG. 5A , this connection is made by extender shaft 39 , but other suitable connections may be supplied. As with transfer case 36 , the output shaft of opposite transfer case 36 a is connected to the synchronizing connectors 28 on that side of the conveyor 10 . Thus, when the rotator 30 rotates the crankshaft 34 of the transfer case 36 , the second output shaft 38 rotates the input shaft 34 a of the opposite transfer case 36 a , which causes the output shaft of opposite transfer case 36 a to rotate the synchronizing connectors 28 on that side of the conveyor 10 . In this fashion, both sides of guide rails 16 are moved at the same time.
[0030] As shown in FIG. 1 , conveyor 10 may include a straight portion 10 a , but it may also include a curved portion 10 b . As shown in FIGS. 6, 7, 8, 9A and 9B , the invention also provides for supporting and adjusting the guide rail 16 in the curved portion 10 b of the conveyor 10 . As shown in those figures, at the center of the curve, the guide rail arm 20 is affixed to the guide rail 16 as described above. However, at each end of the curved section, the respective guide rail arm 20 is connected to the respective portion of the guide rail 16 by means of a slider assembly 40 , which allows relative sliding lateral movement between the guide rail and the guide rail arm. As shown best in FIGS. 8, 9A and 9B , in this embodiment slider assembly 40 is formed of a rail portion 40 a , connected to the guide rail 16 , and an arm portion 40 b connected to the guide rail arm 20 . Rail portion 40 a and arm portion 40 b are connected together in a manner that permits them to slide with respect to each other, laterally, along the lengthwise direction of the guide rail 16 .
[0031] Thus, when guide rail arm 20 on the outside of the curve is moved away from the conveying surface 12 by the action of the synchronizing connectors 28 and pinion 26 , the rail portion 40 a slides along the arm portion 40 b away toward the center point of the curve, as shown in FIG. 9A , whereas when guide rail arm 20 on the outside of the curve is moved toward the conveying surface 12 by the action of the synchronizing connectors 28 and pinion 26 , the rail portion 40 a slides along the arm portion 40 b away from the center point of the curve, as shown in FIG. 9B . Conversely, when guide rail arm 20 on the inside of the curve is moved away from the conveying surface 12 by the action of the synchronizing connectors 28 and pinion 26 , the rail portion 40 a slides along the arm portion 40 b away from the center point of the curve, again as shown in FIG. 9A , whereas when guide rail arm 20 on the inside of the curve is moved toward the conveying surface 12 by the action of the synchronizing connectors 28 and pinion 26 , the rail portion 40 a slides along the arm portion 40 b toward the center point of the curve, again as shown in FIG. 9B .
[0032] In general, FIG. 9A shows the guide rails 16 and 16 a in their widest position, and it can be seen that the guide rails 16 and 16 a forming the outer side of the curve do not overlap each other, whereas the guide rails 16 and 16 a forming the inner side of the curve do overlap to an extent. Conversely, FIG. 9B shows the guide rail 16 and 16 a in their narrowed position, and it can be seen that the guide rails 16 and 16 a forming the outer side of the curve do overlap each other to some extent, whereas the guide rails 16 and 16 a forming the inner side of the curve do not overlap. The overlap described herein is permitted or accommodated in the embodiment shown, by the fact that the straight portion guide rail 16 is a single rail, at a level a bit lower (closer to the level of the conveying surface 12 ) than the curved portion guide rail 16 a , so that the same distance from the opposing guide rail 16 or 16 a is maintained by both straight guide rail 16 and curved guide rail 16 a.
[0033] In connection with the curved portion 10 b of the conveyor 10 , the synchronizing connectors are provided with universal joints 44 , or other suitable connectors, or flexible members may be used, to permit rotational forces to be transmitted to pinion blocks 24 around the curvature of the curved portion.
[0034] FIG. 10 shows an alternative embodiment of the invention. Where the embodiment shown in FIGS. 1 and 2 showed the rotator 30 to include a crank handle 32 , the embodiment shown in FIG. 10 illustrates a rotator 30 that includes a motor 42 . Operation of a motor to bring about a desired number of rotations, or a desired portion of a single rotation, is well known by persons of ordinary skill in the art. The motor 42 may be controlled locally, such as by an operator in the presence of the motor, or may be controlled remotely through a distributed control system.
[0035] FIGS. 11 and 12 show another alternative embodiment of the invention wherein the pinion blocks 24 are mounted in a guide support frame 46 above the conveyor surface 12 , and wherein the guide rail adjustment rack 22 is mounted vertically within the pinion blocks, so that the adjustment permitted is vertical adjustment of the guide rail 16 , higher or lower along the length of the conveyor surface 12 .
[0036] FIG. 13 shows another alternative embodiment of the invention wherein, as alluded to above, the guide rail 16 may be mounted adjustably on one side of the conveying surface 12 . On the opposite side of the conveying surface 12 , the guide rail 16 is mounted by attaching a fixed position mount 48 directly to the frame 14 . Fixed position mounts vary in design and shape, but in general are well known to persons of ordinary skill in the art.
[0037] FIG. 14 shows an embodiment of the invention similar to that shown in FIGS. 11 and 12 , in that the guide rail 16 is vertically adjustable. In this embodiment the guide rail 16 is positioned directly above the conveying surface 12 , and can apply pressure downwardly onto items on the conveying surface.
[0038] FIG. 15 shows an embodiment of the invention having multiple guide rails 16 on each side of the conveying surface 12 . As can be seen, the upper and lower guide rails may be controlled separately from each other, and the respective opposing guide rails may be controlled together as described above.
[0039] FIG. 16 shows an embodiment of the invention having multiple adjustable guide rails 16 sufficient to form multiple lanes 50 on the conveying surface 12 .
[0040] This invention has a number of advantages over prior art. First, the single piece turn rail minimizes catch points and is cleaner without overlapping multiple pieces. Second, there is a linear bearing/slide mechanism in the turn section to facilitate the change in radius and circumferential distance, while maintaining the desired rail gap. This invention permits the use of fewer actuation points per length of conveyor. The design is modular, and thus does not require custom engineering for turns. Some prior art conveyors require all turns to be specially engineered and designed by the manufacturer. In general, the design is cleaner. The housing can be flushed with water to clean the pinion and rack. The fact that the rack can be manufactured of multiple different materials, including steel, facilitates custom lengths and is less expensive to produce. Finally, the implementation of the non-round shaft eliminates need for set collars.
[0041] While the apparatus hereinbefore described is effectively adapted to fulfill its intended objects, it is to be understood that the invention is not intended to be limited to the specific preferred embodiments set forth above. Rather, it is to be taken as including all reasonable equivalents to the subject matter described. | A guide rail system for guiding containers moved by a conveyor defining a path with a straight or curved segment. The guide rail system is adjustable such that by engaging a single mechanism, the distance between a pair of rails (one rail on each side of the conveyor) is changed across multiple conveyor segments (straight and/or curved). The invention provides an adjustable guide rail system for use in connection with a conveying surface capable of moving with respect to the guide rail system. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates generally to biological safety cabinets.
Biological safety cabinets are laboratory containment devices equipped with High Energy Particulate Air (HEPA) filters. These cabinets are used in microbiological laboratories and provide a work area with safe environment in which a variety of experiments and studies can be performed. Rather than providing only a hood above a working surface, these cabinets provide a more protective working environment. The safety cabinet has a frame that surrounds the work area on all but one side. The remaining open side is enclosed by a moveable sash. The sash may be moved upwardly to provide access to the work area, so that work can be performed. The sash may be moved downwardly to partially or completely close the work area. A blower unit is provided in the cabinet above the work area. The blower is used to circulate air downwardly through the safety cabinet. A portion of this downward air flow forms an air curtain at the front of the cabinet work area and passes beneath the floor of the work area and a portion is directed to the back of the cabinet where it is drawn upwardly through a plenum chamber. This air may be contaminated by materials being used within the working environment. Therefore, prior to being exhausted into the room or a fume system, the air is first passed through a HEPA exhaust filter.
The blower is operated so there is sufficient air flow through the work area to insure that any harmful materials are contained and eventually passed to a filter area rather than escaping into the room or exhausted into the atmosphere. To this end some air is drawn into the safety cabinet about the open perimeter formed when the sash is in an open or partially open position.
The prior art safety cabinets are typically provided with a sash grill located below the bottom of the sash. This sash grill forms the lower-most surface of the opening into the work area. Typically, the sash grill is provided with a number of perforations, through which air can flow. Air flows downwardly from the blower along the back of the sash and into these perforations. Air is also drawn inwardly from the exterior of the cabinet along the surface of the sash grill and into the perforations. The air flowing through the sash grill flows under the work surface and upwardly through the plenum at the back of the cabinet to be recirculated or exhausted.
Safety cabinets have heretofore utilized a sash grill having a generally flat surface which gives rise to a number of disadvantages. The flat surface may be used by those operating the safety cabinet as a surface on which to place a variety of labware. This is undesirable because objects located on the sash grill present a source of possible contamination of the room, and may be inadvertently broken if bumped or knocked onto the floor. Moreover, by placing an object on the sash grill, a portion of the perforations therein may be blocked, which can adversely affect the air flow of the safety cabinet. The flat surface of the sash grill also results in a large portion of the perforations therein becoming blocked by a user's arm as the user performs work within the safety cabinet. As the user's arm blocks the perforations in this fashion, it is difficult to properly maintain the negative pressure environment about the user's arm, thereby risking possible contamination. The flat sash grills of the prior art also present a right angle with the work surface which projects far enough above the work surface that labware is sometimes broken when it bumps against the projecting vertical face. It is thus desirable to provide a sash grill which does not provide a flat surface and does not present a right angle corner at the entrance to the work area opening.
Another drawback of prior art sash grills is attributable to the fact that the grills are formed with a front face that is at a right angle to the flat top of the grill. This orthogonal relationship results in an air flow that is less than desirable. When air is drawn inwardly and through the perforations in the sash foil, it may cause a turbulence in the air flowing downwardly along the back of the sash and through the working environment. This turbulence is increased by the right angle relationship, as the air encountering the front face of the grill will be partially directed upwardly over the front face before being drawn through the perforations in the flat top of the grill. Therefore, a biological safety cabinet is needed with a sash grill that improves the air flow and safety of the cabinet.
Similarly, air may be drawn into the opening of the safety cabinet along the sides of the cabinet adjacent the opening when the sash is in an open or partially open position. In prior art safety cabinets, the front sides of the cabinet are oriented at right angles relative to the interior side walls. When air is drawn into the cabinet along these sides, it will initially be directed away from the interior surface of the interior walls. However, it is much more desirable to cleanly “sweep” the interior walls of the cabinet, to ensure the best possible containment of any harmful materials. A biological safety cabinet having a construction that draws air inwardly to cleanly sweep the interior side walls is needed.
After the safety cabinets have been used for a certain period of time, they must be decontaminated. One method for performing this decontamination involves sealing the front of the safety cabinet with a plastic sheet. When the prior art safety cabinets are being decontaminated, it is often necessary to first remove the sash to insure proper decontamination. This is attributable to the location of the sash within a U-shaped channel where contaminants may accumulate. This procedure is time consuming and risks damage to the sash. If the sash is dropped it may shatter, and contaminate an entire room. Thus, a biological safety cabinet which can be decontaminated without removal of the sash is needed.
Another drawback of prior art safety cabinets involves the lower edge or handle of the moveable sash. When the sash is in an open or partially open position, two bodies of air are coming together adjacent the handle of the sash. One body of air is flowing from the exterior of the cabinet into the interior thereof. The second body of air is flowing downwardly from the blower unit of the safety cabinet along the back of the sash. In prior art cabinets, the sash handle has transitioned from the front face to the bottom face at a right angle. This results in the inwardly flowing air meeting the downwardly flowing air at a right angle, causing turbulence. As noted above, turbulent air flow adjacent the opening of the cabinet is undesirable. A sash handle that reduces turbulence would represent an improvement over the prior art.
As stated above, the biological safety cabinet is operated with the benefit of a blower which provides an air flow so that harmful materials are contained within the cabinet. The cabinets are constructed with the blower above the working environment, and the working environment is subject to a continual flow of air to contain contaminants and then move them to a filter area. Above the working environment and beneath the blower, is a supply filter and a positive pressure plenum. The pressure plenum receives air from the blower and directs it through the supply filter.
To monitor the pressure within the cabinet, prior art safety units have used a pressure gauge mounted on the exterior of the cabinet, with the pressure being monitored in the positive pressure environment of the pressure plenum immediately below the blower. Monitoring the positive pressure allows a more meaningful pressure reading to be obtained and used by the laboratory personnel. However, the air within the pressure plenum immediately below the blower has not yet been filtered. As such, the air may contain harmful materials from the working environment below. If the gauge on the exterior of the cabinet were to leak, contaminated air would be allowed into the room. In some instances this concern has been addressed by placing a HEPA filter in the pressure line to the readout gauge. This of course results in additional expense both initially and for ongoing maintenance. Another method of addressing the potential problem of contamination through the pressure gauge has been to monitor the air pressure in a negative pressure environment (relative to the atmosphere surrounding the cabinet) thus eliminating the possibility of contamination as a result of leakage through the gauge into the room. Monitoring and displaying a negative pressure, however, is more difficult to translate into meaningful and usable numbers by laboratory personnel. A monitoring apparatus is therefore needed which does not require any additional filters and allows the monitoring and display of a positive pressure, while eliminating the risk of possible contamination of the room environment.
It has been found that it is desirable to equip the safety cabinet with a “towel catch” to catch or filter out large objects from the returning air flow prior to being recirculated through the blower. This towel catch removes such things as paper towels and small laboratory items from the returning air stream. Prior art safety cabinets have located this towel catch in the plenum formed by the rear wall of the work area and the rear wall of the safety cabinet. While this location is effective in removal of the desired items, it is impossible to visually inspect without taking the cabinet apart. One method typically utilized for inspecting these prior art towel catchers is to reach up within the plenum and feel the towel catch to determine if any paper towels or other objects are lodged within or against the towel catcher. This method can be uncomfortable and dangerous to the extent that pieces of broken laboratory glass and other sharp objects may be lodged within the towel catch. The towel catch itself is normally formed from metal with sharp edges which presents a safety hazard in and of itself if it is placed in a traditional location where it is not visible to a worker cleaning it. Therefore, a towel catch that is readily accessible and can be visually inspected is needed.
Another drawback of prior art safety cabinets involves the construction of the sash. The sash of the safety cabinet is moveable upwardly and downwardly, to allow better access to the working environment when needed and to more fully enclose the working environment when access is no longer needed. In prior art safety cabinets, the rear of the sash is provided with a seal to prevent any contaminated air from escaping the working environment. The seal wipes the back of the sash as the sash is raised. This arrangement is disadvantageous in that the wiping action may create an aerosol containing contaminants from the rear of the sash. While in other prior art constructions holes communicating with the exhaust system have been utilized in place of seals, such constructions have not been particularly effective, largely because there has been no means for insuring a uniform negative pressure across the exhaust holes. Thus, an arrangement is needed for a biological safety cabinet that eliminates the need for a wiping seal at the rear of the sash and instead provides for a uniform negative pressure which will insure removal of any contaminated air from the back side of the sash.
Yet another drawback of existing prior art safety cabinets involves the design of the positive pressure plenum box. This box is located in the area below the blower and above the work area. More specifically, in prior art cabinets, air leaving the blower is directed to a perforated plate and then through a supply filter prior to be recirculated downwardly through the work area. The perforated plate is used to more evenly distribute the air flow over and through the supply filter. The perforated plate creates an undesirable increased load on the blower and can interfere with the function of the supply filter. Moreover, this prior art construction does not distribute air across the supply filter as evenly as desired. Therefore, a structure is needed that both evenly distributes the flow over and across the supply filter while not overly increasing the load on the blower or interfering with the function of the supply filter.
Prior art safety cabinets are typically equipped with exhaust control systems. As contaminated air passes through the blower of the safety cabinet, some of the air is recirculated through the supply filter as described above and some of the air is routed through an exhaust filter. This exhaust air is either discharged into the room, or is passed to an exhaust system associated with the safety cabinet which moves the air out of the building. In cabinets routing the exhaust air directly back into the room, the prior art cabinets have merely routed the air directly upwardly. Prior art units routing the air into a building exhaust system direct typically employ duct work coupling the safety cabinet exhaust to the building exhaust system. Both prior art embodiments require a certain amount of additional space above the ceiling of the safety cabinet to allow for the exhaust control systems. This need for space can place limitations on the rooms in which the safety cabinets can be used.
In addition to routing the exhaust air, the exhaust control systems of the safety cabinets are used to balance the air flow through the safety cabinet. Prior art exhaust control systems use a guillotine damper to allow more or less air to be exhausted, as needed to balance the air flow through the safety cabinet and achieve the proper pressure within the cabinet. This damper places some additional load on the blower by restricting air flow to the filter. Furthermore, a damper is not aerodynamically efficient and interferes with the uniform flow of air. Such dampers are normally not readily accessible for making adjustments. The use of such a damper also tends to cause air to flow unevenly through the filter thus not effectively using the entire filter surface area. Therefore, a more efficient exhaust control system is needed for a biological safety cabinet that reduces undesired blower loading, makes better utilization of available filter surface area and is readily accessible.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide a biological safety cabinet having a novel sash grill that more effectively prevents contaminated air from leaving the cabinet, and more effectively draws air into the cabinet.
It is another object of this invention to provide a sash grill for a biological safety cabinet that prevents objects from being placed thereon.
It is a further object of the invention to provide a biological safety cabinet having exterior front side panels that allow incoming air to more effectively sweep the sides of the cabinet and that allow the cabinet to more easily be decontaminated.
It is yet another object of the invention to provide a handle for the sash of a biological safety cabinet that allows air to more effectively flow thereover.
It is still another object of the present invention to provide a biological safety cabinet in which the pressure gauge measures a positive pressure environment while being contained within the safety cabinet so that any risk of contamination through the gauge is reduced while also eliminating the need for a separate HEPA filter for the gauge.
Another object of the present invention is to provide a towel catch for a biological safety cabinet that is visible to the user thereof and that can be easily removed without disassembling the safety cabinet.
Yet another object of the present invention is to provide a biological safety cabinet that eliminates the need to wipe the back of the sash with a seal so that still another risk of contamination is reduced.
It is another object of the present invention to provide a biological safety cabinet with a plenum box that evenly distributes the air flow across a supply filter without increasing the load on the blower of the cabinet.
A still further object of the present invention is to provide a biological safety cabinet with a low profile, externally adjustable exhaust control that does not require decontamination before adjusting and provides for more uniform distribution of air across the exhaust filter.
It is yet another object of the present invention to provide a plenum chamber seal and tensioning device for the exhaust filter of a biological safety cabinet that allows the supply filter and exhaust filter to be simultaneously sealed.
According to the present invention, the foregoing and other objects are attained by a biological safety cabinet that includes a frame that defines a protected working environment and encloses the working environment on all but one side. A sash is coupled to the frame that at least partially encloses the side that is not enclosed by the frame. A blower is coupled to the frame generally above the working environment. The blower is adapted to circulate air through the working area so that harmful materials are confined. A sash grill is coupled to the frame generally below the sash and has a curved top surface. The curved sash grill provides a superior and less turbulent air-flow into the working environment, thereby better containing any harmful materials. The curved sash grill is perforated, and the curvature and perforations of the sash grill compensate for partial blockage by the user's arms and other objects. The curvature of the sash grill also presents a surface on which objects cannot be easily placed, thereby avoiding a safety hazard. The curved grill also eliminates a protruding right angle corner at the cabinet opening which has been known to cause breakage of labware being placed inside the cabinet.
Additional objects, advantages, and novel features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art upon examination of the following, or may be learned from practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings which form a part of this specification and which are to be read in conjunction therewith and in which like reference numerals are used to indicate like parts in the various views:
FIG. 1 is a perspective view of the biological safety cabinet of the present invention, with parts being broken away to show particular details of construction;
FIG. 2 is a front elevation view of the safety cabinet of FIG. 1, with parts being broken away to show particular details of construction;
FIG. 3 is a side cross sectional view taken along line 3 — 3 of FIG. 2;
FIG. 4 is a partial cross sectional view taken along line 4 — 4 of FIG. 3;
FIG. 5 is an enlarged view of the encircling line 5 of FIG. 2, showing the sealing arrangement between the supply filter and the exhaust filter;
FIG. 6 is an enlarged view of the encircling line 6 of FIG. 1;
FIG. 7 is a partial sectional view taken along line 7 — 7 of FIG. 3 showing a partial top plan view of the sash grill used in the safety cabinet of FIG. 1;
FIG. 8 is a partial sectional view taken along line 8 — 8 of FIG. 3, showing an elevation view of the towel catch used in the safety cabinet of FIG. 1;
FIG. 9 is perspective view of an alternate embodiment of the exhaust body used in the safety cabinet of FIG. 1; and
FIG. 10 is an enlarged view of the encircling line 10 of FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
Referring initially to FIG. 1, a biological safety cabinet according to the present invention is broadly designated in the drawings by the reference numeral 10 . A broad overview of the construction of cabinet 10 is set forth below, followed by a more detailed description of certain features of the cabinet. Broadly, cabinet 10 has a bottom panel 14 and a pair of upwardly extending opposing side panels 16 which are rigidly coupled to bottom panel 14 , such as by welding. Extending upwardly from the bottom panel 14 and rigidly coupled between side panels 16 is a rear panel 18 , as best seen in FIG. 3 . Rear panel 18 extends upwardly from bottom panel 14 as do side panels 16 . Bottom panel 14 , side panels 16 and rear panel 18 form apartial frame in which the other components of cabinet 10 are held. A baffle 20 is coupled between side panels 16 and is spaced outwardly away from real panel 18 . The bottom of baffle 20 is spaced upwardly away from bottom panel 14 . Panels 14 , 16 and 18 , as well as baffle 20 are preferably made from metal, such as stainless steel.
As best seen in FIG. 3, a work surface 22 is suspended above bottom panel 14 . Work surface 22 is used to hold the objects necessary to perform experiments within cabinet 10 , such as beakers, flasks and other conventional labware. Extending generally along the front of cabinet 10 between side panels 16 , and extending from work surface 22 to bottom panel 14 , is a sash grill 24 , the importance of which is further described below.
As best seen in FIGS. 2-4, a blower assembly 26 is located in the upper part of cabinet 10 . Assembly 26 includes a blower 28 , an exhaust filter 30 , a supply filter 32 and a plenum box 33 which is in communication with the blower outlet. A top panel 34 presents the enclosed top of the cabinet. Panel 34 extends from rear panel 18 to the front of the cabinet and between side panels 16 . An exhaust control cap 36 is coupled to top panel 34 directly above exhaust filter 30 . Top panel 34 also has coupled thereto an electronics housing 38 . Housing 38 houses and protects the electronics necessary to operate cabinet 10 . As best seen in FIGS. 1 and 3, a cover panel 40 that is coupled to top panel 34 and extends between side panels 16 . Panel 40 extends only partially down cabinet 10 from top panel 34 . A movable sash 42 is mounted between side panels 16 in a manner allowing it to be moved upwardly and downwardly. Work surface 22 , baffle 20 , side panels 16 and an air diffuser plate 43 below supply filter 32 form a protective work area 44 within which work can be performed.
In use, blower 28 of cabinet 10 is operated to provide an air-flow through the cabinet, and particularly through work area 44 . Prior to the air entering the work area 44 , it is first passed through supply filter 32 to remove any contaminants. Cabinet 10 may be operated with sash 42 located a specified distance away from sash grill 24 , as is shown in FIG. 3 . To ensure that contaminants do not escape through the opening between sash 42 and grill 24 , blower 28 will direct air downwardly along the rear of sash 42 and into the perforations of grill 24 from above the work area to provide a protective curtain of air that facilitates containment within work area 44 . A portion of the air from blower 28 also moves toward the rear of the surface 22 as will be explained hereinafter. The action of blower 28 provides a certain amount of suction, causing an air flow inwardly along the opening defined by the bottom of sash 42 , side panels 16 and sash grill 24 . Air which is drawn through this opening also passes through the perforations in sash grill 24 . The air, once drawn through sash grill 24 , will travel beneath work surface 22 and through the plenum defined by baffle 20 and real panel 18 as it is drawn upwardly by blower 28 . The air moving from the blower to the rear of surface 22 will also be drawn into this same plenum.
Air that has passed through working environment 44 is likely to contain contaminants and thus, before being recirculated or exhausted to the room, is first passed through a HEPA filter. Prior to being recirculated into working environment 44 the air passes through supply filter 32 . Similarly, prior to being exhausted to the room, the air is passed through exhaust filter 30 . Filters 30 and 32 are both High Efficiency Particulate Air (HEPA) filters of a type well known to those skilled in the art. Thus, cabinet 10 is used to perform experiments within work area 44 and to contain any contaminated air within the cabinet. Particular and novel details of construction are more fully set out below.
As best seen in FIG. 3, work surface 22 is positioned above bottom panel 14 by a number of supports 46 that are preferably screwed directly into bottom panel 14 (additional support is provided by a rear lip to be described hereinafter). Supports 46 are thus easily removable and can be decontaminated and cleaned after removal from bottom panel 14 as needed. Work surface 22 rests directly upon supports 46 and is thus spaced from bottom panel 14 . The spacing between bottom panel 14 and work surface 22 allows air to circulate beneath work surface 22 . Surface 22 can be made from a material such as stainless steel and is placed on supports 46 so that the rear edge thereof rests on a lip at the bottom of baffle 20 . Work surface 22 may be held in place through the use of removable fasteners which require no tools. Work surface 22 is thus mounted within safety cabinet 10 in a manner allowing the easy removal thereof, such as may be needed for decontamination and cleaning of the safety cabinet.
Sash grill 24 extends between the front of work surface 22 and bottom panel 14 from one side panel 16 to the other. As best seen in FIGS. 6 and 7, grill 24 has a plurality of main perforations in 48 therein. Perforations 48 allow air to flow through sash grill 24 as air passes downwardly along the rear of sash 42 and inwardly as air enters the safety cabinet adjacent the surface of sash grill 24 . Preferably, perforations 48 extend generally from one side of sash grill 24 to the other. However, as best seen in FIGS. 6 and 7, a series of enlarged side holes 50 are provided along each side of grill 24 . Enlarged holes 50 provide additional air flow adjacent side panels 16 and operate to better contain the air within working environment 44 . Further, grill 24 is provided with a front row of scavenger holes 52 . Scavenger holes 52 operate to provide an additional source of protection should the main perforations 48 become blocked along the length of sash grill 24 .
As best seen in FIGS. 3 and 6, sash grill 24 has a curved surface. This curved surface provides a number of advantages. First, it prevents objects from being placed on the sash grill and blocking any of the perforations within sash grill 24 . This not only prevents blockage of the perforations, but also eliminates any possibility of objects being placed on the grill and then knocked off and broken. The curved shape of the grill also eliminates a sharp edge at the same level as that of the work surface which greatly reduces the possibility of accidental contact when labware is being moved in and out of the work area. Contact at this point has been a source of breakage of glass labware in the past. Further, the curvature provided also prevents all of the main perforations 48 in a particular area from being blocked by a relatively linear object, such as a person's arm. Safety standards require a certain minimal opening for the sash while a user is performing a task in the work area with the sash raised. This means that there must be a certain minimal distance between the bottom of the sash and the top of the sash grill. With the curved grill of the present invention, since the height of the grill relative to the floor is lower than it would be if the grill was flat, the minimal distance between the bottom of the sash and the grill can be met with the sash lower relative to the floor than with prior flat grills. This results in the sash handle, which interferes with the view of the worker, being in a lower position and improves the worker's available viewing area. It also improves work safety by increasing the distance between the opening and the worker's face. The curved surface of grill 24 also operates to allow the air flowing downwardly along the back of sash 42 , and the air flowing inwardly from the opening in cabinet 10 , to more effectively sweep across the grill surface and enter the work area. In prior art systems, the air flowing inwardly is confronted with a front face that is located at a right angle to the flat horizontal surface of the sash foil. This air is then forced in an upward arc away from the surface of the sash grill prior to entering any perforations therein. With the novel curved sash grill of the present invention, the downwardly moving air is not confronted with a surface at a sharp (right) angle to the direction of air flow, which allows it to more effectively enter through the perforations within the sash grill with less turbulence. The curved surface of grill 24 also promotes smooth flow of air across the grill into the work area from outside the cabinet. Less turbulence is experienced then with prior art designs where the grill presents a right angle relative to the work surface.
Turning to the rear of cabinet 10 , baffle 20 is mounted between side panels 16 and can be secured in place such as by bolting or welding. The lower-most edge of baffle 20 may be provided with a support lip 58 as best seen in FIG. 3 . Lip 58 is used to support work surface 22 and may be provided with a number of threaded holes to secure work surface 22 to baffle 20 . Located above the lower most surface of baffle 20 and extending from one side of baffle 20 to the other, are a number of slots 60 , as best seen in FIG. 8 . Slots 60 are provided to allow air flowing downwardly from blower 28 to pass there through and into the plenum formed by baffle 20 and rear panel 18 .
As best seen in FIG. 3, a pressure gauge 62 is mounted within baffle 20 above slots 60 . Gauge 62 can be viewed by the user of safety cabinet 10 through sash 42 , which is made from a clear material such as tempered glass. Gauge 62 is used to measure a positive pressure within a plenum box 64 that is located immediately below blower 28 . Measuring the positive pressure within plenum box 64 allows the user of cabinet 10 to obtain a more accurate indication of the load on filters 30 and 32 . To measure the pressure within plenum box 64 , a hose barb 66 is placed through the rear plate of plenum box 64 . A piece of tubing 68 is mounted to hose barb 66 and extends downwardly through the rear plenum and is connected to a plastic Y-hose barb 70 . Another piece of tubing 72 extends from the lower end of barb 70 downwardly and into the space between bottom panel 14 and work surface 22 . Finally, the remaining end of hose barb 70 is connected to a third piece of tubing 74 which is coupled to the high pressure port of gauge 62 . Gauge 62 thus is mounted entirely within safety cabinet 10 and is adapted to measure the positive pressure within plenum box 64 . Should any leakage occur within gauge 62 , any contaminants within tubing 68 , 72 or 74 would be contained within cabinet 10 and would be filtered prior to being exhausted into the room.
As best seen in FIGS. 3 and 8, cabinet, 10 is also provided with a perforated towel catch 78 . More specifically, a towel catch 78 extends from lip 58 at the bottom of baffle 20 downwardly to bottom panel 14 . Preferably, catch 78 is angled rearwardly as shown in FIG. 3, and is mounted to baffle 20 with the same screws that are used to attach work surface 22 to baffle 20 . This mounting allows towel catch 78 to easily be removed, such as may be necessary to clean towel catch 78 or bottom panel 14 in the event of a spill. As best seen in FIG. 8, catch 78 has a number of rectangular slots 80 which allow air to pass through catch 78 and upwardly behind baffle 20 . Moreover, the lower tubing 72 associated with pressure gauge 62 may be passed through one of the slots 80 . Catch 78 is used to prevent objects such as broken pieces of glass and paper towels from traveling upwardly through the rear plenum and into blower 28 . In use, work surface 22 may be pulled away from baffle 20 which allows towel catch 78 to be visually inspected for any blockage. If an object is lodged against towel catch 78 , it may be easily removed by the user of safety cabinet 10 . Moreover, the visual inspection allows the user of safety cabinet 10 to avoid contact with the catch which might result in injury and to be forewarned if a sharp of dangerous object is lodged against the catch. Prior art safety cabinets have located the towel catch associated therewith upwardly from the bottom of the safety cabinet. Generally, such a prior art towel catch would be located somewhere above the rear intake of the exhaust plenum 20 . In such a location the towel catch becomes a safety hazard in and of itself and can also result in injury if sharp objects are restrained by it. Location of towel catch 78 as described for the present invention allows the towel catch 78 to be visually inspected and cleaned. Further, the towel catch may be much more easily removed from safety cabinet 10 if needed, such as when surface 22 is to be removed for cleaning beneath it.
Turning to details of the plenum box 33 and associated filters, and as best seen in FIGS. 3 and 4, the supply filter 32 is located above work area 44 at the upper end of baffle 20 . Air diffuser 43 is located immediately below supply filter 32 . Diffuser 43 operates to properly direct the air as it exits supply filter 32 to obtain the desired air flow through work area 44 . Immediately above supply filter 32 is the plenum box 33 . Box 33 directly abuts supply filter 32 and is held against it as described below. As best seen in FIG. 4, plenum box 33 extends from the exit of blower 28 and provides a structure for evenly distributing the air flow to both the supply and exhaust filters. More specifically, box 64 includes a distribution baffle 88 that tapers upwardly from the exit of blower 28 as it extends across the side of safety cabinet 10 . Preferably, baffle 88 extends from the front of plenum box 64 to the back thereof. A portion of the output from blower 28 will pass upwardly to exhaust filter 30 while a portion will be directed into a narrow channel 90 . The air leaving channel 90 is directed to a first curved deflector 92 , as shown on the left-hand side of FIG. 4 . Deflector 92 operates to redirect the air downwardly and to the right as viewed in FIG. 4 . Deflector 92 is preferably made from a rigid material such as steel and is rigidly mounted within plenum box 33 , such as by welding. As the air travels back to the right as viewed in FIG. 4, distribution baffle 88 forces the air downwardly and into a second narrow channel 94 . The angle of baffle 88 is selected to insure that the volume of air passing across supply filter 32 is relatively constant across the entire width of the filter. The angle will vary depending upon the output of the blower and the size of filter 32 . The air at the far right hand portion of plenum box 64 , as viewed in FIG. 4, is directed downwardly by a second deflector 96 . Thus, construction of plenum box 64 , with baffle 88 and deflectors 92 and 96 , operates to evenly distribute the air flow across and through supply filter 32 . This is done without restricting the air flow, such as with the use of a prior art perforated plate. Therefore, the above construction of plenum box 64 achieves a more uniform distribution of air across supply filter 32 without placing an increased load on blower 28 .
As best seen in FIG. 4, the upper end of plenum box 64 has an exhaust channel 98 therein that communicates directly with exhaust filter 30 . Baffle 88 directs some of the air leaving blower 28 upwardly through exhaust channel 98 and exhaust filter 30 ultimately exiting cabinet 10 through exhaust control cap 36 . As best seen in FIG. 5, exhaust filter 30 is held in position with an exhaust frame 100 . Frame 100 includes a recessed portion 102 which is shaped to conform to the outer perimeter of exhaust filter 30 . Portion 102 thus operates as a placement guide when filter 30 is to be replaced. Frame 100 also includes an upper bracket 104 and a lower leg 106 , which extends downwardly into a labyrinth seal 108 . As shown in FIG. 5, seal 108 includes a pair of upwardly extending plates 110 which are bolted to the top of plenum box 64 . Leg 106 extends between the plates 110 and is movable there between.
To adjust the position of filter 30 , the upper bracket 104 includes a pair of threaded holes 112 , through which are placed a plurality of bolts 114 . A retaining nut 116 is rigid with bracket 104 and in alignment with each bolt 114 . Each bolt 114 has a head 114 a, a threaded portion 114 b and a length such that it extends to the upper surface of plenum box 64 , and as shown in FIG. 5, may extend to the upper surface of a horizontal portion of plates 110 of the labyrinth seal 108 . Exhaust frame 100 cooperates with bolts 114 , the top of plenum box 64 and labyrinth seal 108 to simultaneously position and seal exhaust filter 30 upwardly and supply filter 32 downwardly. More specifically, in use, bolt head 114 a is turned with a wrench to move portion 102 upwardly or downwardly along threaded portion 114 b. When portion 102 is lowered, lower leg 106 will move lower within labyrinth seal 108 . Thereafter, the exhaust filter 30 may be replaced by placing a new or clean exhaust filter 30 within recessed portion 102 . Exhaust filter 30 is then raised into place by turning bolt 114 in the opposite direction. Bolt 114 may be rotated sufficiently to place a downward force on plenum box 64 . This downward force on plenum box 64 forces exhaust filter 30 into a sealing engagement with top panel 34 . Thus, bolt 114 in cooperation with portion 102 and nut 116 serves as a jack screw to raise and lower the filter housing and apply pressure in opposite vertical directions to hold the filter firmly in place.
Any air that is not recirculated through supply filter 32 and work area 44 must be filtered and exhausted from the cabinets. If air is to be exhausted into the room, exhaust control cap 36 is used. As best seen in FIGS. 1 through 3, exhaust control cap 36 is mounted on top of top panel 34 and directly above exhaust filter 30 . Control cap 36 is generally rectangularly shaped and has a pair of mounting flanges 122 extending from each side thereof. Flanges 122 are used to mount control cap 36 to top panel 34 . Control cap 36 has a solid top 124 and sides 126 which have a plurality of exhaust apertures 128 extending there through. Apertures 128 are preferably varied in diameter and operate to accommodate outward flow of exhaust air in a lateral as opposed to a vertical direction. As can be seen, control cap 36 thus provides a low profile mechanism for directing the exhaust air from safety cabinet 10 in a horizontal direction. As seen in FIG. 2, removable plugs 130 may be used to block the apertures 128 . The number and size of the blocked apertures, in combination with the blower output, determines the volume of air that is exhausted through the control cap. The control cap 36 can therefore be used to regulate the flow of air being exhausted from safety cabinet 10 . This regulation is done while evenly distributing the flow of exhaust air over the entire surface exhaust filter 30 and without placing an increased load on blower 28 by significantly restricting the passage of air.
The above described embodiment of control cap 36 is utilized when the exhaust air from safety cabinet 10 is exhausted directly into the room. In an alternative embodiment, the air is not exhausted directly into the room, but rather is directed into an exhaust system that removes the air from the building. In this embodiment, a different exhaust control cap 131 used, and is shown in FIG. 9 . As shown, control cap 131 has mounting flanges 132 that secured to top panel 34 . In this embodiment, rather than the side surfaces 133 being provided with apertures 128 , the side surfaces 133 are solid. In this embodiment however, a top surface 134 is provided with an exhaust duct 135 . Preferably, duct 135 is cylindrical. Duct 135 may be provided with a damper 136 as is known to those of skill in the art. An apertured plate 138 mounted below duct 135 and above the exhaust filter 30 provides a mechanism for controlling the flow of air through the exhaust filter in much the same manner as control cap 36 described above. As shown in FIG. 9, the apertures 140 within plate 138 can be varied in size. Further, selected apertures 140 may be plugged to regulate the volume of air passing through plate 138 . Plate 138 is preferably attached to control cap 131 with screws 142 . Control cap 131 preferably includes an access port 144 along one side thereof, which is covered with a plate 146 in normal use. Plate 146 may be bolted or screwed to control cap 131 . Port 144 is used to visually inspect plate 138 and obtain access thereto without removing plate 138 . In use, the desired number of apertures 140 are plugged within plate 138 to regulate the amount of air flowing through cap 131 . Plate 138 is then secured within control cap 131 . Thereafter, the exhaust system associated with safety cabinet 10 is coupled to duct 135 so that air passing through exhaust filter 30 would be directed through control cap 131 and into the exhaust system. In the case of both cap 36 and plate 138 the fact that the mechanical device for controlling air flow is located on the “clean” side (i.e the downstream side) of the exhaust filter means that it can be accessed for adjustment or service without danger of contamination to either the worker or the room environment.
The front of cabinet 10 also has a novel construction. As best seen in FIG. 3, front panel 40 is coupled to top panel 34 and extends between side panels 16 to enclose the area above supply filter 32 . Front panel may be held in place with any suitable attachment mechanism, such as by bolting. Sash 42 is held within cabinet 10 and travels along a pair of sash tracks 150 , as best seen in FIG. 7 . Tracks 150 are defined by a pair of front trim panels 152 . As best seen in FIGS. 2 and 7, trim panels 152 have a wide and angled front face 154 . Face 154 thus forms an acute angle with its associated side panel 16 . The angle of face 154 directs air downwardly toward the sash opening and then inwardly to the interior side surfaces of work area 44 . The angle of face 154 thus allows the air entering work area 44 to sweep the interior side surfaces of the work area as it passes over grill 24 .
As best seen in FIG. 3, the lower-most edge of sash 42 is provided with a handle 156 . Handle 156 is used to raise and lower sash 42 as may be needed to gain access to work area 44 . As seen in FIG. 3, handle 156 is equipped with a curved or angled lower surface 158 . While surface 158 is shown as being flat, but angled, it should also be understood that surface 158 could be curved in a concave shape. In use, surface 158 provides for a smooth interface of two bodies of air. The first body of air is that which is entering the cabinet from the outside through the sash opening. This air will travel along surface 158 as it approaches the sash opening. The second body of air is that which is moving downwardly along the back side of the sash inside the cabinet as a result of blower 28 . By providing an angled or curved surface 158 , the two bodies of air will not be meeting at a right angle, resulting in less turbulence and better containment of the air within work area 44 . A third body of air is that which flows from the blower toward the rear of the work area.
Referring to FIGS. 1, 3 and 10 , as sash 42 is moved upwardly within tracks 150 , it will slide behind an upper sash pocket 160 . As best seen in FIGS. 1 and 3, sash pocket 160 is preferably bolted to front panel 40 and trim panels 152 . Pocket 160 is shaped to extend from one side of sash 42 to the other, and is enclosed along the top thereof. Pocket 160 thus cooperates with front panel 40 to enclose the top and sides of sash 42 as it is moved upwardly along tracks 150 . Pocket 160 acts to prevent the operator of cabinet 10 from accessing the upper portion of sash 42 as it slides away from work area 44 . As best seen in FIG. 10, there is no physical contact between the rear of sash 42 and any type of seal. In the prior art, a wiping seal would exist in the area of a screw 133 shown in FIG. 10 . This wiping seal resulted in certain disadvantages as explained above. Such a seal is not needed with the present invention. A front cover 165 is secured over the front of cabinet 10 . More specifically, cover 165 is placed over sash pocket 160 and front panel 40 to present a more appealing front face for cabinet 10 . The design of face 154 also facilitates decontamination of the cabinet as is required from time to time by safety regulations. Decontamination may occur by leaving pocket 160 in place and lowering the sash. The entire front of the cabinet is then sealed with plastic which is secured by tape to the angled surfaces 154 . Alternatively, sash pocket 160 may be removed and the sash completely lowered followed by sealing off the front of the cabinet with plastic. Another alternative is to remove pocket 160 and place the sash in the fully raised position before the front face is sealed with plastic. In the latter two cases the pocket 160 may be placed inside the cabinet so that it will be decontaminated. In all three cases effective decontamination is accomplished without the need to actually remove the sash.
As can be seen in FIG. 10, there is no physical contact with the back of sash 42 and the prior art wiping seal has been eliminated. In order to insure that contaminated air from the work area 44 does not escape into the room a plurality of upper scavenger holes 168 are provided immediately above work area 44 along the front of cabinet 10 . Any air leaving environment 44 will be drawn back through holes 168 and will not be leaked into the room. While the use of scavenger holes in this location has been taught by prior art constructions, it has been discovered that the effectiveness of these holes 168 is greatly enhanced if structure is provided to insure that the area in front of these holes will be a uniform negative pressure area relative to the work area 44 . To this end a restrictor plate 172 is coupled between air diffuser plate 43 and a filter shelf 170 used to hold supply filter 32 in place. Restrictor plate 172 is preferably held in place with a series of screws 174 . The location of plate 172 may be altered by loosening screws 174 and sliding the plate inwardly or outwardly. By adjusting the location of plate 172 the balance between air flow down into the work area and air flow passing through the exhaust is maintained in favor of exhaust air. Plate 172 serves to even out any pressure differences in the area of holes 168 resulting from the competing air flows and the fact that the holes are interrupted with solid areas. This insures that air will flow into the holes and out the exhaust rather than out into the room in the area behind the sash. It is to be understood that holes 168 extend across the entire front of the cabinet to insure that the entire back side of the sash is effectively “sealed” against contaminate air entering the room.
As can be seen from the above, the invention provides a biological safety cabinet with a number of improved features and achieves a better air-flow into and through the cabinet. From the foregoing, it will be seen that this invention is one well adapted to attain all of the ends and objects herein above set forth, together with other advantages which are inherent to the structure. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.
Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense. | A biological safety cabinet is provided that includes a frame. The frame defines a protected work area and encloses the work area on all but one side. A sash is coupled to the frame that at least partially encloses the side that is not enclosed by the frame. A blower is coupled to the frame generally above the work area. The blower is adapted to circulate air through the work area to make the work area a negative pressure area so that harmful materials are confined. A sash grill is coupled to the frame generally below the sash that has a curved top surface. The curved sash grill provides a superior and less turbulent air-flow into the work area, thereby better containing any harmful materials. The curved sash grill is perforated, and the curvature and perforations of the sash grill compensate for partial blockage by such things as the user's arms and other objects. The curvature of the sash grill also avoids a sharp angle at the same height as the work surface which reduces the chance of contact and possible breakage of labware as it is moved into the cabinet. | 1 |
PRIORITY CLAIM
This application claims the benefit, under 35 U.S.C. § 365 of International Application PCT/US02/37559, filed Nov. 22, 2002, which was published in accordance with PCT Article 21(2) on Jun. 5, 2003 in English and which claims the benefit of United States Provisional patent application No. 60/333,435, filed Nov. 27, 2001.
This application claims the benefit of United States Provisional Patent Application No. 60/333,435, filed Nov. 27, 2001 , entitled “SYNCHRONIZATION OF CHROMA AND LUMA USING HANDSHAKING,” which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to digital video signal processing, and in particular, to an apparatus and method for synchronizing chroma and luma data using handshaking.
BACKGROUND OF THE INVENTION
A typical digital video broadcast is transmitted as a series of frames, with each frame composed of a plurality of lines and each line composed of a plurality of pixels. The color of a pixel can be represented as a mathematical combination of a set of colors which, in some systems, is treated like a dot position in a three-dimensional color space. One conventional color model is called YUV color space, in which the color representation is divided into two types of data, namely, luminance (i.e., overall brightness or “luma”) data (“Y”) and chrominance (i.e., color or “chroma”) data (“U” and “V”). In a YUV system, the chrominance data (U, V) is transmitted in such a way that it can be disregarded by a black and white receiver, which uses only the luminance data (Y) to display a black and white picture, while a color receiver decodes both the luminance and the chrominance data to display a color picture. Another typical, similar color model is YCbCr color space, in which luminance is represented by Y data and chrominance is represented by Cb and Cr data.
Some digital video signal processing integrated circuits have two main data paths, one for chroma signals and one for luma signals. Most of the functions of such integrated circuits may treat these two paths as independent. However, some processing operations may require chroma and luma data to be synchronized at the first pixel of each video line. But historical approaches for synchronizing luma and chroma data have required undesirably high numbers of logic gates and/or memory devices which have increased the sizes and costs of video processing circuits and/or slowed processing speeds.
The present invention is directed to overcoming some of the drawbacks of conventional approaches for synchronizing luma and chroma data.
SUMMARY OF THE INVENTION
An apparatus in a digital video signal processing system for synchronizing chroma data and luma data needed for a downstream process includes a first Ready To Send and Ready To Receive (“RTS/RTR”) handshake block ( 104 ) for receiving the luma data, a second RTS/RTR handshake block ( 148 ) for receiving the chroma data, and a means ( 330 , 350 ), coupled to the first handshake block ( 104 ) and to the second handshake block ( 148 ), for providing a Ready To Receive (“RTR”) handshake signal to the first handshake block ( 104 ) and to the second handshake block ( 148 ) based at least in part on a determination that the first handshake block ( 104 ) is ready to transfer the luma data while the second handshake block ( 148 ) is ready to transfer the chroma data, and further for inhibiting provision of the RTR handshake signal based at least in part on a determination that at least one of the first handshake block ( 104 ) and the second handshake block ( 148 ) is not ready to transfer data.
A method for synchronizing chroma data and luma data in a digital video signal processing system including a first Ready To Send and Ready To Receive (“RTS/RTR”) handshake block ( 104 ) coupled to a source of the luma data, a second RTS/RTR handshake block ( 148 ) coupled to a source of the chroma data, and a third RTS/RTR handshake block ( 450 ) coupled to a downstream destination for the luma data and the chroma data includes the steps of providing a Ready To Receive (“RTR”) handshake signal to the first handshake block ( 104 ) and to the second handshake block ( 148 ) based at least in part on a determination that the first handshake block ( 104 ) is ready to transfer the luma data while the second handshake block ( 148 ) is ready to transfer the chroma data and inhibiting the step of providing the RTR handshake signal based at least in part on a determination that at least one of the first handshake block ( 104 ) and the second handshake block ( 148 ) is not ready to transfer data.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a block diagram of a conventional synchronous Ready To Send and Ready To Receive (“RTS/RTR”) handshake block;
FIG. 2 is a block diagram of an exemplary circuit for synchronizing chroma and luma data using handshaking according to the present invention;
FIG. 3 is a timing diagram for one exemplary operational scenario for the circuit of FIG. 2 ; and
FIG. 4 is a timing diagram for another exemplary operational scenario for the circuit of FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The characteristics and advantages of the present invention will become more apparent from the following description, given by way of example.
FIG. 1 is a block diagram of a conventional synchronous Ready To Send and Ready To Receive (“RTS/RTR”) handshake block 10 . In the handshake block 10 , a first handshake channel 14 couples an upstream block 18 to a downstream block 22 . First handshake channel 14 is configured to carry a Ready To Send (“RTS”) handshake signal, which is active to indicate that upstream block 18 is prepared to send at least one word of data over a data bus 26 to downstream block 22 . Meanwhile, a second handshake channel 30 further couples upstream block 18 to downstream block 22 . Second handshake channel 30 is configured to carry a Ready To Receive (“RTR”) handshake signal, which is active to indicate that downstream block 22 is prepared to accept at least one word of data from upstream block 18 via data bus 26 . When a controller (not shown) detects both handshake signals during a clock cycle, a handshake is considered to have occurred. During each clock cycle for which a handshake has occurred, the controller causes one word of data to be transferred from upstream block 18 to downstream block 22 via data bus 26 . In a similar manner, an additional handshake channel 34 and an additional handshake channel 38 may be configured to carry an additional RTS handshake signal and an additional RTR handshake signal, respectively, to facilitate data transfers from a further upstream block (not shown) to block 18 over data bus 26 ; and an additional handshake channel 42 and an additional handshake channel 46 may be configured to carry an additional RTS handshake signal and an additional RTR handshake signal, respectively, to facilitate data transfers to a further downstream block (not shown) from block 22 over data bus 26 .
FIG. 2 is a block diagram of an exemplary circuit 100 for synchronizing chroma and luma data using handshaking according to the present invention. Circuit 100 includes a conventional synchronous Ready To Send and Ready To Receive (“RTS/RTR”) handshake block 104 . Handshake block 104 includes a data input 108 and is arranged to receive luma data (“ydata_in”) from an upstream source of the luma data at input 108 over a data bus 112 . Further, handshake block 104 includes a Ready To Send (“RTS”) handshake input 116 and is arranged to receive an RTS handshake signal (“yinput_rts”) from the upstream source of luma data at input 116 over a conductor 120 . Handshake block 104 also includes a Ready To Receive (“RTR”) handshake output 124 and is arranged to send an RTR handshake signal (“yinput_rtr”) to the upstream source of luma data from output 124 over a conductor 128 . Further, handshake block 104 includes an RTS handshake output 132 and is arranged to send an RTS handshake signal (“youtput_rts”) from output 132 ; handshake block 104 includes a data output 140 and is arranged to transfer the luma data (“ydata_out”) from output 140 ; and handshake block 104 includes an RTR handshake input 144 and is arranged to receive an RTR handshake signal (“youtput_rtr”) at input 144 .
Circuit 100 also includes a conventional synchronous RTS/RTR handshake block 148 . Handshake block 148 includes a data input 152 and is arranged to receive multiplexed chroma data (“CbCrdata_in”) from an upstream source of the chroma data at input 152 over a data bus 156 . Further, handshake block 148 includes an RTS handshake input 160 and is arranged to receive an RTS handshake signal (“CbCrinput_rts”) from the upstream source of chroma data at input 160 over a conductor 164 . Handshake block 148 also includes an RTR handshake output 168 and is arranged to send an RTR handshake signal (“CbCinput_rtr”) to the upstream source of chroma data from output 168 over a conductor 172 . Further, handshake block 148 includes an RTS handshake output 176 and is arranged to send an RTS handshake signal (“CbCroutput_rts”) from output 176 ; handshake block 148 includes a data output 180 and is arranged to transfer the multiplexed chroma data (“CbCrdata_out”) from output 180 ; and handshake block 148 includes an RTR handshake input 184 and is arranged to receive an RTR handshake signal (“CbCroutput_rtr”) at input 184 .
Circuit 100 further includes a luma process and buffer block 200 . Block 200 is configured (in any of various well known manners) to provide an overall first-in first-out (“FIFO”) buffer of word length, L, and further to filter, reformat, and/or otherwise process the luma data as desired to put it into a predetermined form for further downsteam processing. Block 200 includes a data input 204 for receiving luma data (“YINPUT”), an enable input 208 for receiving an enable signal (“SAMP”), a data output 212 for outputting the processed luma data (“yout”), and a pixel count input 214 .
Circuit 100 further includes a chroma process and buffer block 220 . Block 220 is configured (in any of various well known manners) to provide an overall first-in first-out (“FIFO”) buffer of word length, L (the same length as that of block 200 ), and further to filter, reformat, and/or otherwise process the chroma data as desired to put it into a predetermined form for further downsteam processing. Block 220 includes a data input 224 for receiving multiplexed chroma data (“CBCR_INPUT”), an enable input 228 for receiving the SAMP enable signal, a data output 232 for outputting the processed multiplexed chroma data (“CbCrout”), and a pixel count input 236 .
Circuit 100 also includes a demultiplexer and converter block 250 . Block 250 is configured (in any of various well known manners) to demultiplex the CbCrout data and to further to filter, reformat, and/or otherwise process the chroma data as desired to put it into a predetermined form for further downsteam processing. Accordingly, block 250 includes a data input 254 for receiving the multiplexed CbCrout data, a control input 258 for receiving a demultiplexer control signal (“CbCr_sel”), a data output 262 for providing Cb data (“Cbout”), and a data output 266 for providing Cr data (“Crout”).
Further, circuit 100 includes a demultiplexer logic block 270 . Block 270 is configured (in any of various well known manners) to provide the CbCr_sel control signal for demultiplexer and converter block 250 . Block 270 includes an enable input 274 , a reset input 278 , and a control signal output 282 for providing the CbCr_sel control signal.
Circuit 100 also includes a pixel counter 290 . Pixel counter 290 is configured (in any of various well known manners) to provide a count of the pixels for each video line (“p_count”) as the luma and chroma data arrive and move through circuit 100 and to provide a reset signal (“rst”) corresponding to the end of each line. Counter 290 includes an enable input 294 , a reset signal output 298 , and a pixel count output 302 .
Circuit 100 further includes a buffer counter 310 . Buffer counter 310 is configured (in any of various well known manners) to indicate whether luma process and buffer block 200 and chroma process and buffer block 220 have filled with data by making a status signal (“ALL_FULL”) a logical 1 after being enabled for L clock cycles (after power up) and making ALL_FULL a logical 0 otherwise. Counter 310 includes an enable input 314 , and a status signal output 318 .
Circuit 100 also includes an AND gate 330 . AND gate 330 includes an input 334 , an input 338 , and an output 342 . Further, circuit 100 includes an AND gate 350 . AND gate 350 includes an input 354 , an input 358 , and an output 362 . Also, circuit 100 includes an AND gate 370 . AND gate 370 includes an input 374 , an input 378 , and an output 382 . Circuit 100 also includes an OR gate 390 . OR gate 390 includes an input 394 , an input 398 , and an output 402 . Additionally, circuit 100 includes an inverter 410 . Inverter 410 includes an input 414 and an output 418 .
Further, circuit 100 includes a conventional synchronous RTS/RTR handshake block 450 . Handshake block 450 includes a data input 454 and is arranged to receive the yout luma data from block 200 at input 454 . Handshake block 450 also includes an RTS handshake input 458 and is arranged to receive an RTS handshake signal (“output_rts”) from AND gate 370 at input 458 . Handshake block 450 also includes an RTR handshake output 462 and is arranged to send an RTR handshake signal (“output_rtr”) to OR gate 390 from output 462 . Further, handshake block 450 includes an RTS handshake output 468 and is arranged to transfer the output_rts RTS handshake signal from output 468 to a downstream block; handshake block 450 includes a data output 472 and is arranged to transfer the yout luma data (“Y”) to the downstream block from output 472 ; and handshake block 450 includes an RTR handshake input 476 and is arranged to receive the output_rtr RTR handshake signal from the downstream block at input 476 .
Circuit 100 also includes a conventional synchronous RTS/RTR handshake block 500 . Handshake block 500 includes a data input 504 and is arranged to receive the Cbout chroma data from block 250 at input 504 , and includes a data output 506 and is arranged to transfer the Cbout data (“Cb”) to the downstream block from output 506 . Handshake block 500 also includes an RTS handshake input 508 and is arranged to receive the output_rts RTS handshake signal from AND gate 370 at input 508 . Handshake block 500 further includes an RTR handshake input 512 , which is coupled to a logical 1.
Circuit 100 also includes a conventional synchronous RTS/RTR handshake block 550 . Handshake block 550 includes a data input 554 and is arranged to receive the Crout chroma data from block 250 at input 554 , and includes a data output 556 and is arranged to transfer the Crout data (“Cr”) to the downstream block from output 556 . Handshake block 550 also includes an RTS handshake input 558 and is arranged to receive the output_rts RTS handshake signal from AND gate 370 at input 558 . Handshake block 550 further includes an RTR handshake input 562 , which is coupled to a logical 1.
Further, circuit 100 includes a data bus 600 that couples output 140 of handshake block 104 to input 204 of block 200 , a conductor 604 that couples output 132 of handshake block 104 to input 334 of AND gate 330 , a conductor 608 that couples input 144 of handshake block 104 to input 184 of handshake block 148 and to enable input 208 of block 200 and to input 378 of AND gate 370 and to output 362 of AND gate 350 and to enable input 314 of counter 310 and to enable input 228 of block 220 and to enable input 274 of block 270 and to enable input 294 of counter 290 , a conductor 612 that couples output 176 of handshake block 148 to input 338 of AND gate 330 , a data bus 616 that couples output 180 of handshake block 148 to input 224 of block 220 , and a conductor 620 that couples output 342 of AND gate 330 to input 354 of AND gate 350 .
Circuit 100 also includes a conductor 624 that couples input 358 of AND gate 350 to output 402 of OR gate 390 , a conductor 628 that couples output 418 of inverter 410 to input 394 of OR gate 390 , a conductor 632 that couples output 318 of counter 310 to input 414 of inverter 410 and to input 374 of AND gate 370 , a data bus 636 that couples output 232 of block 220 to input 254 of block 250 , a conductor 640 that couples output 282 of block 270 to input 258 of block 250 , a conductor 644 that couples output 298 of counter 290 to input 278 of block 270 , and a conductor 648 that couples output 302 of counter 290 to input 214 of block 200 and to input 236 of block 220 .
Circuit 100 also includes a data bus 652 that couples output 212 of block 200 to input 454 of handshake block 450 , a conductor 656 that couples output 382 of AND gate 370 to input 458 of handshake block 450 and to input 508 of handshake block 500 and to input 558 of handshake block 550 , a conductor 660 that couples output 462 of handshake block 450 to input 398 of OR gate 390 , a conductor 664 that couples output 262 of block 250 to input 504 of handshake block 500 , and a conductor 668 that couples output 266 of block 250 to input 554 of handshake block 550 .
In operation of circuit 100 (see FIG. 2 ), unsychronized luma data (ydata_in) and chroma data (multiplexed, CbCrdata_in) come from the upstream luma channel and the upstream chroma channel, respectively. The signal INPUT_RTS becomes logical 1 only when: 1.) the upstream source of the luma data becomes ready to send the luma data (the youtput_rts signal becomes logical 1), and 2.) the upstream source of the chroma data becomes ready to send the chroma data (the CbCroutput_rts signal becomes logical 1). Meanwhile, the upstream luma channel and the upstream chroma channel are prevented from transferring data when INPUT_RTS is not logical 1 (i.e., when the luma and chroma data transfers would not be synchronized) because any logical 0 into AND gate 350 makes the signal youtput_rtr and the signal CbCroutput_rtr both logical 0.
The RTR signal becomes logical 1 when: 1.) the downstream process becomes ready to receive data (the output_rtr signal becomes logical 1), or 2.) more data is needed to fill the lengths of luma process and buffer 200 and chroma process and buffer 220 .
AND gate 350 operates on the INPUT_RTS signal and the RTR signal to provide the SAMP signal. When the SAMP signal becomes logical 1, the signals Y_INPUT and CBCR_INPUT have synchronized luma and chroma data. At this time, circuit 100 enables luma process and buffer 200 and chroma process and buffer 220 as well as buffer counter 310 , pixel counter 290 , and demultiplexer block 270 , and, accordingly, synchronously latches data into luma process and buffer 200 and chroma process and buffer 220 .
When SAMP becomes logical 0, there is either: 1.) no luma or chroma data at input 108 or input 152 (and, accordingly, INPUT_RTS is logical 0), or 2.) the luma and chroma data are not synchronized (INPUT_RTS is logical 0), or 3.) the downstream process is not ready to receive data (RTR is logical 0) and luma process and buffer 200 and chroma process and buffer 220 are full (ALL_FULL is logical 1, which in turn makes RTR logical 0). In any event, when SAMP is logical 0 all data transfers into and/or out of circuit 100 are suspended.
Thus, circuit 100 provides synchronized luma and chroma data at outputs 472 , 506 , and 556 , respectively, when the downstream process is ready to receive the data. It should be appreciated that since the data is provided in synchronism, full handshaking is needed only for handshake block 450 , and some of the conventional handshaking signals are not necessary for handshake block 500 and handshake block 550 (see FIG. 2 ).
FIG. 3 is a timing diagram for one exemplary operational scenario for the circuit 100 of FIG. 2 . At clock cycle No. 2 , the chroma data arrives at circuit 100 (before the luma data arrives). Circuit 100 suspends further flow of the chroma data until the luma data becomes available at clock cycle No. 3 . After both the luma data and the chroma data become available, circuit 100 provides synchronous flow of the data (clock cycle No. 3 and beyond). It should be appreciated, however, that FIG. 3 is merely exemplary and numerous other operational scenarios may exist for circuit 100 .
FIG. 4 is a timing diagram for another exemplary operational scenario for the circuit 100 of FIG. 2 . At clock cycle No. 1 , the luma data arrives at circuit 100 (before the chroma data arrives). Circuit 100 suspends further flow of the luma data until the chroma data becomes available at clock cycle No. 2 . When both the luma data and the chroma data become available at clock cycle No. 2 , circuit 100 provides synchronous flow of the data until the luma data becomes unavailable from the upstream source at clock cycle No. 3 . Then, circuit 100 again suspends flow of the chroma data until the luma data again becomes available at clock cycle No. 5 , after which circuit 100 again provides synchronous luma and chroma data flow. It should be appreciated, however, that FIG. 4 is merely exemplary and numerous other operational scenarios may exist for circuit 100 . | An apparatus for synchronizing chroma and luma data includes a first handshake block for luma data, a second handshake block for chroma data, and a means for providing a handshake signal to the first block and to the second block based at least in part on a determination that they are both ready to transfer data, and further for inhibiting provision of the handshake signal based at least in part on a determination that at least one of the first block and the second block is not ready to transfer data. | 7 |
BACKGROUND
1. Field
Embodiments of the claimed invention relate to electropolishing and electroplating, and in particular, systems and methods for electropolishing or electroplating localized areas of continuous assemblies of interconnected components, such as conveyor belts.
2. Description of Related Art
Conveyor belt systems are used in various industrial fields for material handling and processing purposes. For instance, conveyor systems are used within food processing systems in which food items are placed on the support surface of a conveyor belt and processed, while being conveyed from one location to another. Various types of conveyor belts exist, including modular conveyor belts, which are especially popular in food processing systems. Moreover, conveyor systems are often used in a helical accumulator such as that disclose in U.S. Pat. No. 5,070,999 to Layne et al. which allows storage of a large number of items in the conveyor system.
In the food processing industry, it is of the utmost importance that conveyors belts are sanitary. To accomplish this, conveyor belts are conventionally wiped down, washed, and/or steamed on a regular basis. However, conveyor belts are often very long, extending hundreds or even thousands of feet. In these cases, the belts can be difficult to clean and may become less durable over time due to the thorough process needed to maintain their sanitation.
Electropolishing and electroplating has been previously used in a number of applications. U.S. Pat. No. 4,895,633 to Seto et al. discloses a conventional molten salt electroplating apparatus for forming plating on steel strips, sheets, and wires. A steel strip is continuously unwound from a pay-off reel, passed through a looper, and sent to a pretreatment apparatus. Next, the surface of the steel strip is plated as it passes between electrodes immersed in electroplating solution. The steel strip is then washed and dried, passed through a looper and a shearing machine, then wound onto a tension reel.
U.S. Pat. No. 7,407,051 B1 to Farris et al. discloses a stainless steel sprocket support shaft for a nozzleless conveyor belt and sprocket cleaning apparatus. The stainless steel sprocket may be surface finished by electropolishing. U.S. Pat. No. 5,491,036 to Carey, II et al. generally discloses an electrolysis process for applying a tin coating of carbon steel.
SUMMARY OF THE INVENTION
The above described patents propose a variety of methods for electropolishing or electroplating various materials. However, there still exists a need for a system and method for electropolishing and electroplating metal conveyor belts that improves sanitation and product release characteristics, particularly with respect to conveyor belts used in food processing. There also exists a need for a system and method for electropolishing and electroplating metal conveyor belts that reduces wear and friction on the conveyor belts. There further exists a need for a system and method for electropolishing and electroplating localized areas of metal conveyor belts.
In view of the foregoing, one aspect of the present invention provides a continuous electropolishing and/or electroplating process for localized areas of metal conveyor belts. This process provides benefits such as improved sanitation, improved product release characteristics, brighter cosmetic appearance, removal of weld discoloration, and reduced wear and friction, which are particularly important for conveyor belts used in food processing.
As opposed to conventional polishing processes in which the product is guided around rollers which direct the product into and out of an electrolyte bath, embodiments of the present invention pass the product through a housing supplied with a continuous directional flow of electrolyte. Thus, the electroplating or electropolishing can be targeted to specific areas of the product, such as the edges of a conveyor belt, and straight products can pass through the housing without deformation (i.e., because guiding by rollers into and out of a bath is not required). This reduces the amount of electrolyte required in the system; reduces human exposure to the electrolyte during operation; reduces evaporation and environmental contamination of the electrolyte; reduces set-up time because the electrolyte can be quickly removed from the polishing area; and optimizes current and fluid flow to improve efficiency compared to conventional processes. In addition, fresh electrolyte can be concentrated at the polishing site, without solution in a bath of used electrolyte, for more effective electropolishing or electroplating.
Belts can be separated into smaller sections, typically 50 to 100 feet long, for ease of handling and shipping. These sections may be connected sequentially, such that the leading end of a new roll of belt is connected to the trailing end of the previous roll of belt, to maintain a continuous process. These sections can be disconnected and placed on separate take-up rolls after processing. Leader chains may also be used to guide the ends of the belt into and out of the bath while maintaining tension. Materials used in the process, such as the plate material and electrolyte material, may be of any suitable type such as are currently used or may be developed for electropolishing and electroplating.
According to one embodiment, a system for electropolishing or electroplating a conveyor belt is described. The system comprises a housing comprising an electrical conductor and an opening configured to receive a portion of the conveyor belt in the opening; a seal provided in the opening; an inlet configured to supply electrolytic solution to the housing; and an electrical contact configured to apply current to the conveyor belt.
According to another embodiment, a method for electropolishing or electroplating a conveyor belt is described. The method comprises guiding a portion of the conveyor belt through a housing comprising an electrical conductor and a seal; applying current to the conveyor belt with an electrical contact; and supplying an electrolytic solution to the housing through an inlet, thereby electroplating or electropolishing the portion of the conveyor belt.
Still other aspects, features and advantages of the present invention are readily apparent from the following detailed description, simply by illustrating a number of exemplary embodiments and implementations, including the best mode contemplated for carrying out the present invention. The present invention also is capable of other and different embodiments, and its several details can be modified in various respects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and descriptions are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be understood more fully from the detailed description given below and from the accompanying drawings of various embodiments of the invention, which, however, should not be taken to limit the invention to the specific embodiments, but are for explanation and understanding only.
FIG. 1 is a perspective view of a system for electropolishing or electroplating a continuous assembly of interconnected components in accordance with an embodiment.
FIG. 2 is a perspective view of a system for electropolishing or electroplating a continuous assembly of interconnected components in accordance with an embodiment.
FIG. 3 is a perspective view of a system for electropolishing or electroplating a continuous assembly of interconnected components in accordance with an embodiment.
DETAILED DESCRIPTION
A system and method for electropolishing or electroplating a continuous assembly of interconnected components is described. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the exemplary embodiments. It is apparent to one skilled in the art, however, that the present invention can be practiced without these specific details or with an equivalent arrangement.
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, FIG. 1 is a perspective view of a system for electropolishing or electroplating a continuous assembly of interconnected components in accordance with an embodiment. In this embodiment, the continuous assembly of interconnected components is a conveyor belt 105 . As illustrated in FIG. 1 , two housings 115 A and 115 B are positioned at the edges of conveyor belt 105 in order to electropolish or electroplate edge links 120 A and edge links 120 B, respectively. In some embodiments, however, only a single housing 115 A or 115 B can be positioned on an edge of conveyor belt 105 to electropolish or electroplate only one of edge links 120 A or edge links 120 B, respectively. It is understood that housing 115 B is cutaway in FIG. 1 for purposes of explanation only, and that in practice, the exterior of housing 115 B resembles housing 115 A. Further, it is understood that the interior of housing 115 A resembles that shown with respect to housing 115 B. Although not shown in FIG. 1 , it is contemplated that other features of the conveyor belt may be electropolished or electroplated with or instead of edge links 120 A and edge links 120 B, such as edge guards or lane dividers.
Electrical contacts 110 A and 110 B placed on conveyor belt 105 cause the conveyor belt 105 to become an anode (in the case of electropolishing) or cathode (in the case of electroplating). Force may be placed on electrical contact 110 A and/or electrical contact 110 B to ensure consistent contact with conveyor belt 105 and consistent current. Such a force can be applied by a spring, a pneumatic system, a hydraulic system, gravity, and/or similar means. In one embodiment, electrical contact 110 A and/or electrical contact 110 B are movable or floating to accommodate variations in the dimensions of conveyor belt 105 .
In this embodiment, an electrical conductor 125 B is placed in housing 115 B to serve as a cathode (in the case of electropolishing) or anode (in the case of electroplating). In a similar fashion, an electrical conductor (not shown) is placed in housing 115 A to serve as a cathode (in the case of electropolishing) or anode (in the case of electroplating). In this embodiment, electrical conductor 115 B is placed proximate to the edge of edge links 120 B in order to target polishing or plating at the weld 135 B of conveyor belt 105 . However, it is contemplated that electrical conductor 115 B can be placed in any position proximate to any particular area to be electropolished or electroplated.
In one embodiment, housing 115 A and housing 115 B are made of copper or another conductive material, and can themselves serve as a cathode (in the case of electropolishing) or anode (in the case of electroplating), with or without electrical conductors internal to housing 115 A or housing 115 B. Housing 115 A, housing 115 B and the electrical conductors (i.e., the electrical conductor internal to housing 115 A and electrical conductor 125 B) can be sized and positioned such that the surface of the electrical conductors are equidistant from all surfaces of edge links 120 A and edge links 120 B for even polishing. Nonconductive wear surfaces may be placed in housing 115 A and housing 115 B in any practical configuration, such as a bushing or perforated liner, to prevent contact between conveyor belt 105 and the electrical conductors, to prevent contact between conveyor belt 105 and the electrical conductors while allowing current to flow between the electrical conductors and conveyor belt 105 .
Although shown as rectangular and elongated in shape, it is contemplated that housing 115 A and housing 115 B can be of any shape or size suitable to achieve electropolishing or electroplating as described herein. Further, housing 115 A and housing 115 B can be constructed as a single body, or can be made of separable components, such as a body and removable lid.
Electrolyte may be introduced at any point along the length of housings 115 A and 115 B. In this embodiment, electrolyte is introduced into housing 115 A via inlet 130 A. It is understood that electrolyte is introduced into housing 115 B via a similar inlet (not shown). Electrolyte may flow in either direction through housings 115 A and 115 B, i.e., in the direction of travel of conveyor belt 105 through housings 115 A and 115 B, or counter to the direction of travel of conveyor belt 105 through housings 115 A and 115 B.
In one embodiment, housings 115 A and 115 B are open at the ends to allow electrolyte to flow out and to allow conveyor belt 105 to pass through. In another embodiment, a separate orifice is provided for the electrolyte outflow. The outflow orifice may be arranged in an upward direction to facilitate removal of gases produced during the electropolishing or electroplating process. Orifices are sized to restrict outflow, and housings 115 A and 115 B are provided with seals 140 A and 140 B, respectively, so that the housings 115 A and 115 B are flooded to a level that provides effective electropolishing or electroplating. Seals 140 A and 140 B need not stop liquid flow altogether, but rather restrict it enough to cause flooding of the housing. Exemplary seals can be made of rubber sheeting or brushes.
FIG. 2 is a perspective view of a system for electropolishing or electroplating a continuous assembly of interconnected components in accordance with another embodiment. In this embodiment, the continuous assembly of interconnected components is a conveyor belt 205 having a plurality of center links 220 to be electropolished or electroplated. Center links 220 are any links positioned between the edges of conveyor belt 205 , and do not necessarily need to be centered between the edges of conveyor belt 205 . Center links 220 are positioned laterally to create a desired turn radius and to control expansion and collapse of the edge links of conveyor belt 205 . A single housing 215 is positioned along the width of the conveyor belt 205 in order to electropolish or electroplate center links 220 . It is understood that housing 215 is cutaway in FIG. 2 for purposes of explanation only, and that housing 215 is rectangular in shape in use. Although not shown in FIG. 2 , it is contemplated that other features of the conveyor belt may be electropolished or electroplated with or instead of center links 220 , such as edge guards or lane dividers. Further, although shown and described with respect to a single housing 215 and a single column of center links 220 , it is contemplated that multiple columns of center links 220 may be present, or multiple other features to be electropolished or electroplated, as well as their accompanying housings.
Electrical contacts 210 A and 210 B are placed on conveyor belt 205 in a manner similar to that described with respect to electrical contacts 110 A and 110 B of FIG. 1 . An electrical conductor 225 is placed in housing 215 to serve as a cathode (in the case of electropolishing) or an anode (in the case of electroplating). In this embodiment, electrical conductor 225 is placed on the bottom of housing 215 , underneath both of the welded edges 235 A and 235 B of center links 220 . However, it is contemplated that electrical conductor 225 can be placed in any position proximate to any particular area to be electropolished or electroplated.
As with respect to FIG. 1 , housing 215 can be made of copper or another conductive material, and can itself serve as a cathode (in the case of electropolishing) or anode (in the case of electroplating), with or without electrical conductors internal to housing 215 . Housing 215 and electrical conductor 225 can be sized and positioned such that the surface of the electrical conductor 225 is equidistant from all surfaces of center links 220 for even polishing. Nonconductive wear surfaces may be placed in housing 225 in any practical configuration, such as a bushing or perforated liner, to prevent contact between conveyor belt 205 and the electrical conductors, to prevent contact between conveyor belt 205 and the electrical conductors while allowing current to flow between the electrical conductors and conveyor belt 205 .
Although shown as rectangular and elongated in shape, it is contemplated that housing 215 can be of any shape or size suitable to achieve electropolishing or electroplating as described herein. Further, housing 215 can be constructed as a single body, or can be made of separable components, such as a body and removable lid.
Electrolyte is introduced via inlet 230 at a central location with respect to the length and width of housing 215 , as is described with respect to FIG. 1 . Electrolyte may flow in either direction through housing 215 , i.e., in the direction of travel of conveyor belt 205 through housing 215 , or counter to the direction of travel of conveyor belt 205 through housing 215 .
In this embodiment, housing 215 is open at the ends to allow electrolyte to flow out and to allow conveyor belt 205 to pass through. As is described above with respect to FIG. 1 , a separate orifice may instead be provided for the electrolyte outflow. Housing 215 is provided with a seal 240 so that the housing 215 is flooded to a level that provides effective electropolishing or electroplating, while minimizing electrolyte loss. In this embodiment, seal 240 is positioned on both sides of center links 220 . Although shown and described as separate embodiments, it is contemplated that both the edge links and the center links of a conveyor belt can be polished simultaneously, by combining the embodiment of FIG. 1 with that of FIG. 2 .
FIG. 3 is a perspective view of a system for electropolishing or electroplating a continuous assembly of interconnected components in accordance with an embodiment. In this embodiment, the continuous assembly of interconnected components is conveyor belt 305 . To create a continuous electropolishing or electroplating process, conveyor belt 305 is unrolled from an in-feed roll 340 into cleaning station 345 , traveling in a direction A. Cleaning station 345 cleans the edge links of conveyor belt 305 and degreases them, for example. Conveyor belt 305 is then rinsed at rinse station 350 .
Electroplating or electropolishing is achieved at electroplating/electropolishing stations 355 . Although illustrated with two electroplating/electropolishing stations 355 , it is contemplated that only a single electroplating/electropolishing station 355 can be provided, or multiple electroplating/electropolishing stations 355 can be provided in series. Electroplating/electropolishing stations 355 have housings 315 A to polish one edge of the conveyor belt, as well as housings opposite to housing 315 A (not shown) to polish the opposite edge of conveyor belt 355 . It is contemplated that housings 315 A, as well as the opposing housings, may be similar or identical to housings 115 A and 115 B, respectively, of FIG. 1 . Further, although shown and described herein only with respect to housings 315 A, it is contemplated that a similar or identical process may be carried out with respect to the opposing housings. Although not shown in FIG. 3 , it is contemplated that other features of the conveyor belt may be electropolished or electroplated with or instead of the edge links of conveyor belt 305 , such as edge guards or lane dividers.
Electrical contacts placed on conveyor belt 305 cause the conveyor belt to become an anode (in the case of electropolishing) or cathode (in the case of electroplating). Electrical conductors are placed in housings 315 A to serve as a cathode (in the case of electropolishing) or anode (in the case of electroplating). Electrolytic solution is provided via inlets 330 A to housings 315 A, immersing the edges of conveyor belt 305 within the housings 315 A in electrolytic solution.
With respect to electroplating, a current is applied to the electrical conductors, oxidizing the metal atoms that comprise the electrical conductors and allowing them to dissolve into the electrolytic solution. The dissolved metal ions are moved by the electric field to conveyor belt 305 , coating conveyor belt 305 and depositing a layer of metallic material on the surface of conveyor belt 305 .
With respect to electropolishing, a current is applied to conveyor belt 305 , oxidizing the metal atoms on the surface of conveyor belt 305 and allowing them to dissolve into the electrolytic solution. The dissolved metal ions in the electrolytic solution are moved by the electric field to the electrical conductors. Thus, a smoother, polished surface results on conveyor belt 305 .
Once conveyor belt 305 has been electropolished or electroplated, it is moved into post-treatment station 360 (where it undergoes, e.g., a nitric acid rinse), then undergoes a final rinse at rinse station 365 . Optionally, conveyor belt 305 can be moved through a dryer (not shown). Conveyor belt 305 is moved onto take-up roll 370 . It is contemplated that conveyor belt 305 can be moved from in-feed roll 340 to take-up roll 370 by any suitable means, such as, for example, a system drive or motor. Although shown and described with respect to the electropolishing or electroplating of the edge links, it is contemplated that FIG. 3 can be modified to instead or additionally electropolish or electroplate center links, if present.
Although described herein with respect to conveyor belts, it is contemplated that the methods and systems described herein can be applied to any rollable and/or conductive materials, including chains or other continuous assemblies of interconnected components. Such electropolishing or electroplating applied in accordance with the described embodiments results in improved sanitation, reduced wear and friction on the treated parts, and improved product release characteristics, particularly with respect to food processing applications.
The present invention has been described in relation to particular examples, which are intended in all respects to be illustrative rather than restrictive. Those skilled in the art will appreciate that many different combinations of materials and components will be suitable for practicing the present invention.
Other implementations of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. Various aspects and/or components of the described embodiments may be used singly or in any combination. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims. | An electropolishing or electroplating system and method for metal conveyor belts is described. As opposed to conventional polishing processes in which the product is guided around rollers which direct the product into and out of an electrolyte bath, embodiments of the present invention pass the product through a housing supplied with a continuous directional flow of electrolyte. Thus, the electroplating or electropolishing can be targeted to specific areas of the product, such as the edges and/or the center of a conveyor belt, and straight products can pass through the housing without deformation. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional application 60/563,247 filed Apr. 15, 2004 hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
BACKGROUND OF THE INVENTION
[0002] The present invention relates to computerized automation systems and in particular to automation systems employing autonomous cooperating units (“ACU”).
[0003] Distribution systems, for example, those found in a modem warship, distribute materials such as fuel, ballast water, fire water, chilled water and compressed air, fresh air, as well as electrical power, to different points in the ship and to various devices, machines, computers, and other electronic equipment. Materials, air, and power flow through complex networks of conduits or wiring that form branches between nodes such as pumps, generators, valves, switches, sensors and the like.
[0004] Under changing demand, disturbances, or disruption to the networks, the networks may be reconfigured, taking advantage of redundancy built into the nodes and branches of the distribution system and the priority of users. For example, in a warship, chilled water provides cooling for critical electrical components and machines such as radar, communications equipment, and armaments, as well as cooling for crew quarters and work areas. Should the network be damaged through the loss of a section of pipe or a pump failure or water chiller failure, autonomous agents may collaborate to confirm the type and extent of damage or failure. Further collaboration may result in control valves being adjusted to minimize water loss or reduce consequential damage. Subsequent collaboration may establish routing plans to route chilled water around damaged pipe sections to critical heat loads and re-allocating cooling capacity from less critical needs to critical ship systems. If sufficient chilled water cannot be obtained, further, more drastic reconfiguration options may be exercised such as violating the segregation of chilled water between port and starboard sides of the ship.
[0005] Effectively controlling a complex chilled water system with a commercial programmable logic controller (PLC) is difficult, requiring the anticipation and preparation of pre-programmed responses for each of a large number of possible combinations of water demand, system disturbances, and network component availability or failure, according to changing strategic goals. U.S. application Ser. No. 10/737,384 filed Dec. 16, 2003, hereby incorporated by reference and assigned to the same assignee as the present invention, describes a control system for chilled water or other materials in which the various nodes and branches of the distribution network are associated with autonomous cooperating units (“ACUs”). The ACUs independently provide reasoning about component health or condition and electrical control or sensing of a different component of the distribution network, for example, a pump, pipe or valve. Together, the ACUs receive generalized instructions for the delivery of chilled water and then organize themselves, according to a bidding process, to deliver the water as required. Because the bidding process reflects the current state of the distribution system (e.g., ACUs don't bid for tasks if their associated components are damaged) an efficient solution may be obtained even when the distribution network is subject to unanticipated damage.
[0006] The ACU architecture can provide better control over a distribution system than manual systems or conventional centralized control systems can.
SUMMARY OF THE INVENTION
[0007] The present inventors have recognized that a given distribution system is ordinarily operating in parallel with other distribution systems and operational systems (e.g. ship propulsion) that inevitably both augment and compete with the given distribution systems for limited resources. Improved control of a distribution system may be possible by cross communication among parallel distribution systems enabled by the versatility, speed, and scalability of the ACU architecture.
[0008] For example, by allowing communication between a chilled water distribution system and the electrical power distribution, the chilled water system can invoke power resources in bidding, for example, by bidding for additional power for a power degraded pump. The degraded pump may have a worn impellor requiring the motor to run at a much higher speed to maintain the required hydraulic head or flow rate. Given that this is a viable operating scenario, the motor-pump control agent may request additional power from the associate owner control agent in order to realize the new, higher pump speed operating scenario.
[0009] The significantly increased complexity of such a cross-connected or coupled system is managed through the use of a cluster structure that flexibly and dynamically controls the degree to which such cross-communication between and among agents in different ship services occurs. By changing the cluster structure, flexible trade-offs are achieved between, on the one hand, rapid and efficient organization of a limited number of autonomous cooperative units and, on the other hand, highly sophisticated control requiring communication of far larger numbers of autonomous cooperative units.
[0010] Specifically then, the present invention provides an autonomous control system for managing at least two different distribution services, each distribution service providing distribution nodes and branches. The at least two different distribution services are coupled in the sense that a change in one service may impact the other service or an alteration in one service is required to realize a change in the other service. The autonomous control system includes a plurality of autonomous cooperative units, at least some of which are associated with nodes and branches of each distribution service. Each autonomous cooperative unit is programmed to cooperatively implement a job command by a bidding process among autonomous cooperative units associated with a predefined cluster related to one of the distribution services. At least one of the autonomous cooperative units is programmed to cooperatively implement the job command by a bidding process among autonomous cooperative units associated with a predefined cluster related to at least two of the distribution services.
[0011] Thus, it is one objective of at least one embodiment of the invention to provide a more sophisticated control of distribution services by communication with coupled distribution services.
[0012] The distribution services may include the distribution of a physical material, for example, compressed air, chilled water, fuel, chilled air and ballast water.
[0013] Thus it is another objective of at least one embodiment of the invention to provide a system that is well suited for distribution of utilities and the like, for example on a warship, in an aircraft, or in a municipality.
[0014] The nodes may be motor-pumps, tanks, chillers, heaters, valves, and the branches pipes.
[0015] Thus it is another objective of at least one embodiment of the invention to provide a distribution control system that works with a wide variety of distribution services.
[0016] The distribution service may include the distribution of electrical power, in which case the nodes may be switches, power controllers, power sources (e.g. generators or batteries) and power sinks (e.g. motors or electrical equipment) and the branches wire.
[0017] It is thus another objective of at least one embodiment of the invention to provide a control system that allows for intercommunication between a distributed utility and the power which services the nodes and branches of that utility.
[0018] The autonomous cooperative units that are associated with at least two of the distribution services may not be associated with nodes or branches of either distribution service.)
[0019] Thus it is another objective of at least one embodiment of the invention to allow for a hierarchical communication between distribution services using agents dedicated solely to that intercommunication. Such an agent is referred to as a cluster agent.
[0020] The system may include a plurality of directory facilitators communicating with the multiple autonomous cooperative units, wherein the autonomous cooperative units communicate in the bidding process among autonomous cooperative units of a predefined cluster defined by the directory facilitator.
[0021] Thus it is an object of at least one embodiment of the invention to provide for a mechanism to flexibly change the clusters on a dynamic basis.
[0022] It is another object of at least one embodiment of the invention to manage the communication among agents according to desired trade-offs by changing cluster sizes and cluster members using the directory facilitators.
[0023] The autonomous control unit may connect to different numbers of directory facilitators under predefined conditions of the bidding process.
[0024] Thus it is an object of at least one embodiment of the invention to allow change in clusters, including the destruction of clusters and the formation of new clusters during the bidding process as required.
[0025] These particular objects and advantages may apply to only some embodiments falling within the claims and thus do not define the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a phantom view of a warship showing a simplified set of distribution systems for chilled water, electrical power and compressed air having nodes and branches under the control of autonomous control units;
[0027] FIG. 2 is a schematic representation of these multiple distribution systems showing agents for control of the various nodes and branches of FIG. 1 communicating among themselves and showing communications across coupled distribution services per the present invention;
[0028] FIG. 3 is a schematic representation of the distribution systems of FIG. 2 showing a logical clustering of agents according to clusters defined by directory facilitators the latter of which may be changed to change the cluster sizes; and
[0029] FIG. 4 is a more detailed view of a directory facilitator communicating with an agent showing a change of cluster scope according to the results of the bidding process.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] Referring now to FIG. 1 , a warship 10 may have a variety of separate distribution services, for example, including a chilled water service 12 a , an electrical power service 12 b , and a compressed air service 12 c , each for distributing respectively, chilled water, electrical power and compressed air throughout the warship 10 . The warship 10 is representative of a general distribution system infrastructure such as may be found in other systems such as aircraft and submarines, and in environments such as factories and cities.
[0031] Each of the distribution services 12 may be characterized as a set of nodes 14 joined by branches 16 . For the chilled water service 12 a and the compressed air service 12 c , the nodes 14 may be motor-pumps, tanks, valves and sensors and the branches 16 pipes. In the case of the electrical power service 12 b , the nodes 14 may be generators, batteries, fuel cells, power loads, power converters, switches and sensors and the branches 16 wires. Other distribution services that distribute utilities such as fuel, compressed air, fresh conditioned air, fire water, elevators, and ballast water may also be found in the warship 10 but are not shown for clarity. Generally but not necessarily, each of the distribution services 12 operates independently, in parallel, and shares no common nodes 14 or branches 16 .
[0032] Referring now to FIG. 2 , each distribution service 12 a - 12 c may be controlled by a series of autonomous control units (ACUs) 18 . ACUs 18 suitable for use in the present invention are described in U.S. patents: U.S. Pat. No. 6,091,998 issued Jul. 18, 2000; U.S. Pat. No. 6,272,391 issued Aug. 7, 2001; and U.S. Pat. No. 6,647,300 issued Nov. 11, 2003; and pending U.S. applications: Ser. No. 09/407,474 filed Sep. 28, 1999; Ser. No. 09/621,718, filed Jul. 24, 2000; and Ser. No. 10/242,597 filed Sep. 12, 2002 all assigned to the present assignee and hereby incorporated by reference.
[0033] Each ACU 18 represents a separate logical entity capable that may be associated with each of the nodes 14 and branches 16 to monitor that particular component of the distribution service 12 and to act as its agent in organizing the components to work together in particular distribution tasks.
[0034] Each ACU 18 is logically separate and preferably many ACUs 18 are independent electronic computers so as to provide a distributed computing environment more tolerant of damage and providing sustained operation if several components fail or become disabled. The ACUs 18 communicate with each other preferably by means of a network of a type well known in the art (not shown).
[0035] As described in the above referenced patents and co-pending U.S. patent applications, each ACU 18 is programmed with: generalized knowledge of the capabilities of its associated node 14 or branch 16 , the functional connections between its associated node 14 or branch 16 and at least some other nodes 14 and branches 16 , a bidding protocol, and the ability to interpret and parse a job instruction written in a job description language (JDL).
[0036] Based on a job instruction provided to the ACUs 18 and propagated through the network, for example, to deliver a certain quantity of chilled water to a particular consumer, the ACUs 18 may organize themselves to complete the job based on the current capabilities of their associated nodes 14 and branches 16 and previous commitments of these resources or perhaps likely or expected future capabilities or future operating requirements. In organizing themselves, the ACUs 18 identify portions of the job that they can complete and pass other portions of the job along to other ACUs 18 associated with nodes 14 or branches 16 that may complete the remaining portions of the job. The passage of the job among the ACUs 18 creates bid chains which ultimately are compared to select a winning bid.
[0037] In creating the bid chain, each ACU 18 looks at a subset of other ACUs 18 and 18 ′, within a “cluster” for complementary resources needed to complete the job. Thus, ACUs 18 and 18 ′ evaluating a job for delivery of chilled water communicate with those ACUs 18 and 18 ′ associated with nodes 14 and branches 16 of the chilled water service 12 a . Only ACUs 18 from this cluster will be part of the winning bid. Thus the chilled water service 12 a defines generally a cluster 22 a , the electrical power service 12 b defines generally a cluster 22 b and the compressed air service 12 c defines generally a cluster 22 c and typically jobs related to a particular service is passed primarily among the ACUs 18 within the clusters 22 of these services. The use of clusters 22 a - 22 c greatly simplifies the bidding process by limiting the universe of potential bid participants and bid permutations.
[0038] The topology of a given organization of ACUs 18 is shown by communication paths 20 representing communications between the ACUs 18 required for the execution of that job and representing a subset of the larger scale communication between ACUs 18 over the network during the organizational process.
[0039] As will be understood by those of ordinary skill in the art from this description and the cited applications, a similar organization of ACUs 18 can be effected for the electrical power service 12 b and the compressed air service 12 c , each controlled by separate job instructions passed among independent ACUs associated with those particular distribution services 12 .
[0040] As a first approximation, a job of distributing chilled water will best be addressed by ACUs 18 associated with nodes 14 and branches 16 (shown in FIG. 1 ) of the chilled water cluster 22 a and similarly the job of distributing electrical power and compressed air will best be addressed by ACUs 18 associated with the electrical power cluster 22 b and compressed air cluster 22 c respectively.
[0041] Nevertheless, the present inventors have determined that despite this logical partitioning of ACUs 18 into clusters 22 a , 22 b and 22 c , improved solutions sets can be obtained in some cases by allowing certain ACUs 18 ″ to communicate with multiple different clusters. Thus one ACU 18 ″ of cluster 22 a may communicate with a corresponding ACU 18 ″ of electrical power cluster 22 b.
[0042] This communication across clusters 22 may be illustrated by a simple example in which a water distribution problem occurs because of failure of a pump. ACUs 18 looking solely within their cluster 22 a may attempt to reroute the water flow using a secondary or backup pumps, but in certain cases that may be impossible or may carry with it an extremely high performance penalty. By allowing some of the ACUs 18 ″ of chilled water cluster 22 a to communicate with ACUs 18 ″ of electrical power cluster 22 b , the ACUs 18 may discover, for example, that the pump failure was caused by a lack of electrical power or a power problem such as a phase imbalance. Cooperation between chilled water clusters 22 a and electrical power cluster 22 b through this communication path 20 ″ can allow this knowledge to be incorporated into the optimization of the bidding process of each service (i.e. chilled water and electrical power) while preserving the cluster concept prevents the need for a complete expansion of the solution space such as could create problems of communication bandwidth and solution convergence. The association of nodes from different clusters 22 is called a cluster association.
[0043] In the example of FIG. 2 , selected ACUs 18 ″ will communicate with other ACUs 18 ″ across boundaries of clusters 22 a , 22 b and 22 c as may be appropriate. For example, typically an ACU 18 associated with a pipe of a chilled water service 12 a may not communicate with ACU 18 associated with the electrical cluster 22 b , but in the example of the failed pump above, such communication could be useful. In a similar manner, ACUs 18 ″ of the electrical power cluster 22 b may communicate with the ACUs 18 ″ of the compressed air cluster 22 c and ACUs 18 ″ of the compressed air cluster 22 c may communicate with the chilled water cluster 22 a . Generally this intercommunication provides both individual information for optimization and the possible enlisting of resources from the other distribution services 12 , for example, by shutting down an air compressor to save electrical power to provide for chilled water. It also provides for the coordinated reconfiguration of individual services that are coupled, e.g., electrically, mechanically, or functionally.
[0044] Limited connections between the clusters 22 a - 22 c limits the scalability problems of having too many agents interconnected. It will be understood from review of FIG. 2 that certain of the ACUs 18 ″ are associated with multiple clusters, for example clusters 22 a and 22 b.
[0045] Note that the present system allows for multiple overlapping clusters 22 . A pump may be, for example, in a cluster 22 associated with a ballast water distribution service (not shown) and may also be in a cluster 22 associated with a fire water distribution service (not shown). Further, a particular resource (e.g. motor, pump, pipe) may be used in a way not intended during unusual conditions. I understand this is not unique. For example, fuel tanks may be filled with ballast water in emergency conditions. This unusual operating condition may be readily managed by agent clusters.
[0046] Referring now to FIG. 3 , in an alternative embodiment particular ACUs 18 ′″ may be used to provide for the intercommunication between the ACUs 18 of each of the distribution services 12 a , 12 b and 12 c , these ACUs 18 ′″ acting in a supervisory capacity as part of a new cluster 22 d . As a general matter, this supervisory capacity may be extended in hierarchical form to provide for a second higher level of ACUs 18 ′″ forming top level cluster 22 e . In this way, separate job instructions, for example providing for priorities between different distribution services 12 a , 12 b and 12 c or interoperability functions may be integrated into the control process.
[0047] The definition of the clusters 22 may be made in a number of ways, including, for example, programming into each of the ACUs 18 knowledge of its cluster 22 . In this case, the ACUs 18 communicate with only the ACUs 18 of their clusters 22 , thus limiting bands with demands on the system. Alternatively, a directory-type system such as is described in the above referenced U.S. patent applications may be created using a series of directory facilitators 26 a - 26 e , each associated with one of the clusters 22 a - 22 e . An individual ACU, for example ACU 18 a in cluster 22 a associated with the chilled water service 12 a , may thus determine its cluster by communicating with a particular pre-assigned directory facilitator 26 a , which lists other ACUs 18 and their capabilities within the particular cluster 22 a , to which ACU 18 a belongs.
[0048] The directory facilitator 26 a not only defines a cluster 22 and provides capabilities to improve performance in the searching for other ACUs 18 to meet a particular bid, but also provides a convenient method for programming particular clusters 22 into the system or in dynamically modifying those clusters 22 . Changing the allegiance of ACU 18 a is readily done by redirecting it to a different directory facilitator 26 , for example the directory facilitator 26 of supervisory agent cluster 22 d , such as may allow it to take advantage of resources of ACUs 18 in supervisory agent cluster 22 d . Conversely, the ACUs 18 ′″ of the supervisory agent cluster 22 d may communicate with selected ones of the ACUs 18 in the distribution system clusters 22 a - 22 c by connecting to their directory facilitators 26 a - 26 c of their clusters 22 a - 22 c.
[0049] The directory facilitators 26 may be implemented within ACUs 18 in a manner ancillary to the other logical functions of the ACUs 18 or in separate hardware attached to the network. Insofar as the directory facilitators 26 are relatively simple tables having the ability to parse requests from the ACUs 18 during bidding, multiple directory facilitators 26 may be contained in hardware for one particular ACU 18 and may be freely created as additional clusters 26 need to be defined.
[0050] Referring now to FIG. 4 , a particular ACU 18 in attempting to implement a job instruction may thus start by looking at a directory facilitator 26 a associated with its cluster 22 to see if it can obtain sufficient resources to create a bid chain on the particular job. Thus, for example, an ACU 18 associated with a pump may look at a small local cluster, all or a portion of the chilled water cluster 22 a , to find a necessary pipe and water supply to deliver chilled water to a particular location. In the event that no successful bid is created, or the bid chains do not meet certain threshold criteria, the ACU 18 may expand its cluster by examining also an additional directory facilitator 26 a to create an expanded cluster 22 , for example, including adjacent distribution services 12 . This is the case for an ACU 18 associated with a pump which cannot produce or find sufficient pumping capacity in its natural cluster 22 , and thus examines ACUs 18 of the electrical power cluster 22 b to look for solutions which may, for example, include providing additional power to a disabled pump. A nested hierarchy of directory facilitators 26 providing a dynamically changing cluster can thus be created.
[0051] The definition of clusters 22 may change arbitrarily with new clusters 22 created and old clusters 22 destroyed as determined by the progress of the bid, an operational state of the control system, or under the control of supervisory ACUs 18 of supervisory agent cluster 22 d.
[0052] The organization of ACUs 18 into clusters 22 permits various levels of granularity and problem-solving, and flexible trade-offs between solution time, bandwidth and problem solving sophistication. The clusters 22 may be used not simply for control, but also for other ACU functions, such as simulation, reconfiguration, monitoring, modeling, diagnosis or prediction.
[0053] The directory facilitators 26 may provide “blackboard” communication techniques, in which communication between ACUs 18 is accomplished on demand by exchanging information entered on a blackboard without the need for broadcasting or point-to-point communication.
[0054] It will be understood by one of ordinary skill in the art that the clusters 22 can provide diagnostics, re-configuration, control, surveillance, and threat assessment/risk assessment as well as simple control of nodes and branches and that although the examples given are for a ship systems they are applicable equally to commercial, industrial, and vehicle (e.g. aircraft) systems. The ACU and clusters described above are those used in distribution services but the invention does not preclude connections with other relevant systems . and components such as propulsion components that may need to be part of the cluster but are not technically a distribution service.
[0055] It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims. | Autonomous cooperative units working together to solve diagnostics, monitoring, surveillance, reconfiguration, and control problems may be organized into clusters and cluster associations, for example along the lines of a particular distribution system for water, power or the like. The clusters allow controlled communication among agents within different services and support the coordinated diagnostics, reconfiguration, and control across coupled systems. | 6 |
FIELD OF THE INVENTION
The present invention relates to a method of securing a liquid impervious sheet to a wound pad that is comprised of an elastic, hydrophilic material and that will expand in all directions when absorbing fluid. The invention also relates to a dressing that includes a wound pad to which a liquid-impervious sheet is fastened with the aid of said method.
BACKGROUND OF THE INVENTION
Such a wound pad will often be provided with liquid impervious film, to prevent fluid from seeping from the pad and onto the overlying dressing or onto the wearer's clothing. A wound pad in the form of an hydrophilic foam plate (e.g. polyurethane foam) will endeavour to expand by 30 to 40% in all directions when taking-up fluid, such wound pads often being used in the treatment of traumatic or chronic wounds. Other materials can strive to expand by as much as 100%. Plastic film cannot be made to stretch in keeping with the expansion of the wound pad. Film attached to the upper surface of the wound pad will counteract the expansion of the wound pad, wherewith the wound pad will attempt to arch or curve as the wound pad takes up fluid. There is thus a danger that the ends of such a wound pad applied to a wound will loosen from the wearer's skin, which is, of course, most undesirable.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide an absorbent wound pad of the aforesaid kind with which the liquid im pervious sheet is able to accompany the expansion of the wound pad as the pad takes up fluid. A secondary object is to increase the flexibility of such a wound pad.
These objects are achieved in accordance with the invention by means of a method of the kind described in the first paragraph, which is characterized by stretching the wound pad to a given extent in the plane of the pad, both longitudinally and laterally, fastening a flat liquid-impervious sheet to the stretched pad, and then removing the load acting on the pad. This results in a three-dimensional liquid-impervious sheet that includes a large number of projections formed by folding or puckering of the sheet as the pad retracts from its stretched state. A sheet of this nature is able to follow the expansion of the pad as it absorbs fluid without the occurrence of any tension in the sheet, such tension otherwise striving to bend the pad. The flexibility and pliability of the pad is also enhanced by virtue of the general ability of the liquid-pervious sheet to follow the curved path of a pad applied to a knee wound for instance, simply by straightening out the folds or puckers.
In one preferred embodiment of the invention the wound pad is stretched to an extent that corresponds to its maximum expansion when taking up fluid.
The invention also relates to an absorbent dressing that includes an elastic and hydrophilic wound pad which expands when taking up fluid, and a liquid-impervious sheet fastened to that side of the wound pad that is intended to lie proximal from the wound when the dressing is used. The inventive dressing is characterized in that the liquid-impervious sheet includes a relatively large number of projections that are formed when the elastic wound pad, to which the liquid-impervious sheet is fastened after having expanded the wound pad mechanically in the plane of said sheet to a size that corresponds to the area of the sheet when flat, returns to a relaxed state. In one preferred embodiment, the area of the liquid-impervious sheet when flat corresponds to the area of the wound pad in an expanded state after maximum fluid absorption.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in detail with reference to the accompanying drawings, in which
FIG. 1 is a schematic side view of apparatus for fastening plastic film to an elastic wound pad;
FIG. 2 shows the apparatus from above;
FIG. 3 is a sectional view taken on the line III--III in FIG. 2; and
FIG. 4 shows a wound pad that has been provided with a liquid-impervious sheet in accordance with one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The apparatus shown in FIGS. 1-3 includes four pairs of rolls 1-4 between which there is advanced a web 5 of plastic foam material, such as polyurethane foam for instance. A glue applying roller 6 is mounted downstream of the roll pair 2 and functions to apply glue to the by-passing web 5. Polyurethane film is then taken from a storage reel 8 and applied to the web 5, with the aid of a roller 9. The composite web then passes through the nip of the third roll pair 3. The long edges of the web 5 are held firmly by clamps 10 that run freely in fixed rails 11 on wheels 12, as evident from FIGS. 2 and 3. The rails 11 are mutually divergent between the roll pairs 1 and 2 and function to expand the web 5 laterally. The rolls of the roll pair 2 rotate at a higher speed than the rolls of the roll pair 1, so as to expand the web correspondingly in its longitudinal direction. Thus, the web 5 will have been stretched both transversally and longitudinally when reaching the roll pair 2. This stretched state is maintained at least until the web 5 leaves the roll pair 3. The plastic film 7 is thus applied and fastened to the web 5 whilst the web is in stretched state. The rails 11 are mutually convergent downstream of the roll pair 3 and the rolls of the roll pair 4 are driven at the same speed as the rolls of the roll pair 1, wherewith the web 5 will contract from its stretched state, both transversely and longitudinally, causing the film 7 to pucker and therewith reduce its transversal and longitudinal dimensions.
When the web 5 has passed the roll pair 4, wound pads that include a liquid-impervious sheet 7 are cut from the web 5, with the aid of means suitable to this end. The web is preferably held stretched until individual wound pads have been cut from the web. Alternatively, the web may be allowed to contract under its own elasticity, to the form that it had in its relaxed state or to the form that it obtains in the absence of any load thereon (a small degree of deformation may remain in the web when it relaxes from a stretched state) before cutting the individual wound pads therefrom.
FIG. 4 is a schematic perspective view of one such wound pad. This wound pad includes a piece 14 of absorbent foam material that has plastic film 15 fastened to its upper surface. The Figure shows the wound pad in a dry state, immediately after its manufacture. The wound pad has thus contracted to a relaxed state, meaning that its area has decreased in comparison with its area in its stretched state. The area of the film fastened to the upper side of the wound pad will, of course, have decreased to a corresponding extent. Consequently, as the piece of foam 14 contracts elastically, a relatively large number of small projections will form in the film as the film puckers in following the reduction in area of the piece of foam 14. The plastic film will therewith become three-dimensional.
When the wound pad is in use, the foam 14 will absorb excessive fluid from the wound to which an absorbent pad that includes the wound pad has been applied. As the wound pad absorbs fluid, it will expand, or swell, both transversally and longitudinally and the area of the pad will increase at the rate at which fluid is absorbed. This increase in area is not counteracted by the film 15 in any way, and the film is able to follow the increase in area of the pad, by smoothing out the puckers or folds that form said projections. When the amount of fluid absorbed by the wound pad has reached an extent at which the pad has expanded so that its increase in area corresponds to the increase in area from a relaxed to a stretched state in the aforedescribed manufacture, the film 15 will have been smoothed out to a flat state. In the case of earlier known wound pads where the plastic film is applied to a piece of foam with said piece in a relaxed state, i.e. not stretched, the plastic film is unable to follow the increase in area of the piece of foam and the wound pad will strive to bend or arch as it absorbs fluid. Thus, because the plastic film is able to increase in area from a three-dimensional state to a flat state without the risk of tension forces occurring in the piece of foam 14, there is no danger of the edges of the foam 14 losing contact with the skin surrounding the wound onto which the wound pad 13 has been applied, solely as a result of the piece of foam absorbing fluid. In order to eliminate this risk completely, the extent to which the area of the piece of foam is increased when applying the plastic film during manufacture of the wound pad will correspond at least to the increase in area of the foam from a dry state to a saturated state.
In addition to eliminating the aforesaid risk, the described wound pad is more flexible than a similar wound pad provided with a flat plastic film, because the absorbent foam material 14 is able to curve with out requiring the plastic sheet to lengthen longitudinally and/or transversally through elastic deformation. When a dressing that includes an inventive wound pad is intended to be used in the treatment of knee wound or an elbow wound, it may therefore be suitable to give the plastic film in a flat state a larger area than what is motivated solely by expansion of the piece of foam in a saturated state, so that the flexibility of the foam can be utilized to a maximum.
The described dressing 13 can be held against a wound with the aid of some suitable fixation bandage, or may be affixed with the aid of an adhesive that will adhere to the skin but not to the bed of the wound.
Foam materials that swell when absorbing fluid may be used as an alternative to polyurethane foam. It is also conceivable to use other liquid-impervious materials as an alternative to plastic foams, such as nonwoven material for example, provided that these materials are sufficiently flexible to form said projections by folding or pleating as the absorbent material contracts from a stretched state to a relaxed state or non-loaded state.
The described wound pads may be sterile-packaged or otherwise.
It will be understood that the described embodiment can be modified without departing from the concept of the invention. For instance, the plastic film can be fastened to a stationary piece of extended or stretched foam material instead of to a moving web. The invention can also be applied with other absorbent materials, such as other elastic, pattern-cut or pleated-woven fabric included in surgical pads for instance. The elastic, absorbent material may also be stretched by other means than those described, prior to applying the liquid-impervious sheet. The invention is therefore restricted solely by the scope of the following claims. | A method of fastening a liquid-impervious sheet (7) to a wound pad (5) that is comprised of an elastic, hydrophilic material and that will expand in all directions when absorbing fluid. The pad (5) is stretched to a given extent both longitudinally and transversally in the plane of the pad and a flat liquid-impervious sheet (7) is then applied to the stretched pad and the load acting on the pad is removed. An absorbent dressing that includes an inventive wound pad (13) is also disclosed. | 1 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to tool inserts and more particularly to cutting tool inserts for use in drilling and coring holes in subterranean formations.
[0002] A commonly used cutting tool insert for drill bits is one which comprises a layer of polycrystalline diamond (PCD) bonded to a cemented carbide substrate. The layer of PCD presents a working face and a cutting edge around a portion of the periphery of the working surface.
[0003] Polycrystalline diamond, also known as a diamond abrasive compact, comprises a mass of diamond particles containing a substantial amount of direct diamond-to-diamond bonding. Polycrystalline diamond will generally have a second phase which contains a diamond catalyst/solvent such as cobalt, nickel, iron or an alloy containing one or more such metals.
[0004] In drilling operations, such a cutting tool insert is subjected to heavy loads and high temperatures at various stages of its life. In the early stages of drilling, when the sharp cutting edge of the insert contacts the subterranean formation, the cutting tool is subjected to large contact pressures. This results in the possibility of a number of fracture processes being activated such as the initiation of fatigue cracks, high energy impacts, in the normal direction, resulting in spalling of the PCD layer, and high energy impacts in the cutting direction, resulting in chipping of the PCD layer.
[0005] As the cutting edge of the insert wears, the contact pressure decreases and is generally too low to cause high energy failures. However, this pressure can still propagate cracks initiated under high contact pressures, and will eventually result in spalling-type failures.
[0006] Spalling failures are particularly damaging in that these failures represent a mechanism for the rapid removal of wear resistant material and consequently reduce the life of the cutting tool insert. Localised spalling leads to a localised thinning of the PCD table which in turn gives rise to a grooving type of wear. This wear phenomenon redistributes the loading on the wearflat and can result in an increase in the contact pressure. As the grooving wear continues, the contact pressure will continue to increase, eventually initiating new spalling type failures from the high contact pressure areas. In a worst case scenario, this becomes a self-sustaining wear mode that will lead to the premature failure of the cutting tool due to the rapid removal of the PCD layer by a spalling mechanism.
[0007] U.S. Pat. No. 5,135,061 describes a cutting tool insert for use in rotary drill bits of the kind generally described above. The cutting element has a layer of superhard material such as PCD bonded to a cemented carbide substrate. The layer of superhard material has a front layer at the cutting face and a second layer behind the front layer. The front layer comprises a form of superhard material which is less wear-resistant than the super-hard material forming the second layer. Generally, a plurality of further layers are stacked behind the second layer, the further layers being of reducing wear-resistance as they extend away from the second layer towards the substrate.
[0008] U.S. Pat. No. 6,290,008 discloses a PCD enhanced insert which includes a body portion adapted for attachment to an earth-boring bit and a top portion for contacting an earthen formation. The top portion of the insert is provided with two different compositions of polycrystalline diamond. In the primary surface of the top portion, a tougher or less wear-resistant polycrystalline diamond layer is provided, whereas a more wear-resistant polycrystalline diamond layer is provided in the remaining region of the top portion. In addition to polycrystalline diamond, polycrystalline boron nitride and other superhard materials may also be used.
[0009] U.S. Pat. No. 6,443,248 describes a cutter element for use in a drill bit, comprising a substrate and a plurality of layers thereon. The substrate comprises a grip portion and an extending portion. The layers are applied to the extending portion such that at least one of the layers is harder than at least one of the layers above it. The layers can include one or more layers of polycrystalline diamond and can include a layer in which the composition of the material changes with distance from the substrate.
SUMMARY OF THE INVENTION
[0010] According to the present invention, a tool insert comprises a working layer of ultra-hard abrasive, particularly PCD, bonded to a substrate along an interface, the working layer presenting a working surface and a periphery around the working surface which provides a cutting edge for the insert, the working layer of ultra-hard abrasive having a first region extending into the working layer from the working surface, and a second region in contact with the first region, the wear resistance of the first region being less than that of the second region, wherein the wear resistance of the first region is between 50% and 95% of that of the second region, preferably between 60% and 90%, most preferably between 70% and 89%.
[0011] Generally, the first and second regions will comprise layers, typically successive layers, extending from the working face into the working layer. The regions, or at least one of the regions, may comprise an annulus extending inwards from a periphery of the layer of ultra-hard abrasive. In some cases, the thickness of the first, thin region may be non-uniform across the diameter of the cutter; so that the interface between the first and second regions may be specifically designed for optimal behaviour.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0012] A tool component of the invention comprises a layer of ultra-hard abrasive that has a first region which is less wear resistant than a second region thereof. Accordingly, essential to the invention is that the first region differs in material characteristics to that of the second region leading to a controlled and reduced spalling and reduced fatigue in the layer of ultra-hard abrasive. The first region will generally be relatively thin and extend to a depth of about 750 microns, preferably no more than about 500 microns, and most preferably about 50 to 250 microns, for a wear ratio of between 50% and 95%, from the working surface.
[0013] In the tool component of the invention, there is a relationship between the wear resistances of the two regions to achieve a minimising of the failure problems of prior art tool inserts described above. The first region preferably has a wear resistance of between 50% and 95%, more preferably between 60% and 90%, and most preferably between 70% and 89% of the wear resistance of the second region. An example of such a tool component, in one embodiment of the invention, is one in which the first region comprises a composite structure of two or more materials. The materials may be uniformly distributed throughout the region or randomly distributed. For example, the one material may be the same material as that of the second region and this will be combined with another material which provides that first region with a wear resistance lower than that of the second region.
[0014] This type of arrangement can also be obtained in a number of other ways. For instance, the tool component in a further embodiment of the invention can be designed such that the first and second regions are both regions of PCD and contain catalyst/solvent, the amount of catalyst/solvent in the first region being higher than that in the second region. Alternatively, the tool component in yet a further embodiment of the invention can be designed such that the first region has ultra-hard abrasive particles of a unimodal particle size distribution only, and the second region has ultra-hard abrasive particles which have a multimodal particle size distribution.
[0015] In both these cases, it is preferable that the average grain or particle sizes in the two regions are similar. In other words, the range of particle sizes in the second region will not differ materially from the range of particle sizes of the ultra-hard abrasive in the first region.
[0016] In a further alternative embodiment of the invention, the tool component is one in which both the first and second regions comprise ultra-hard abrasive particles of more than one particle size, the size distribution of the particles in the first region being coarser than that of the second region. In such a case, the ultra-hard abrasive in the first region is preferably made from a mass which comprises at least 25% by mass particles having an average particle size in the range 10 to 100 microns and consisting of particles having three different average particle sizes and at least 4% by mass of the particles having an average particle size of less than 10 microns. Further, the ultra-hard abrasive in the second region preferably is made from a mass of particles which has an average particle size of less than 20 microns and consists of particles having at least three different average particle sizes.
[0017] In another embodiment of the invention, the ultra-hard abrasive is PCD and the thermal stability of the PCD in the first region is less than that of the PCD in the second region. A metal or other material which has thermal expansion properties significantly different to that of PCD may be provided in the first region. Also, the first region may have a second phase which includes in it a metal such as iron or manganese which can react with the diamond under high temperature.
[0018] In a further embodiment of the invention, the ultra-hard abrasive is PCD and sinter quality of the PCD in the first region is compromised by the introduction of a material such as a sintering agent in small quantities, which is not introduced into the second region. The compromising material will generally not be present in quantities sufficient for the mechanical or thermal properties of the material itself to affect the properties of the first region. The role of the compromising material is to influence the diamond sintering process during synthesis. This may be achieved in one of two ways. First, the material may act as an inhibitor/poison where the agent interferes with the sintering. Second, the material may be more catalytic, for example where the presence of the material encourages sintering, but at a too rapid rate, producing a less well-sintered structure. Further examples of compromising the quality of the PCD is by treatment of the diamond particle surface or the introduction of additional carbon material into the first region.
[0019] In another embodiment of the invention, where both the first and second regions are regions of PCD containing a catalyst/solvent in a second phase, the catalyst/solvent in the first region is cobalt with another transition metal such as nickel, or the other transition metal; and the catalyst/solvent in the second region is essentially cobalt. The nickel will tend to increase the thermal stability of the PCD in the first region. However, the sintering action of the nickel is less effective than another transition metal such as cobalt. Thus, the presence of nickel in the PCD in the first region, where the other catalyst/solvent is cobalt, will have the effect of reducing the overall strength of the sintered PCD in the first region and hence rendering it less wear resistant.
[0020] The invention will now be described in more detail, by way of example only, with reference to the following non-limiting examples.
EXAMPLE 1
[0021] A number of tool inserts as generally described above (A1, B1 and C1) were manufactured with respective first PCD abrasive regions or top layers each 150 μm in depth from their respective working surface. The respective top layers of the tool inserts had different wear resistances relative to their respective second regions of PCD abrasive as follows:
[0000] i) A1—0.94 (94%) wear resistance ratio;
[0000] ii) B1—0.91 (91%) wear resistance ratio; and
[0000] iii) C1—0.88 (88%) wear resistance ratio.
[0022] These were then tested in a vertical borer test against a base PCD product X1, and the result of these tests are depicted schematically in FIG. 1 of the accompanying drawings. In a vertical borer test, the wearflat area is measured as a function of the number of passes (or the total distance bored) of the cutter element boring into the workpiece, which in this case was SW granite. It will be noted that the wear behaviour improved as the wear ratio moved away from 1 at the 150 μm depth for the respective top layers. Referring to the base PCD product X1, the “deviations” from the curve are due to instances of spalling behaviour.
[0023] In the vertical borer test, data was collected in the range of 0-100 passes.
EXAMPLE 2
[0024] A number of tool inserts (A2, B2, C2 and D2) were manufactured with a wear ratio of the respective first regions or top layers to the respective second regions or top layers of 0.91 (91%). The respective tool inserts had different depths of the top layers from their working surfaces as follows:
[0000] i) A2—750 μm depth of first region;
[0000] ii) B2—500 μm depth of first region;
[0000] iii) C2—250 μm depth of first region; and
[0000] iv) D2—150 μm depth of first region.
[0025] These were again tested in a vertical borer test against a base PCD product X2, and the results of these tests are depicted schematically in FIG. 2 of the accompanying drawings. It will be noted that at a wear ratio of 0.91, wear behaviour improved as the top layer become thinner.
[0026] In the vertical borer test, data was collected in the range of 0-100 passes.
[0027] From the above Examples, the following observations can be made.
[0028] As the thickness of the top layer is increased, spalling behaviour will be reduced, but this can be at the cost of cutting efficiency. At the extreme, the wear resistance of the top layer will dominate the overall wear resistance of the cutter. Hence a thinner top layer is desirable for achieving most benefit from the more wear resistant underlying PCD. Where the wear ratio is close to 1, thinner layers will not yield the desired stress-reducing behaviours because of inadequate “rounding” of this layer. Maximum cutting efficiency will be achieved by optimising the thickness of the top layer and the wear ratio between the top layer and the underlying PCD. The top layer must be thick enough to reduce contact pressures on the cutting edge, but still thin enough that it does not negatively impact on the overall wear resistance of the cutter. The closer that the wear ratio is to 1, the less efficient this optimisation will be. In the case of lower wear ratios, the top layer will yield the required reduction in spalling behaviour, in an appropriate thickness region which still allows optimal cutter performance.
[0029] However, it is believed that this behaviour is not just a function of the relative wear ratio of the two layers and the top layer thickness, but will also be decided by the absolute strength of the material. Where this approach is applied to PCD material of lower strength, which is therefore less prone to spalling type failure, maximum benefit is unlikely to be realised.
[0030] The invention has particular application to tool inserts wherein the ultra-hard abrasive is PCD and, more particularly, to such inserts which are intended to be used as cutting inserts for drill bits in the drilling or coring of drill holes or the like in subterranean formations. | A tool insert comprises a working layer of ultra-hard abrasive, particularly PCD, bonded to a substrate along an interface. The working layer presents a working surface and a periphery around the working surface which provides a cutting edge for the insert. The working layer of ultra-hard abrasive has a first region extending into the layer from the working surface, and a second region in contact with the first region, the wear resistance of the first region being less than that of the second region. The wear resistance of the first region is between 50% and 95% of that of the second region, preferably between 60% and 90%, most preferably between 70% and 89%. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is a continuation of commonly-owned and copending U.S. patent application Ser. No. 10/355,761, filed on Jan. 31, 2003, which is a continuation of U.S. patent application Ser. No. 09/875,766, filed on Jun. 6, 2001, now abandoned, both of which applications are incorporated herein by reference.
[0002] This patent application is also a continuation-in-part of commonly-owned and copending U.S. patent application Ser. No. 09/070,969,-filed on May 1, 1998; which is a continuation-in-part of U.S. patent application Ser. No. 08/823,894 filed Mar. 17, 1997, now U.S. Pat. No. 5,748,371; which is a continuation of U.S. patent application Ser. No. 08/384,257, filed Feb. 3, 1995, now abandoned, all of which are incorporated herein by reference.
[0003] This patent application also relates to commonly-owned and copending U.S. patent application Ser. No. 09/766,325, filed Jan. 19, 2001, now U.S. Pat. No. 6,783,733, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0004] 1. Field Of The Invention
[0005] This invention relates to apparatus and methods for using Wavefront Coding to improve contrast imaging of objects which are transparent, reflective or vary in thickness or index of refraction.
[0006] 2. Description Of The Prior Art
[0007] Most imaging systems generate image contrast through variations in reflectance or absorption of the object being viewed. Objects that are transparent or reflective but have variations in index of refraction or thickness can be very difficult to image. These types of transparent or reflective objects can be considered “Phase Objects”. Various techniques have been developed to produce high contrast images from essentially transparent objects that have only variations in thickness or index of refraction. These techniques generally modify both the illumination optics and the imaging optics and are different modes of what can be called “Contrast Imaging”.
[0008] There are a number of different Contrast Imaging techniques that have been developed over the years to image Phase Objects. These techniques can be grouped into three classes that are dependent on the type of modification made to the back focal plane of the imaging objective and the type of illumination method used. The simplest Contrast Imaging techniques modify the back focal plane of the imaging objective with an intensity or amplitude mask. Other techniques modify the back focal plane of the objective with phase masks. Still more techniques require the use of polarized illumination and polarization-sensitive beam splitters and shearing devices.
[0009] Contrast Imaging techniques that require polarizers, beam splitters and beam shearing to image optical phase gradients, we call “Interference Contrast” techniques. These techniques include conventional Differential Interference Contrast (Smith, L. W., Microscopic interferometry, Research (London), 8:385-395, 1955), improvements using Nomarski prisms (Allen, R. D., David, G. B, and Nomarski, G, The Zeiss-Nomarski differential interference equipment for transmitted light microscopy, Z. Wiss. Mikrosk. 69:193-221, 1969), the Dyson interference microscope (Born and Wolf, Principals of Optics, Macmillan, 1964), the Jamin-Lebedeff interferometer microscopes as described by Spencer in 1982 (“Fundamentals of Light Microscopy”, Cambridge University Press, London), and Mach-Zehnder type interference microscopes (“Video Microscopy”, Inoue and Spring, Plenum Press, NY, 1997). Other related techniques include those that use reduced cost beam splitters and polarizers (U.S. Pat. No. 4,964,707), systems that employ contrast enhancement of the detected images (U.S. Pat. No. 5,572,359), systems that vary the microscope phase settings and combine a multiplicity of images (U.S. Pat. No. 5,969,855), and systems having variable amounts of beam shearing (U.S. Pat. No. 6,128,127).
[0010] FIG. 1 (Prior Art) is a block diagram 100 , which shows generally how Interference Contrast Imaging techniques are implemented. This block diagram shows imaging of a Phase Object 110 through transmission, but those skilled in the art will appreciate that the elements could just as simply have been arranged to show imaging through reflection.
[0011] Illumination source 102 and polarizer 104 act to form linearly polarized light. Beam splitter 106 divides the linearly polarized light into two linearly polarized beams that are orthogonally polarized. Such orthogonal beams can be laterally displaced or sheared relative to each other. Illumination optics 108 act to produce focussed light upon Phase Object 110 . A Phase Object is defined here as an object that is transparent or reflective but has variations in thickness and/or index of refraction, and thus can be difficult to image because the majority of the image contrast typically is derived from variations in the reflectance or absorbtion of the object.
[0012] Objective lens 112 and tube lens 118 act to produce an image upon detector 120 . Beam splitter 114 acts to remove the lateral shear between the two orthogonally polarized beams formed by beam splitter 106 . Beam splitter 114 is also generally adjustable. By adjusting this beam splitter a phase difference between the two orthogonal beams can be realized. Analyzer 116 acts to combine the orthogonal beams by converting them to the same linear polarization. Detector 122 can be film, a CCD detector array, a CMOS detector, etc. Traditional imaging, such as bright field imaging, would result if polarizer and analyzer 104 and 116 and beam splitters 106 and 114 were not used.
[0013] FIG. 2 (Prior Art) shows a description of the ray path and polarizations through the length of the Interference Contrast imaging system of FIG. 1 . The lower diagram of FIG. 2 describes the ray path while the upper diagram describes the polarizations. The illumination light is linearly polarized after polarizer 204 . This linear polarization is described as a vertical arrow in the upper diagram directly above polarizer 204 . At beam splitter 206 the single beam of light becomes two orthogonally polarized beams of light that are spatially displaced or sheared with respect to each other. This is indicated by the two paths (solid and dotted) in both diagrams. Notice that the two polarization states of the two paths in the top diagram are orthogonally rotated with respect to each other. Beam splitter 214 spatially combines the two polarizations with a possible phase offset or bias. This phase bias is given by the parameter Δ in the upper plot. By laterally adjusting the second beam splitter 214 the value of the phase bias Δ can be changed. A Nomarski type prism is described by the ray path diagram, although a Wollaston type prism could have been used as well. Analyzer 216 acts to convert the orthogonal component beams to linearly polarized light. The angle between the polarizer 204 and analyzer 216 can typically be varied in order to adjust the background intensity. Image plane 218 acts to display or record a time average intensity of the linearly polarized light, the sheared component possibly containing a phase shift. This image plane can be an optical viewing device or a digital detector such as CCD, CMOS, etc.
[0014] The interactions of the polarizers, beam splitters, and Phase Objects of the Interference Contrast imaging systems have been studied in great detail. For additional background information see “Confocal differential interference contrast (DIC) microscopy: including a theoretical analysis of conventional and confocal DIC imaging”, Cogswell and Sheppard, Journal of Microscopy, Vol 165, Pt 1, January 1992, pp 81-101.
[0015] In order to understand the relationship between the object, image, and phase shift Δ consider an arbitrary spatially constant object that can be mathematically described as:
Obj=a exp( j θ), where j=√{square root over (−1)}
where “a” is the amplitude and θ is the object phase. If the two component beams of the system of FIG. 2 have equal amplitude, and if the component beams are subtracted with relative phases ±Δ/2 then just after analyzer 216 the resulting image amplitude is given by:
amp=a exp( j[θ−Δ/ 2])− a exp( j[θ+Δ/ 2])=2 j a exp( j θ)sin(Δ/2)
[0016] The image intensity is the square of the image amplitude. The intensity of this signal is then given by:
int o =4 a 2 sin(Δ/2) 2 .
[0017] The image intensity is independent of the object phase θ. The phase difference or bias between the two orthogonal beams is given by Δ and is adjusted by lateral movement of the beam splitter, be it a Wollaston or a Nomarski type. If instead of a spatially constant object, consider an object whose phase varies by Δφ between two laterally sheared beams. This object phase variation is equivalent to a change in the value of the component beam phases of Δ. If the component beam phases Δ is equal to zero (no relative phase shift) then the resulting image intensity can be shown to have increases in intensity for both positive and negative variations of object phase. If the component beam bias is increased so that the total phase variation is always positive, the change in image intensity then increases monotonically throughout the range Δφ. The actual value of the change in image intensity with object phase change Δφ can be shown to be:
Int 1 =4 a 2 Δφ sin(Δ).
[0018] In Interference Contrast imaging the phase bias Δ determines the relative strengths with which the phase and amplitude information of the object will be displayed in the image. If the object has amplitude variations these will be imaged according to into above. At a phase bias of zero (or multiple of 2 pi ) the image will contain a maximum of phase information but a minimum of amplitude information. At a phase bias of pi the opposite is true, with the image giving a maximum of amplitude information of the object and a minimum of phase information. For intermediate values of phase bias both phase and amplitude are imaged and the typical Interference Contrast bias relief image is produced, as is well known.
[0019] Variation of the phase bias can be shown to affect the parameters of image contrast, linearity, and signal-to-noise ratio (SNR) as well. The ratio of contrast from phase and amplitude in Interference Contrast imaging can be shown to be given by:
[contrast due to phase/contrast due to amplitude]=2 cot(Δ/2)
[0020] The overall contrast in the Interference Contrast image is the ratio of the signal strength to the background and can be shown to be given by:
overall contrast=2 Δφ cot(Δ/2).
[0021] The linearity between the image intensity and phase gradients in the object can be described by:
L =[(1+sin(Δ)) (2/3) ]/[2 cos(Δ)].
[0022] The signal-to-noise ratio (SNR), ignoring all sources of noise except shot noise on the background, can be shown to be given by
SNR= 4 a cos(Δ/2).
[0023] In Interference Contrast imaging systems the condenser aperture can be opened to improve resolution, although in practice, to maintain contrast, the condenser aperture is usually not increased to full illumination. Imaging is typically then partially coherent. Description of the imaging characteristics for Interference Contrast imaging therefore needs to be expressed in terms of a partially coherent transfer function. The partially coherent transfer function (or transmission cross-coefficient), given as C(m,n;p,q), describes the strength of image contributions from pairs of spatial frequencies components m; p in the x direction and n; q in the y direction (Born and Wolf, Principals of Optics, Macmillan, 1975, p. 526). The intensity of the image in terms of the partially coherent transfer function image can be written as:
l ( x,y )=∫∫∫ T ( m,n ) T ( p,g )* C ( m,n;p,q )exp(2 pi j [( m−p ) x +( n−q ) y ]) dm dn dp dq
where the limits of integration are +infinity to −infinity. The term T(m,n) is the spatial frequency content of the object amplitude transmittance t(x,y):
T ( m,n )=∫∫ t ( x,y )exp(2 pi j [mx+ny ]) dx dy
where again the limits of integration are +infinity to −infinity. ( )* denotes complex conjugate. When the condenser aperture is maximally opened and matched to the back aperture or exit pupil of the objective lens, the partially coherent transfer function reduces to (Intro. to Fourier Optics, Goodman, 1968, pg.120):
C ( m, n; p, q )=δ( m−n )δ( p−q )[ a cos(ρ)−ρ sqrt {(1−ρ 2 )}]
where ρ=sqrt(m 2 +p 2 ) and δ (x)=1 if x=0, δ (x)=0 otherwise.
[0024] The effective transfer function for the Interference Contrast imaging system can be shown to be given as:
C ( m,n;p,q ) eff =2 C ( m,n;p,q ){cos[2 pi ( m−n )Λ]−cos(Δ)cos([2 pi ( m+n )Λ]−sin(Δ)sin [2 pi ( m+p )Λ]}
where Λ is equal to the lateral shear of the beam splitters and C(m,n;p,q) is the partially coherent transfer function of the system without Interference Contrast modifications.
[0025] Interference Contrast imaging is one of the most complex forms of imaging in terms of analysis and design. These systems are also widely used and studied. But, there is still a need to improve Interference Contrast Imaging of Phase Objects by increasing the depth of field for imaging thick objects, as well as for controlling focus-related aberrations in order to produce less expensive imaging systems than is currently possible.
SUMMARY OF THE INVENTION
[0026] An object of the present invention is to improve Contrast Imaging of Phase Objects by increasing depth of field and controlling focus-related aberrations. This is accomplished by using Contrast Imaging apparatus and methods with Wavefront Coding aspheric optics and post processing to increase depth of field and reduce misfocus effects. The general Interference Contrast imaging system is modified with a special purpose optical element and image processing of the detected image to form the final image. Unlike the conventional Interference Contrast imaging system, the final Wavefront Coding Interference Contrast image is not directly available at the image plane. Post processing of the detected image is required. The Wavefront Coding optical element can be fabricated as a separate component, can be constructed as an integral component of the imaging objective, tube lens, beam splitter, polarizer or any combination of such.
[0027] Apparatus for increasing depth of field and controlling focus related aberrations in an Interference Contrast Imaging system having an illumination source, optical elements for splitting light polarizations, and illumination optics placed before a Phase Object to be imaged, and elements for recombining light polarizations and objective optics after the Phase Object to form an image at a detector, includes an optical Wavefront Coding mask having an aperture and placed between the Phase Object and the detector, the coding mask being constructed and arranged to alter the optical transfer function of the Interference Contrast Imaging system in such a way that the altered optical transfer function is substantially insensitive to the distance between the Phase Object and the objective optics over a greater range of object distances than was provided by the unaltered optical transfer function, wherein the coding mask affects the alteration to the optical transfer function substantially by affecting the phase of light transmitted by the mask. The system further includes a post processing element for processing the image captured by the detector by reversing the alteration of the optical transfer function accomplished by the coding mask.
[0028] The detector might be a charge coupled device (CCD).
[0029] The phase of light transmitted by the coding mask is preferably relatively flat near the center of the aperture with increasing and decreasing phase near respective ends of the aperture.
[0030] As an alternative, the phase of light transmitted by the coding mask could substantially follow a cubic function.
[0031] In one embodiment, the phase of light transmitted by the coding mask substantially follows a function of the form:
Phase ( x,y )=12 [ x 3 +y 3 ]
where |x|≦1, |y|≦1.
[0033] In another embodiment the phase of light transmitted by the coding mask substantially follows a rectangularly separable sum of powers function of the form:
phase( x,y )=3 [ a i sign( x ) | x| b i +c i sign( y ) | y| d i ]
where the sum is over the index i,
sign( x )=−1 for x< 0, sign( x )=+1 for x≧0.
[0035] In another embodiment, the phase of light transmitted by the coding mask substantially follows a non-separable function of the form:
phase( r, θ)=3[ r a i cos( b i θ+φ i )]
where the sum is again over the index i.
[0037] In another embodiment the phase of light transmitted by the coding mask substantially follows a function of the form:
Phase profile ( x,y )=7[sign( x ) | x| 3 +sign( y ) | y| 3 +7[sign( x ) | x| 9.6 +sign( y ) | y| 9.6 ]
where |x|≦1, |y|≦1.
[0039] The coding mask further may be integrally formed with a lens element for focussing the light, or with the illumination optics.
[0040] The coding mask could comprise an optical material having varying thickness, an optical material having varying index of refraction, spatial light modulators, or micro-mechanical mirrors.
[0041] A method for increasing depth of field and controlling focus related aberrations in a conventional Interference Contrast Imaging system comprises the steps of modifying the wavefront of transmitted light between the Phase Object and the detector, the wavefront modification step selected to alter the optical transfer function of the Interference Contrast Imaging system in such a way that the altered optical transfer function is substantially insensitive to the distance between the Phase Object and the objective optics over a greater range of object distances than was provided by the unaltered optical transfer function, and post processing the image captured by the detector by reversing the alteration of the optical transfer function accomplished by the mask.
[0042] A Wavefront Coding optical element can also be used on the illumination side of the system in order to extend the depth of field of the projected illumination due to the duality of projection and imaging. This projected illumination would be broader than without Wavefront Coding, but the optical density as a function of distance from the object would be less sensitive with Wavefront Coding than without. Without Wavefront Coding on the illumination side of the system, the object can technically be imaged clearly but is not illuminated sufficiently. See “Principal of Equivalence between Scanning and Conventional Optical Imaging Systems”, Dorian Kermisch, J. Opt. Soc. Am., Vol. 67, no. 10, pp. 1357-1360 (1977).
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] FIG. 1 (prior art) shows a standard prior art Interference Contrast imaging system.
[0044] FIG. 2 (prior art) shows ray paths and polarization states for the Interference Contrast imaging system of FIG. 1 .
[0045] FIG. 3 shows a Wavefront Coding Interference Contrast imaging system including Wavefront Coding optics and post processing in accordance with the present invention.
[0046] FIG. 4 describes in detail the Object Modifying Function and Object Imaging Function of the Wavefront Coding Interference Contrast system.
[0047] FIG. 5 shows the aperture transmittance function and the corresponding ambiguity function for the Object Imaging Function of the prior art system of FIG. 1 .
[0048] FIG. 6 shows the Wavefront Coded cubic phase function and the corresponding ambiguity function for the Object Imaging Function of FIG. 3 .
[0049] FIG. 7 shows another Wavefront Coded phase function and the corresponding ambiguity function for the Object Imaging Function of FIG. 3 .
[0050] FIG. 8 shows misfocus MTFs for the prior art Object Imaging Function of FIG. 1 and the Object Imaging Functions for the Wavefront Coded Interference Contrast systems described in FIGS. 3, 6 and 7 .
[0051] FIG. 9 shows single plane of focus images of human cervical cells with darkly stained nuclei imaged with a 40X, NA=1.3 objective with a conventional Interference Contrast system and with a Wavefront Coded Interference Contrast imaging system similar to that of FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0052] Wavefront Coding can be used with conventional objectives, polarizers and beam splitters in Interference Contrast systems, as shown in FIG. 3 , to achieve an increased depth of field in an optical and digital imaging system. This can be explained by considering the Object Modifying Functions of conventional Interference Contrast systems separately from the Object Imaging Functions, as shown in FIG. 4 . By considering these two functions separately, modification of depth of field can be explained in terms of the Object Imaging Function. Extending the depth of field of the Object Imaging Functions of Interference Contrast systems is shown in FIGS. 5-8 . FIG. 9 shows real-world images of human cervical cells taken with a system having only Interference Contrast and a comparison to an image from a Wavefront Coding Interference Contrast system.
[0053] FIG. 3 shows a Wavefront Coded Interference Contrast imaging system 300 including Wavefront Coding and post processing in accordance with the present invention. Similar reference numbers are used in FIG. 3 as are used in FIG. 1 , since the systems are very similar, except for the addition of Wavefront Coding element 324 and post processing 326 . The general Interference Contrast imaging system of FIG. 1 is modified with a special purpose generalized aspheric optical element 324 and image processing 326 of the detected image to form the final image. Unlike the conventional Interference Contrast system, the final image in combined system 300 is not directly available at detector 322 . In fact, no sharp and clear image of any kind is available in system 300 , except after image processing 326 . Image processing 326 of the detected image is required to remove the spatial Wavefront Coding effects (other than the extended depth of field).
[0054] Wavefront Coding optical element 324 can be fabricated as a separate component as shown in FIG. 3 , or can be combined with objective lens 312 , tube lens 318 , beam splitter 314 , analyzer 316 , or any combination of these. Any material or configuration that can impart a range of spatial phase shifts to a wavefront can be used to construct Wavefront Coding element 324 . For example, optical glass or plastic of varying thickness and/or index of refraction can be used. Holograms and mirrors can also be used as the material for the Wavefront Coding element. In order to dynamically adjust the amount of depth of field, or to essentially change the Wavefront Coding element 324 for different objectives or desired depth of field, spatial light modulators or dynamically adjustable micro mirrors or similar can also be used.
[0055] Wavefront Coding optical element 324 can also be used on the illumination side of system 300 in order to extend the depth of field of the projected illumination due to the duality of projection and imaging. This projected illumination would be broader than without Wavefront Coding, but the optical density as a function of distance from the object would be less sensitive with Wavefront Coding than without.
[0056] The components that distinguish the Wavefront Coding Interference Contrast system of FIG. 3 from a general or brightfield imaging system is polarizer 304 , beam splitter 306 , beam splitter 314 , analyzer 316 , and Wavefront Coding element 324 and image processing 326 . The polarizer, analyzer, and beam splitters essentially use phase to modify the imaging characteristics of the object 310 . The Wavefront Coding element 324 and image processing 326 are used to increase the depth of field or remove misfocus effects in images of the modified object as shown below. By grouping the components of system 300 by their function, the Wavefront Coding Interference Contrast imaging system can be understood.
[0057] The locations of polarizer, analyzer, and beam splitters of FIG. 3 have been chosen because of historical reasons. These are the traditional locations for these components in prior art systems relative to the illumination and imaging optics. The same relative locations are seen in FIG. 1 . The beam splitter 314 and analyzer 316 can theoretically be moved relative to objective lens 312 without changing the imaging behavior of the system. See system 400 A of FIG. 4 . Numbering conventions of FIG. 4 are also similar to those of FIGS. 1 and 3 due to the similar nature of the components. In system 400 A the beam splitter and analyzer have been moved before the objective lens but after the object. The wavefront after analyzer 416 is polarized as is the wavefront after analyzers 216 and 316 in FIGS. 2 and 3 respectively. Since, ideally, lenses do not change the polarization, shear, or bias of the wavefront this new location is technically equivalent to that of FIG. 3 . Consider the ray paths of FIG. 2 . Notice that the ray paths between beam splitters 206 and 214 are parallel. Moving beam splitter 206 before objective lens 212 theoretically will not change the parallel nature-of the ray paths. Analyzer 216 can also move before objective lens 212 with no adverse affects. The component arrangement of system 400 A allows the “Object Modifying Functions” to be clearly distinguished from the Object Imaging Functions.
[0058] In order to further characterize the Object Modifying Function of system 400 A consider system 400 B of FIG. 4 . In this system a new phase and amplitude object 410 B replaces the original object 410 A of system 400 A. This new object is selected so that its three dimensional structure produces an identical wavefront from illumination source 402 , polarizer 404 , and illumination optics 408 as from object 410 A when combined with the polarizer, analyzer, and beam splitters of system 400 A. It is well known that a phase and amplitude object can be theoretically constructed so that any given linearly polarized wavefront can be reproduced from linearly polarized illumination. Although it is theoretically possible to produce such a new object 410 B, in practice it might be difficult. Since a new object 410 B can be substituted for the combination of original object 410 A, beam splitter 406 , beam splitter 414 , and analyzer 416 , it is clear that the polarizers and analyzers act to modify the imaging characteristics of the object. Notice that the right sides of systems 400 A and 400 B are identical. The right sides of these systems are the Object Imaging Function. The Object Imaging Function images the object that has had its imaging characteristics modified by the Object Modifying Function. With the Wavefront Coding optical element 424 and image processing 426 the Object Imaging Function can have a very large depth of field and be able to control focus-related aberrations.
[0059] If the Object Imaging Function of system 400 B has a large depth of field, then the New Object of 410 B can be imaged over a large depth. Likewise, when the Object Imaging Function of system 400 A has a large depth of field, object 410 A (as modified by the Object Modifying Function) can be imaged with a large depth of field. Since system 400 B produces identical images to system 400 A, and system 400 A produces identical images to system 300 , this also means that system 300 will image object 310 with a large depth of field. This large depth of field is also independent of the object or Object Modifying Functions as shown in FIG. 4 .
[0060] The Object Imaging Function can be made to have a large depth of field by use of a generalized aspheric optical element and signal processing of the detected images. Ambiguity function representations can be used to succinctly describe this large depth of field. Only the magnitude of the ambiguity functions in this and following figures are shown. Ambiguity functions are, in general, complex functions. One-dimensional systems are given for simplicity. Those skilled in the art of linear systems and ambiguity function analysis can quickly make extensions to two-dimensional systems. An ambiguity function representation of the optical system is a powerful tool that allows modulation transfer functions (“MTFs”) to be inspected for all values of misfocus at the same time. Essentially, the ambiguity function representation of a given optical system is similar to a polar plot of the MTF as a function of misfocus. The in-focus MTF is described by the trace along the horizontal v=0 axis of the ambiguity function. An MTF with normalized misfocus value of Ψ=(2 π/λ)W 20 , where W 20 is the traditional misfocus aberration coefficient and λ is the illumination center wavelength, is described in the ambiguity function along the radial line with slope equal to (Ψ/pi). For more information on ambiguity function properties and their use in Wavefront Coding see “Extended Depth of Field Through Wavefront Coding”, E. R. Dowski and W. T. Cathey, Applied Optics, vol. 34, no 11, pp.1859-1866, April, 1995, and references contained therein.
[0061] FIG. 5 gives an ambiguity function perspective on the Object Imaging Function of conventional Interference Contrast systems. The top plot of FIG. 5 shows the aperture transmittance function of an ideal conventional Interference Contrast system such as that shown in FIG. 1 . The bottom plot of FIG. 5 shows the associated ambiguity function associated with the Object Imaging Function for the prior art system of FIG. 1 .
[0062] Over the normalized aperture (in normalized coordinates extending from −1 to +1) the conventional system has a transmittance of 1, i.e., 100%. The phase variation (not shown) is equal to zero over this range. The corresponding ambiguity function has concentrations of optical power (shown as dark shades) very close to the horizontal v=0 axis. From the relationship between the ambiguity function and misfocused MTFs, we see that the conventional Interference Contrast Systems has a small depth of field because slight changes in misfocus lead to MTFs (represented by radial lines with non-zero slope in the ambiguity function) that intersect regions of small power.
[0063] FIG. 6 shows an example of a phase function for the Wavefront Coding optical element 324 and corresponding ambiguity function for an improved system of FIG. 3 . This phase function is rectangularly separable and can be mathematically described in two dimensions as:
Phase ( x,y )=12 [ x 3 +y 3 ]|x|≦ 1, | y|≦ 1.
[0064] Only one dimension of this phase function is shown in the upper plot of FIG. 6 . Increasing the peak-to-valley phase height (as can be done by increasing the constant 12 above), results in increasing depth of field. The transmittance of this system (not shown) is unity (i.e., 100%) over the entire aperture, as in the top plot of FIG. 5 .
[0065] The ambiguity function shown in FIG. 6 for this Wavefront Coded Interference Contrast system is seen to have optical power spread over a much larger region in the ambiguity domain than does the diffraction-limited system plotted in FIG. 5 . Broader regions of optical power in the ambiguity function translate to larger depth of field or depth of focus since the ambiguity function is essentially a radial plot of misfocused MTFs with the angular dimension pertaining to misfocus. Thus, this Wavefront Coded Interference Contrast system has a larger depth of field than the conventional Interference Contrast system.
[0066] There are an infinite number of different Wavefront Coding phase functions that can be used to extend the depth of field. Other more general rectangularly separable forms of the Wavefront Coding phase function are given by:
phase( x,y )=3 [ a i sign( x ) | x| b i +c i sign( y ) | y| d i ]
where the sum is over the index i,
sign( x )=−1 for x< 0, sign( x )=+1 for x≧ 0.
[0068] Rectangularly separable forms of Wavefront Coding allow fast processing. Other forms of Wavefront Coding complex phases are non-separable, and the sum of rectangularly separable forms. One non-separable form is defined as:
phase( r, θ)=3[ r a i cos( b i θ+φ i )]
where the sum is again over the index i.
[0070] FIG. 7 shows the Wavefront Coding phase function and the ambiguity function for a further improved system of FIG. 3 . The top plot of FIG. 7 shows the phase function from FIG. 6 (curve 701 ) and a further improved phase function (curve 702 ). The aperture transmittance function is the same as shown in FIG. 5 . The form of the new phase profile 702 , in radians, of this system is given by:
Phase profile ( x,y )=7[sign( x ) | x| 3 +sign( y ) |y| 3 +7[sign( x ) | x| 9.6 +sign( y ) | y| 9.6 ] where |x|≦1, |y|≦1.
[0072] The ambiguity function related to phase function 702 is shown in the bottom of FIG. 7 . This ambiguity function is seen to have more optical power uniformly spread about the horizontal v=0 axis when compared to either the Wavefront Coding Interference Contrast system plotted in FIG. 6 or the Conventional Interference Contrast system plotted in FIG. 5 . Thus, the Wavefront Coded Interference Contrast system of FIG. 7 will have a larger depth of field than the systems represented in FIGS. 6 or 5 .
[0073] FIG. 8 shows MTFs as a function of misfocus for the prior art Interference Contrast system, and the Wavefront Coded Interference Contrast systems of FIGS. 6 and 7 . The top plot of FIG. 8 shows the MTFs of the conventional Interference Contrast imaging system of FIG. 1 and FIG. 5 and the MTFs of the Wavefront Coded Interference Contrast system of FIG. 6 . The bottom plot shows the MTFs of the Interference Contrast imaging system of FIGS. 1 and 5 (again) and the MTFs from the Wavefront Coding Interference Contrast imaging system of FIG. 7 . These plots are the particular MTFs given in the respective ambiguity functions for the normalized misfocus values Ψ={0, 2, 4}. Notice that the MTFs for the conventional Interference Contrast system (top and bottom plots) vary appreciably with even this slight amount of misfocus. The image from the conventional system will thus change drastically due to misfocus effects for only small, misfocus values. This is expected from the narrow ambiguity function associated with the conventional system (shown in FIG. 5 ).
[0074] By comparison, the MTFs from the Wavefront Coded Interference Contrast imaging systems (top and bottom plots) show very little change with misfocus as predicted by the ambiguity functions associated with these systems (shown in FIGS. 6 and 7 ). If the MTFs of the system do not change, the resulting MTFs (and hence also point spread functions, or “PSFs”) can be corrected over a large range of misfocus with a single post processing step 326 . A single post processing step is not possible with conventional systems, which change appreciably with misfocus since the MTFs and PSFs of the system change with misfocus to values that are unknown and often impossible in practice to calculate. The MTFs from the Wavefront Coded Interference Contrast system in the top plot are seen to have lower values for most spatial frequencies than the MTFs from the Wavefront Coded Interference Contrast system of the bottom plot. This is expected from the ambiguity functions of FIGS. 6 and 7 respectively. The two-term phase function (curve 702 ) yields MTFs that not only have similarly small change with misfocus but also give a higher MTF than those associated with the simple cubic phase function (curve 701 ). This higher MTF results in a more compact PSF (not shown) as well as less signal-to-noise ratio penalties needed for the image processing 326 .
[0075] In general, the Wavefront Coded objective mask phase function that yields the smallest MTF variation with misfocus and also the highest MTF is preferred in practice. There are an infinite number of different objective mask phase functions that are good candidates for control of the MTF. The characteristics that practical Wavefront Coding mask phase functions have can generally be described as being relatively flat near the center of the aperture with increasing and decreasing phase near the respective edges of the aperture. The central portion of the phase function controls the majority of the light rays that would not need modification if the objective were stopped down, for the depth of field extension required. For increasing amounts of depth of field, the size of the central phase region that can be flat decreases. Increasing the flatness of the central region of the rays leads to larger MTFs as seen in comparison to the phase functions and MTFs of FIGS. 6, 7 , and 8 . The edge portion of the phase function controls the light rays that increase the light gathering and spatial resolution of the full aperture system but, without modification, cause the largest amount of misfocus effects in traditional systems. It is these edge rays that should be modified most by the objective mask phase function because they control the variation of the MTFs and PSFs with misfocus. The actual modification made to these edge rays should position them so that the sampled PSFs and MTFs are maximally insensitive to changes in misfocus.
[0076] Notice that the MTFs from the Wavefront Coding Interference Contrast system of FIG. 8 (upper and lower plots) essentially do not change with misfocus but also do not have the same shape as that of the in-focus MTF (Ψ=0) of the conventional Interference Contrast system. In the spatial domain, the Wavefront Coding Interference Contrast systems form images with a specialized blur where the blur is insensitive to the amount of misfocus. The Image Processing function 326 is used to remove-this blur. The Image Processing function can be designed so that after processing the MTFs and PSFs of the combined Wavefront Coding Interference Contrast system, over a range of misfocus, closely match that of the in-focus Interference Contrast system. The Image Processing function can also produce an effective MTF that has more or less contrast than the in-focus Interference Contrast system, depending on the needs of the particular application.
[0077] In essence, the image processing function restores the Wavefront Coding Interference Contrast transfer functions to those expected from the conventional Interference Contrast system with no misfocus. Since all the Wavefront Coding MTFs are essentially identical, after image processing 326 all MTFs (and hence all PSFs) will be nearly identical for each value of misfocus.
[0078] More specifically, the image processing function, say F, implements a transformation on the blurred Wavefront Coding Interference Contrast system, say H WFC , so that after processing the system has an ideal response H ideal . Typically the ideal response is chosen as the in-focus response from the general Interference Contrast system. If implemented as a linear filter, then F is (in the spatial frequency domain) equivalent to:
F ( w ) H WFC ( W )= H ideal ( w )
where w denotes a spatial frequency variable. If the ideal response is fixed then changing the Wavefront Coding Interference Contrast system H WFC changes the image processing function F. The use of a different Wavefront Coding phase function can cause a change in the image processing function. In practice, it is common to be able to measure slight changes in the Wavefront Coding Interference Contrast system as a function of misfocus. In this case the image processing F is chosen as a best fit between the measured data and the desired system after processing.
[0079] There are many linear and non-linear prior art techniques for removing known and unknown blur in images. Computationally effective techniques include rectangularly separable or multi-rank linear filtering. Rectangularly separable linear filtering involves a two step process where the set of one-dimensional columns are filtered with a one-dimensional column filter and an intermediate image is formed. Filtering the set of one-dimensional rows of this intermediate image with a one-dimensional row filter produces the final image. Multi-rank filtering is essentially the parallel combination of more than one rectangularly separable filtering operation. A rank N digital filter kernel can be implemented with rectangularly separable filtering by using N rectangularly separable filters in parallel.
[0080] The form of the processing (rectangularly separable, multi-rank, 2D kernel, etc.) is matched to that of the Wavefront Coding element. Rectangularly separable filtering requires a rectangularly separable Wavefront Coding element. The element described in FIG. 6 is rectangularly separable.
[0081] FIG. 9 contains real world images of human cervical cells made with a conventional Interference Contrast system and a Wavefront Coded Interference Contrast System. The image on the left of FIG. 9 was made with a conventional 40X, NA=1.3 Interference Contrast system similar to that of FIG. 1 . The image on the right of FIG. 9 was made with a Wavefront Coding Interference Contrast system similar to that of FIG. 3 . The Wavefront Coding Element 324 was a rectangularly separable cubic phase element. Rectangularly separable digital filtering was used for image processing 326 .
[0082] Notice the phase shading visible in the conventional image. This phase shading results in a 3D-like appearance of the object. This is a characteristic of Interference Contrast imaging. Notice also that many parts of the Interference Contrast images are blurred due to misfocus effects. The bottom part of the left image, for example, is particularly badly blurred by misfocus. The Wavefront Coded Interference Contrast image is also seen to have similar phase shading and 3D-like appearance as the conventional image. The depth of field visible in the image is much larger in the Wavefront Coded image than in the conventional image. Many parts of the cells that could not be resolved in the conventional image are clearly visible in the Wavefront Coding image. Thus, the Wavefront Coding Interference Contrast image produces both the characteristic Interference Contrast phase object imaging characteristics and a large depth of field.
[0083] As shown in FIGS. 6 through 9 , the Wavefront Coding Interference Contrast imaging system removes the effects of misfocus on the final images. The Wavefront Coding Interference Contrast system will control the misfocus effects independent of the source of the misfocus. When increasing the depth of field, as shown in FIG. 9 , the misfocus effects are produced from the object or parts of the object not being in the best focus position relative to the imaging optics. Misfocus effects can also be produced by non-ideal optics, temperature changes, mechanical positioning errors, and similar causes that lead to optical aberrations. Controlling misfocus effects besides those related to object positioning allows inexpensive systems to be produced that image with a high quality. For example, if the objective lens 312 of FIG. 3 has a noticeable amount of chromatic aberration then misfocus effects will be produced as a function of illumination wavelength. The Wavefront Coding Interference Contrast system can control the chromatic aberration misfocus effects while also extending the depth of field. Other optical aberrations that can similarly be controlled include petzval curvature, astigmatism, spherical aberration, temperature related misfocus, and fabrication or alignment related misfocus. Many other aberrations in prior art systems may be improved in Wavefront Coding Interference Contrast systems | An interference contrast imaging system images phase objects. The system includes an illumination source, illumination optics, polarizing optics for splitting the illumination into orthogonal polarizations and for recombining the polarizations, objective optics that form an image at a detector, a wavefront coding element and a post processor for processing the image by removing a phase shift imparted by the wavefront coding element. The wavefront coding element has an aperture, is between the phase object and the detector, and provides an altered optical transfer function of the imaging system by imparting the phase shift to the illumination transmitted through the wavefront coding element. The altered optical transfer function is insensitive to an object distance between the phase object and the objective optics over a greater range of object distances than would be provided by an optical transfer function of a corresponding interference contrast imaging system without the wavefront coding element. | 6 |
The present invention relates generally to electrostatic discharge (ESD) protection circuits, and more particularly to ESD protection circuits and structures that support input/output (I/O) standards such as the low voltage differential signaling (LVDS) standard and the on-chip termination (OCT) standard.
BACKGROUND
The LVDS and OCT standards are widely accepted among I/O standards that support high data rates in electronic and opto-electronic systems. LVDS has been used in applications that require low voltage, high speed, low noise, low power, and lower electromagnetic interference. In addition, LVDS supports the high data throughput necessary for high-speed interfaces such as those in backplane circuits. LVDS compliant I/O interfaces have several advantages compared to other known interface levels, including differential signals with good noise margin and compatibility over different supply voltage levels, etc. But LVDS interfaces need precise line termination resistors.
OCT compliant I/O interfaces include series, parallel, and/or differential terminations on chip, where OCT resisters are placed adjacent to I/O buffers to eliminate stub effect and to help prevent reflections. OCT provides the benefit of high signal integrity, simpler board design, lower cost systems and good system reliability. OCT also allows system designers to use fewer resistors, fewer board traces, smaller board space, and fewer excess components on printed circuit boards.
A common LVDS compliant I/O interface includes an I/O buffer and stacked transistors coupled in parallel with the I/O buffer. Since the same type of devices are typically used to form the stacked transistors and the I/O buffer, the LVDS stacked transistors are stressed at the same time as the I/O buffer during an ESD event.
OCT compliant I/O interfaces also have ESD issues because OCT transistors are often connected to the I/O pads. These OCT transistors are typically far narrower than the ones used in the I/O buffers. As such, the OCT transistors have even lower ESD threshold voltages than the transistors in the I/O buffers.
Therefore, there is a need for improved ESD protection for the LVDS and OCT compliant interface circuits.
SUMMARY
The present invention provides electrostatic discharge protection for I/O circuits that support the low voltage differential signaling (LVDS) and on-chip termination (OCT) standards. At least one additional transistor is connected across an I/O transistor. In the case of LVDS, a pair of stacked transistors is used in which the distance between the source/drain region and a well tap is substantially greater for the transistor connected to the I/O pad. A PMOS transistor and an NMOS transistor may also be connected in series between a first node such as a power supply node and the I/O pad. An OCT circuit is also disclosed in which the spacing between the source/drain region and a well tap in the OCT transistor is smaller than that in the I/O transistor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a circuit schematic of a LVDS I/O circuit according to one embodiment of the present invention.
FIG. 1B is a circuit schematic of a LVDS I/O circuit according to an alternative embodiment of the present invention.
FIG. 2 is a layout drawing of two LVDS transistors in the LVDS I/O circuit.
FIG. 3 is a circuit schematic of an OCT I/O circuit according to one embodiment of the present invention.
FIG. 4 is a layout drawing of I/O pull-down and OCT transistors in the OCT I/O circuit.
FIG. 5 is a circuit schematic of a parallel OCT I/O circuit according to one embodiment of the present invention.
FIG. 6 is a layout drawing of parallel OCT transistors in the parallel OCT I/O circuit.
FIG. 7 is a circuit schematic of a differential OCT I/O circuit according to one embodiment of the present invention.
FIGS. 8A and 8B are layout drawings of stacked PMOS and NMOS transistors, respectively, in the OCT I/O circuit.
DETAILED DESCRIPTION
FIG. 1 illustrates an LVDS-compliant interface circuit 100 A, according to one embodiment of the present invention. The LVDS interface circuit 100 can be part of an I/O interface of an integrated circuit chip. As shown in FIG. 1 , the LVDS interface circuit 100 A includes an I/O pad 110 and an I/O buffer having a pull-down transistor 120 and a pull-up transistor 130 serially connected with each other between an I/O power line VCCIO and an I/O ground line VSSIO. The LVDS interface circuit 100 further includes stacked transistors 140 and 150 connected in parallel with the pull-down transistor 120 of the I/O buffer. The gates of transistors 120 , 130 , 140 , and 150 are connected to other parts of the integrated circuit via inverters 121 , 131 , 141 , and 151 , respectively. The substrates of the stacked transistors 140 and 150 are tied to VSS, which is the ground line for a core circuit in the integrated circuit. A decoupling device 105 is used to separate the core ground VSS from the I/O ground VSSIO.
To allow the I/O buffer to function as an ESD protection device, a parasitic bipolar transistor associated with the stacked transistors should not turn on in the event of an ESD pulse on the I/O pad 110 . The turn on of the parasitic bipolar transistor can be prevented by placing the stacked transistors 140 and 150 , which are usually NMOS (N-type metal-oxide-semiconductor) transistors in different P-wells separated by a trench isolation. This way, a very high voltage (about 15V) is required between the I/O pad 110 and the I/O ground VSSIO to simultaneously turn on the parasitic bipolar transistors associated with the stacked transistors 140 and 150 .
Although the parasitic bipolar transistors are unlikely to turn on, the drain-substrate diode of 140 can breakdown when there is a positive ESD potential between the I/O pad 110 and the I/O ground VSS. The breakdown current associated with the drain-substrate diode should be limited to protect the drain-substrate diode from ESD damage. This can be achieved by using the layout of 140 and 150 shown in FIG. 2 .
FIG. 2 illustrates how the stacked transistors are laid out on a semiconductor substrate according to one embodiment of the present invention. As shown in FIG. 2 , transistor 140 and 150 are formed in different P-wells 210 and 230 , respectively. P-wells 210 and 230 are separated by an isolation region such as a trench isolation (not shown). Transistor 140 includes at least one gate 240 and at least one pair of N-type source/drain diffusion regions 242 on two opposite sides of gate 240 . Transistor 150 includes at least one gate 250 and at least one pair of N-type source/drain diffusion regions 252 on opposite sides of gate 250 . To prevent the parasitic bipolar transistors associated with the stacked transistors 140 and 150 from turning on in the event of an ESD pulse on the I/O pad 110 , the N-type source/drain diffusion regions 242 of transistor 140 are separated from the N-type source/drain diffusion regions 252 of transistor 150 by their location in two different P-wells separated by the trench isolation.
Transistor 140 further includes a P-well tap region 215 , and transistor 150 also includes a P-well tap region 235 . To prevent the drain-substrate junction(s) from being damaged by an ESD pulse on the I/O pad 110 , the P-well tap region 215 for transistor 140 is placed far from the source/drain diffusion region(s) 242 . In particular, this placement should be such that the minimum distance between tap region 215 and source/drain diffusion regions 242 is about twice the minimum separation required by the design rules associated with the technology used to fabricate the integrated circuit. This raises the substrate resistance between the N+ diffusion regions 242 and the P-well tap 215 and thus limits any breakdown current from the drain-substrate junction(s) in transistor 140 . To further increase the substrate resistance and reduce the breakdown current, transistor 140 may also include a P-well block region 220 between the N-type source/drain diffusion regions 242 and the P-well tap region 215 . The presence of the P-well block region makes it possible to reduce the spacing between the N-type source/drain diffusion regions 242 and the P-well tap region 215 and thus makes the layout of 140 more compact.
In one embodiment of the present invention, the N-type source drain diffusion regions 242 and 252 are doped with N+ or N++ dopant concentrations, the P-well tap regions 215 and 235 are doped with P+ or P++ dopant concentrations, and the P-well block region 220 is undoped silicon substrate that has high resistivity.
Transistor 150 may be laid out the same as transistor 140 , but such a layout for transistor 150 is usually not necessary because transistor 150 is not connected directly to the I/O pad 110 and because the decoupling device 105 provides a low-voltage clamp between VSS and VSSIO. In particular, a P-well block region is not necessary. In practice, transistor 150 can be made small by requiring the distance d 2 between the N+ diffusions 252 and the P-well tap 235 to be equal to or not much larger than the minimum separation required by the design rules associated with the technology used to fabricate the integrated circuits. Thus, the distance d 1 between the N+ diffusions 242 and the P-well tap 215 in transistor 140 will be significantly greater than d 2 .
To minimize any stress voltage at the drain-substrate junction(s) in transistor 140 , it is preferred that decoupling device 105 of FIG. 1A be eliminated and the substrate near transistor 140 be tied to the I/O ground line VSSIO, as in an I/O interface circuit 100 B shown in FIG. 1B . In other respects, the components of I/O interface circuit 100 B are the same as those of I/O interface circuit 100 A and have been numbered the same. In the absence of decoupling device 105 , the parasitic bipolar transistor in the I/O pull-down transistor 120 can be turned on at a lower voltage when a positive ESD voltage is across the I/O pad and the core ground VSS because the additional voltage drop across the decoupling device 105 is not present.
Furthermore, transistor 140 should be placed as far away from the I/O pad 110 as other design considerations allow so that the interconnect resistance and inductance between the I/O pad 110 and transistor 140 can be used to help limit the ESD current.
FIG. 3 illustrates a series OCT interface circuit 300 according to another embodiment of the present invention. The series OCT interface circuit 300 can be part of an I/O interface of an integrated circuit chip. As shown in FIG. 3 , the series OCT interface circuit 300 includes an I/O pad 310 and an I/O buffer having a pull-down transistor 320 and a pull-up transistor 330 serially connected with each other between an I/O power line VCCIO and an I/O ground line VSSIO. The series OCT interface circuit 300 further includes a narrow OCT transistor 340 connected in parallel with the pull-down transistor 320 of the I/O buffer. The gates of transistors 320 , 330 , and 340 are connected to other parts of the integrated circuit via inverters 321 , 331 , and 341 , respectively. To protect the series OCT transistor 340 during an ESD event, the parasitic bipolar transistors associated with the I/O buffer should have a lower triggering voltage than the series OCT transistor 340 . This can be achieved by laying out the I/O pull-down transistor 320 and the series OCT transistor 340 according to the layout drawing in FIG. 4 .
As shown in FIG. 4 , the series OCT transistor 340 includes at least one gate 440 and at least one pair of N-type source/drain diffusion regions 442 that are formed in a P-well or P-substrate 450 . The series OCT transistor 340 may further include a P-well tap region 460 surrounding the N-type source/drain diffusion region 442 . In one embodiment of the present invention, the N-type source drain diffusion regions 442 are doped with N+ or N++ dopant concentrations, while the P-well tap region 460 is doped with a P+ or P++ dopant concentration. The spacing between the P-well tap region 460 and the source/drain diffusion regions 442 for the series OCT transistor 340 is small, and in many cases should be as small as the minimum spacing between N+ (or N++) and P+ (or P++) regions allowable by design rules associated with the fabrication technology for making the integrated circuit chip.
The I/O pull-down transistor 320 includes at least one gate 420 and at least one pair of N-type source/drain diffusion regions 422 that are formed in an isolated P-well 425 , which is surrounded by a deep N-well 430 . The I/O pull-down transistor 320 further includes a P-well tap region 435 between the N-type source/drain diffusion regions 422 and the deep N-well 430 . In one embodiment of the present invention, the N-type source drain diffusion regions 422 in the I/O pull-down transistor 320 are doped with N+ or N++ dopant concentrations, the P-well tap region 435 is doped with a P+ or P++ dopant concentration, and the deep N-well region 430 is doped with a N-well dopant concentration, which is much lower than the dopant concentrations in the N-type source/drain regions 422 . The P-well tap region 435 is laid out such that it is spaced far from the N-type source/drain regions 422 and, in particular, is at least twice the minimum spacing required by the design rules associated with the technology used to fabricate the integrated circuit. In many cases, the spacing between the P-well tap region 435 and the N-type source/drain regions 422 should be as wide as space in the integrated circuit chip allows. Thus, the spacing d 4 between the P-well tap region 435 and the N-type source/drain regions 422 for the I/O pull-down transistor 320 should be significantly wider than the spacing d 3 between the P-well tap region 460 and the N-type source/drain regions 442 in the series OCT transistor 340 .
The wider spacing between the P-well tap region 435 and the N-type source/drain regions 422 enables the I/O pull-down transistor 320 to be triggered by a lower substrate current generated by the breakdown of the junction between the drain diffusion 422 and the isolated P-well 425 . By isolating the P-well 425 for the I/O pull-down transistor 320 using the deep N-well 430 , the P-well 425 can also charge up faster to forward-bias the source/P-well junction, which forward-biasing is required for triggering the parasitic bipolar transistor in the event of a ESD pulse on the I/O pad 310 . This, when combined with the lower triggering current, provides a lower trigger voltage for the I/O pull-down transistor 320 . If possible, the series OCT transistor 340 should be placed far away from the I/O pad so that the higher resistance and inductance associated with the interconnect between the series OCT transistor 340 and the I/O pad 310 can be used to limit the ESD current through the series OCT transistor 340 .
FIG. 5 illustrates a parallel OCT interface circuit 500 according to another embodiment of the present invention. The parallel OCT interface circuit 500 can be part of an I/O interface of an integrated circuit chip. As shown in FIG. 5 , the parallel OCT interface circuit includes an I/O pad 510 and an I/O buffer having a pull-down transistor 520 and a pull-up transistor 530 serially connected with each other between an I/O power line VCCIO and an I/O ground line VSSIO. The parallel OCT interface circuit 500 further includes two cascaded NMOS transistors 540 and 550 connected between the I/O pad 510 and the I/O ground VSSIO, and one pair of PMOS and NMOS transistors 560 and 570 , respectively, that are connected serially with each other between the I/O power line VCCIO and the I/O pad 510 . The gates of transistors 520 , 530 , 540 , 550 , 560 , and 570 are connected to other parts of the integrated circuit via inverters 521 , 531 , 541 , 551 , 561 and 571 , respectively.
ESD protection for the two cascaded NMOS transistors 540 and 550 and the pair of PMOS and NMOS transistors 560 and 570 can be achieved by laying out transistors 540 and 550 similar to LVDS transistors 140 and 150 , respectively, as shown in FIG. 2 , and by laying out transistors 560 and 570 according to the layout drawing shown in FIG. 6 .
As shown in FIG. 6 , the PMOS transistor 560 includes at least one gate 610 and at least one pair of P-type source/drain diffusion regions 612 that are formed in a N-well 620 . PMOS transistor 560 further includes a N-well tap region 630 that is spaced from the P-type source/drain diffusion regions 611 by a distance d 6 . On the other hand, the NMOS transistor 570 includes at least one gate 640 and at least one pair of N-type source/drain diffusion regions 642 that are formed in a P-well 650 . The NMOS transistor 570 may further include a P-well tap region 660 that is spaced from the N-type source/drain diffusion regions 642 by a distance d 7 .
In one embodiment of the present invention, the P-type source/drain diffusion regions 612 and the N-type source drain diffusion regions 642 are doped with P+ (or P++) and N+ (or N++) dopant concentrations, respectively; the N-well 620 and P-well 650 are doped with a N-well dopant concentration and a P-well dopant concentration lower than the dopant concentrations of the source/drain diffusion regions in these wells; and the N-well tap region 630 and the P-well tap region 660 are doped with a N+ (or N++) and P+ (or P++) dopant concentrations, respectively.
In one embodiment of the present invention, the distance d 7 between the P-well tap region 660 and the N-type source/drain diffusion regions 642 is made large to protect the drain-substrate diode associated with the transistor, which is connected directly to the I/O pad 510 . In particular, d 6 should be at least about twice the minimum spacing allowed by the design rules associated with the technology for fabricating the integrated circuit. On the other hand, since the substrate of transistor 560 is connected to VCCIO, the associated drain-substrate diode has no potential drop during an ESD event. Thus, the layout for transistor 560 can be made compact, requiring only that the distance d 6 between the P+ diffusion regions 612 and the N-well tap 630 to be equal to or not much larger than the minimum spacing between a P+ diffusion region and a N-well tap allowed by the design rules associated with the technology for fabricating the integrated circuit. Alternatively, if the substrate of transistor 560 is not tied to VCCIO, the spacing d 6 must be made larger to protect the drain-substrate diode in transistor 560 .
FIG. 7 illustrates a differential OCT interface circuit 700 according to one embodiment of the present invention. The differential OCT interface circuit 700 can be part of an I/O interface of an integrated circuit chip. As shown in FIG. 7 , the differential OCT interface circuit 700 includes two I/O pads 711 and 712 and two I/O buffers coupled to the respective ones of the I/O pads. The I/O buffer coupled to the I/O pad 711 includes a pull-down transistor 721 and a pull-up transistor 731 that are serially connected with each other between an I/O power line VCCIO and an I/O ground line VSSIO. Likewise, the I/O buffer coupled to the I/O pad 712 includes a pull-down transistor 722 and a pull-up transistor 732 that are serially connected with each other between the I/O power line VCCIO and the I/O ground line VSSIO. The gates of transistors 721 , 731 , 722 and 732 are connected to other parts of the integrated circuit through inverters 725 , 735 , 726 and 736 , respectively.
The differential OCT interface circuit 700 further includes a pair of stacked PMOS transistors 740 and 750 connected between the I/O pads 711 and 712 , and a pair of stacked NMOS transistors 760 and 770 connected between the two I/O pads 711 and 712 . The gates of transistors 740 , 750 , 760 and 770 are connected to other parts of the integrated circuit through inverters 741 , 751 , 761 and 771 , respectively. When the I/O pads 711 and 712 are used as input pads, signals from the I/O pads 711 and 712 are fed to a differential amplifier 780 . In one embodiment of the present invention, the substrates of transistors 740 and 750 are connected to input pads 711 and 712 , respectively, or to VCCIO if VCCIO has a higher voltage than the input voltages on the input pads. The substrates of transistors 760 and 770 are tied to the core ground VSS. ESD protection for the differential OCT interface circuit 700 can be achieved with a layout similar to transistor 560 in FIG. 6 for the PMOS transistors 740 and 750 but with a larger d 6 and a layout similar to transistor 570 in FIG. 6 for the NMOS transistors 760 and 770 .
In particular, as shown in FIG. 8A , PMOS transistor 740 or 750 includes at least one gate 810 and at least one pair of P-type source/drain diffusion regions 812 that are formed in N-well 820 . PMOS transistor 740 or 750 further includes an N-well tap region 830 that is spaced from the P-type source/drain diffusion regions by a distance d 8 , which is substantially larger than the minimum distance between a P-type source/drain diffusion region and a N-well tap region allowed by the design rules for the technology used to fabricate the integrated circuit. As shown in FIG. 8B , the NMOS transistor 760 or 770 includes at least one gate 840 and at least one pair of N-type source/drain diffusion regions 842 that are formed in P-well 850 . NMOS transistor 760 or 770 further includes a P-well tap region 860 that is spaced from the N-type source/drain diffusion regions by a distance d 10 , which is substantially larger than the minimum distance between a N-type source/drain diffusion region and a P-well tap region allowed by in the design rules for the technology used to fabricate the integrated circuit. By substantially larger is meant at least twice the minimum spacing allowed between the diffusion regions and the tap region by the design rules associated with the technology for fabricating the integrated circuit.
As will be apparent to those skilled in the art, numerous embodiments of the invention may be devised within the spirit and scope of the claims. | Circuits are described that provide electrostatic discharge protection for I/O circuits that support the low voltage differential signaling (LVDS) and on-chip termination (OCT) standards. At least one additional transistor is connected across an I/O transistor. In the case of LVDS, a pair of stacked transistors is used in which the distance between the source/drain region and a well tap is considerably greater for the transistor connected to the I/O pad. A PMOS transistor and an NMOS transistor may also be connected in series between a first node such as a power supply node and the I/O pad. An OCT circuit is also disclosed in which the spacing between the source/drain region and a well tap in the OCT transistor is smaller than that in the I/O transistor. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority from German Patent Application No. 10 2004 055 310.6 dated Nov. 16, 2004, the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The invention relates to an apparatus at a spinning room machine, especially a flat card, roller card, cleaner or the like, for drawing a clothing onto a roller.
In the textile industry sector, especially in the carding sector, it is necessary for the clothings of the working apparatus, for example of a cylinder, to be replaced from time to time. The clothings are parts that are subject to wear.
In a known apparatus (DD 240 569 A1), there is provided a drive system for flat cards or roller cards having at least one speed-controlled three-phase current motor, with which there is associated a speed control device. The speed of rotation of each three-phase current motor can be controlled using a frequency converter, which can in turn be controlled, via a D/A converter, by a micro-computer. Stored in the RAM memory thereof are speed control program blocks for all-steel clothing drawing-on procedures. In the all-steel clothing drawing-on procedure, one of the speed-controlled three-phase current motors is arranged to be in mechanical drive connection with the licker-in, cylinder and/or doffer. In that arrangement, in accordance with the stored program and the speed program blocks stored in the RAM, the CPU in question, timed by means of a CTC, controls the output of actuation pulses to the frequency converters and, consequently, the speeds of the three-phase current motors, in accordance with operational requirements, during drawing-on of the all-steel clothing. The speed control program blocks for all-steel clothing drawing-on procedures serve exclusively for the purpose of controlling the speed of the three-phase current motors. Ascertaining data during the drawing-on of the clothings is dealt with under operator control. A disadvantage, amongst others, in the case of that apparatus is that checking of the drawing-on procedure is not removable as can be necessary, for example, in the event of changes in loading.
It is an aim of the invention, in contrast, to provide an apparatus of the kind mentioned at the beginning that avoids or mitigates the mentioned disadvantages, that especially is simple in terms of equipment, and that makes possible checking of the drawing-on procedure and/or of the measurement data.
SUMMARY OF THE INVENTION
The invention provides a drawing-on apparatus for drawing a clothing onto a roller of a spinning room machine having an electronic control and regulation device, the drawing-on apparatus comprising a measuring device for measurement of data relating to drawing-on, wherein the measuring device is arranged to co-operate, in use, with the control and regulation device of the spinning room machine for permitting passage of data between the drawing-on device and the control and regulation device.
In accordance with the invention, provision can be made for the control and regulation device of the spinning room machine to be used for checking—especially by visualisation and documentation—of the current drawing-on procedure. As a result, correcting the drawing-on procedure is advantageously made possible, especially by means of the operating and display device of the spinning room machine. The ascertained data of the drawing-on procedure are available at all times where they are needed, that is to say directly at the spinning room machine, and without additional devices. When a clothing management means is installed in the control system of the carding machine, the ascertained data represent an optimum addition for the user insofar as a large number of individual drawing-on procedures are registered. The fact that the internal computer of the spinning room machine is used constitutes a very substantial simplification in terms of equipment and, in addition, advantageously allows linkage with internal data of the machine.
A display device for showing the data is advantageously connected to the electronic control and regulation device. Advantageously, the electronic control and regulation device comprises a storage device for storing the ascertained data. Advantageously, the device ascertaining the drawing-on data can communicate directly with the machine in which the roller is being clothed. Advantageously, the data ascertained during the drawing-on procedure are transferred to the spinning room machine, for example a flat card, are stored therein and can be shown at any time on the operating and display device of the machine. Advantageously, the control system of the machine in which the roller is being clothed assumes functions—especially those of operation and display—of the device ascertaining the drawing-on data. Advantageously, the communication between the machine and the device ascertaining the drawing-on data is effected by cable-based means. Advantageously, the communication between the machine and the device ascertaining the drawing-on data is effected without cables. Advantageously, the communication is effected by radio. Advantageously the communication is effected using infra-red light. Advantageously, the communication is effected using visible light. Advantageously, the interface in the spinning room machine, for example a flat card, is used for the communication with other apparatus and/or devices of the spinning room machine and/or spinning room systems. Advantageously, the communication with other apparatus and/or devices is effected by cable-based means. Advantageously, the communication with other apparatus and/or devices is effected without cables. Advantageously, the drawing-on device comprises a roller drive unit having a drive motor. Advantageously, the drawing-on device comprises a braking device acting on the clothing for producing winding-on pretensioning in the region of the clothing between the roller and braking device. Advantageously, the electronic control and regulation device comprises a microcomputer. Advantageously, the measurement device communicates with the electronic control and regulation device. Advantageously, the display device for showing (visualising) the data is connected to the electronic control and regulation device. Advantageously, a visual display device is provided. Advantageously, the storage device for storage of the data is connected to the electronic control and regulation device. Advantageously, a playback device for showing the data is connected to the electronic control and regulation device. Advantageously, the measurement device ascertaining the drawing-on data communicates directly with the spinning machine in which the roller is being clothed. Advantageously, the data ascertained during the drawing-on procedure are transferred to the electronic control and regulation device, are stored therein and can be re-shown on the operating and display device of the spinning room machine. Advantageously, the control system of the machine in which the roller is being clothed assumes functions of the measurement device ascertaining the drawing-on data. Advantageously, the functions comprise operation and/or display. Advantageously, the communication between the spinning room machine and the measurement device ascertaining the drawing-on data is effected without cables (without wires). Advantageously, during the drawing-on procedure, the electronic control and regulation device assumes the display and operating functions and/or the current supply to the measurement device ascertaining the drawing-on data. Advantageously, the interface in the spinning room machine is also used for communication with further devices, for example machines, systems or the like and/or networks of the spinning room. Advantageously, the data ascertained during drawing-on are arranged to be compared and/or linked with machine-relevant data of the spinning room machine. Advantageously, the data include one or more of: the drawing-on force; the drawing-on speed; the temperature of the braking elements; the length of clothing drawn on; the braking force.
Advantageously, the drawing-on procedure can be logged. Advantageously, the data and/or measurement log can be printed out. Advantageously, the drawing-on tension is recorded. Advantageously, any stretching that may be present is recorded. Advantageously, the braking device comprises a braking force sensor. Advantageously, the braking device comprises a speed sensor. Advantageously, the roller drive unit is integrated into the control and regulation circuit of the control and/or regulation unit, and the roller drive unit is arranged to be controlled and/or regulated for automatic matching to the predetermined winding-on tensioning. Advantageously, the roller is the cylinder of a flat card. Advantageously, the roller is the doffer of a flat card. Advantageously, the display and/or storage device is integrated into the electronic machine control and regulation device. Advantageously, the operating device of the spinning room machine is used for operation of the display and/or playback device. Advantageously, the display device of the spinning room machine is used. Advantageously, before, during and after drawing-on, the user receives instructions, messages, information and the like by way of the display device. Advantageously, for the clothing process, for the drive motor in question, a set of parameters optimising the function of the motor is loaded into the corresponding drive control system. Advantageously, the braking device is integrated into the control and/or regulation device, by means of which the braking action can be automatically matched to the winding-on pretensioning. Advantageously, with the spinning room machine there is associated an operating and display device which has a visual display unit and/or a touch-screen and/or a keyboard.
The invention also provides an apparatus at a spinning room machine, especially a flat card, roller card, cleaner or the like, for drawing a clothing onto a roller using a drawing-on device, the spinning room machine having an electronic control and regulation device, wherein an ascertaining device for the measurement of data ascertained during drawing-on is associated with the drawing-on device, and the ascertaining device co-operates with the electronic control and regulation device of the spinning room machine, the ascertaining device and the control and regulation device being capable of exchanging data unidirectionally and/or bidirectionally.
BRIEF DESCRIPTION OF THE DRAWINGS
Certain illustrative embodiments of the invention will be described hereinafter in greater detail with reference to the accompanying drawings, in which:
FIG. 1 is a diagrammatic side view of a flat card for use with an apparatus according to the invention;
FIG. 2 is a diagrammatic side view of a first arrangement of winding-on and winding-off apparatus;
FIG. 3 shows a block circuit diagram comprising sensors, a transfer device for measurement data, an electronic machine control and regulation device and an operating and display device, wherein the data ascertained during drawing-on are transferred unidirectionally and by wire-based means;
FIG. 4 shows a block circuit diagram which corresponds in many respects to FIG. 3 , but wherein the data ascertained during drawing-on are transferred unidirectionally and without wires;
FIG. 5 shows a block circuit diagram for an apparatus according to the invention, wherein the machine control and regulation device during the drawing-on procedure assumes the display and/or operating functions and/or the current supply to the unit ascertaining the drawing-on data;
FIG. 6 shows a measurement log for the dependence, in each case on time, of the drawing-on force (a), drawing-on speed (b), total meters (c) and temperature (d) in use of one apparatus according to the invention;
FIG. 7 a shows a speed-controlled drive motor for the doffer during production by the doffer of the flat card according to FIG. 1 ; and
FIG. 7 b shows a second arrangement of a winding-on and winding-off apparatus comprising the speed-controlled drive motor for the doffer according to FIG. 7 a during clothing of the cylinder.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
With reference to FIG. 1 , a flat card, for example a TC 03 (trademark) flat card made by Trutzschler GmbH & Co. KG of Monchengladbach, Germany, has a feed roller 1 , feed table 2 , lickers-in 3 a , 3 b , 3 c , cylinder 4 , doffer 5 , stripper roller 6 , nip rollers 7 , 8 , web-guiding element 10 , draw-off rollers 11 , 12 , revolving card top 13 having card-top-deflecting rollers 13 a , 13 b and card top bars 14 , can 15 and can coiler 16 . Curved arrows denote the directions of rotation of the rollers. Reference letter M denotes the centre (axis) of the cylinder 4 . Reference numeral 4 a denotes the clothing and reference numeral 4 b denotes the direction of rotation of the cylinder 4 . Reference letter C denotes the direction of rotation of the revolving card top 13 at the carding location and reference letter B denotes the direction in which the card top bars 14 are moved on the reverse side. Reference numeral 17 denotes a cleaning roller for the stripper roller 6 and reference numeral 18 denotes a card feeder.
The drawing-on apparatus shown in FIG. 2 substantially comprises a holding station 20 for a supply bobbin 21 , on which a carding clothing 22 in the form of sawtooth wire is flatly wound, and also a braking device 23 and a roller 4 . The roller 4 is driven in the clockwise direction 4 b by means of a motor 24 and a transmission device 25 . The motor 24 has a control and regulation device 26 , by which the speed of the roller 4 and the direction of rotation can be controlled. The braking device 23 comprises a control and regulation device 27 , which brings about a particular braking action. The control and regulation device 26 and the control and regulation device 27 are in operative connection with one another. In a further arrangement, they may also be used as a unit for controlling both the braking device 23 and the motor 24 . The carding clothing 22 is wound off from the supply bobbin 21 , which is arranged on a mounting block 28 , and is then passed through the braking device 23 and wound onto the outer circumference of the roller 4 . Following the winding-on procedure, the carding clothing 22 then extends in a helical configuration on the outer circumference of the roller 4 . The braking device 23 , in co-operation with the roller 4 and, in this instance, particularly by means of the roller drive (the motor 24 ), is intended to provide pretensioning in the region 29 of the carding clothing 22 . This pretensioning ensures that the carding clothing 22 is uniformly and lastingly wound-on or drawn-on.
The embodiment of FIG. 3 , there is provided an ascertaining and registering device 30 for the data ascertained during drawing-on of the clothing 22 , to which device there are connected a sensor 31 for the drawing-on force, a sensor 32 for the drawing-on speed, a sensor 33 for total meters (length) and a sensor 34 for temperature. In the case of the embodying example according to FIG. 3 (and the example shown in FIG. 4 ), the ascertaining and registering device 30 comprises a display device 30 a . Connected to the ascertaining or registering device 30 is a transmitter 35 for wire-based data transfer. Also provided is an electronic control and regulation device 26 , for example a TMS 2 device made by Trützschler GmbH & Co. KG, to which a receiver 36 for wire-based data transmission is connected. The transmitter 35 and the receiver 36 are connected to one another by a unidirectional cable 37 . The arrow (cable 37 ) indicates the transfer direction. The electronic control and regulation device 26 also comprises a data memory 38 for storage of the data ascertained during drawing-on. Connected to the electronic control and regulation device 26 , by way of a unidirectional cable 40 , is an operating and display device 39 .
The embodiment of FIG. 4 corresponds substantially to that of FIG. 3 , although wireless data transmission is carried out between the ascertaining and registering device 30 and the electronic control and regulation device 26 . For the purpose, a transmitter 41 is connected to the ascertaining and registering device 30 and a receiver 42 is connected to the control and regulation device 26 , in each case for wireless data transfer.
In the embodiment of FIG. 5 , wire-based data transfer is provided between the control and regulation device 26 , the ascertaining and registering device 30 and the operating and display device 39 , the control and regulation device 26 being connected to the ascertaining and registering device 30 and to the operating and display device 35 , in each case, by a bidirectional cable 43 and 44 , respectively, allowing data exchange in two directions. The data exchange directions are indicated by the double-headed arrows (see cables 43 , 44 ). Instead of a bidirectional cable 43 and 44 , there can also be provided, in each case, two unidirectional cables (not shown), in which the data are transferred in different and opposite directions. The arrangement according to FIG. 5 is especially suitable when the control and regulation device 26 of, for example, the carding machine assumes certain functions or tasks of the drawing-on device, for example the current supply to the drawing-on device.
Indicated on the display devices 30 a and 39 a shown in FIGS. 3 to 5 are, by way of example, a drawing-on force of 5 dN, a drawing-on speed of 44 m/min and a temperature of 32.5° C.
FIG. 6 shows a measurement log wherein, as data ascertained during drawing-on, there are shown the drawing-on force in dN (a), the drawing-on speed in m/min (b), the total meters in km (c) and the temperature in ° C. (d), in each case over time t. Alternate embodiments of the invention may display the total meters in m. Besides being shown on the visual display unit 39 a , it is possible to output the measurement log, for example by means of a printer (not shown) or the like, which is connected to the electronic control and regulation device 26 .
In accordance with FIGS. 7 a , 7 b , the speed-controlled motor 24 is associated with the doffer 5 . During production by the carding machine, the motor 24 drives the doffer 5 by way of the belt 45 (see FIG. 7 a ). The belt 45 loops around the belt pulleys 46 and 47 . During clothing of the cylinder 4 , the motor 24 drives the cylinder 4 by means of another belt 48 (see FIG. 7 b ). The belt 48 loops around the belt pulleys 46 and 49 .
By that means, a motor already present in the machine and equipped with speed control is used for driving the rollers during the clothing process at the customer's premises. That motor can be a motor which is in any case present for the production region of the roller ( 4 or 5 ) in question. However, it is also possible, in accordance with FIGS. 7 a , 7 b , for, for example, the doffer motor 24 , which is provided as standard with highly accurate speed control, to be used for clothing of the cylinder 4 . For that purpose it is merely necessary to remove the drive belts between the doffer motor 24 and the doffer 5 and between the cylinder motor 50 and the cylinder 4 and to fit a belt 48 or the like between the doffer motor 24 and the cylinder 4 ( FIG. 7 b ). The machine is so constructed mechanically that a transmission of such a kind is possible and corresponding belt pulleys of the correct size and kind are already present. By that means it is possible, very simply, rapidly and with only minimal outlay, to produce the drive for clothing of the rollers.
Although the foregoing invention has been described in detail by way of illustration and example for purposes of understanding, it will be obvious that changes and modifications may be practised within the scope of the appended claims. | In an apparatus at a spinning room machine, especially a flat card, roller card, cleaner or the like, for drawing a clothing onto a roller using a drawing-on device, the spinning room machine has an electronic control and regulation device. In order to provide an apparatus that is simple in terms of equipment and that makes possible checking of the drawing-on procedure and/or of the measurement data, a measurement device for registering data ascertained during drawing-on is associated with the drawing-on device, and the measurement device co-operates with the electronic control and regulation device of the spinning room machine for permitting passage of data between the drawing-on device and the control and regulation device. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and an apparatus for winding metal wires on a coiling structure (which is hereinafter referred to as "a spool"), and more particularly to a metal winding method and apparatus whereby, if the end portion of the metal wire wound on the spool springs back, the last group of coils near the wire end are prevented from becoming entangled with each other so as to facilitate drawing-out of the wire.
2. Description of the Prior Art
In the following description, the term "coil radius" signifies the expansion in a radial direction of the coil or the radius of the coil when the restraining force is released from the wire, and the word "coil pitch" means the distance between adjacent coils of the wire in the direction of the pitch when the coils are released from the restraining force.
Every type of metal wire wound on the spool is strained to have a certain radius. In the case of welding wire on the market, the wire is strained to have a certain coil radius and wound on the spool with its end fixed to the spool flange. This is accomplished to control the degree of the spring back action of the wire and to stabilize the feeding of the wire into a curved conduit tube. When this wire is to be unwound and used, the wire end is taken off the spool flange or is released from restraint by cutting the wire at the flange and then the wire end is conducted into a draw-out device. During this process, however, the smooth drawing-out of the wire is often blocked due to the spring-back action of the wire itself.
Wire materials such as welding wires are strained during the winding process to obtain a certain coil radius, but at the same time the coil pitch is adjusted to almost zero to ensure smooth feeding of the wire, for example, into the conduit tube. As long as the wire end is secured to the spool flange, the wire does not become loose. But if the wire end slips from a grip when it is being released from the flange, about 10 coils near the wire end spring back due to their own elastic force, with the result that they become entangled. This tendency is prominent in a reeled wire that has a smaller coil pitch. In the welding wire whose coil pitch is almost zero, several coils at the end of the wire gather and become entwined in one knot. This makes it difficult to draw out the wire end and if the wire end is drawn out with the coils entangled, the coils are squeezed so that the resistance against the drawing out of wire increases, thus causing the wire feeding to become unstable or in the worst case blocking the feeding. In the course of novelty search, the following U.S. Patents were located.
U.S. Pat. No. 4,019,359 to Smith, 3,587,274 to Rotter, 3,581,389 to Mori, 2,997,076 to McVoy, Jr., 2,739,763 to Silfverling et al, 2,265,246 to Ott and 1,258,092 to Clark.
U.S. Pat. No. 2,739,763 to Silfverlin et al discloses an apparatus for coiling cold rolled strips in which it is desired that the final turns of the strip be bent to such a curvature that the coil does not unwind to any appreciable extent. The strip is bent by a plurality of bending rolls mounted upon movable arms. The cylinder may be actuated to move the roller closer to rollers near the end of the strip so that the last few turns of the strip will have a smaller diameter and the strip will coil tightly about the coiler. Silfverlin et al patent therefore discloses the general idea of providing the last few turns of a coil strip with a diameter, or round habit, from the remainder of the strip for a specific purpose. Furthermore, Silfverlin et al suggests, on lines 43-46 of the column 2, that the tensioning of the strip will not lessen the amount of prebending or circular habit which is imparted upon a metal strip. This is contrary to the teaching of the present invention which discloses that the tensioning, or straining, of the strip will decrease the amount of prebending, thereby providing a larger diameter round habit.
U.S. Pat. No. 2,265,246 to Ott discloses a metal coil and a method for forming the same in which the last turn of the strip is given a lesser diameter by being progressively curled on a curling dye as it is wound on a core. The lesser diameter end portion of the coil is then allowed to curl adjacent the remainder of the coil. Ott discloses that the purpose of curling the end portion of the strip is to prevent a straight strip end which would become entangled with the remainder of the coil or with other coils prior to unwinding.
U.S. Pat. No. 4,019,359 to Smith discloses a method and apparatus for hot rolling metal strip. In Smith, the metal strip is prebent or given a round habit by a set of three bending rollers prior to being wound upon a coil. Furthermore, Smith discloses, at lines 60 and 61 of column 4, that the required degree of curl, or the required round habit, decreases as the amount of strip is fed onto the coil. Smith therefore generally suggests progressively increasing the diameter of the round habit of the strip as one approaches the end of the strip. However, the suggestion in Smith is for a gradual, progressive increase in the diameter of the round habit of the strip along the entire length of the strip while, in the present invention, only the last turn or the last few turns are given the larger diameter round habit. Furthermore, the round habit in Smith is not provided by means which strain the last few turns but rather is provided by traditional bending rollers.
The remainder of the cited references generally show prebending or tensioning means for metal wires or strips which are to be coiled, however, they are not believed to be as pertinent as the above references.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a method and an apparatus of winding metal wires around a reel structure which enables manufactured stocks of wound wires to easily utilized without the danger of entaglement. The above and the other objects can be achieved by the novel features of the invention which is hereinafter described with reference to the reference numerals of the attached drawings in the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
Various other objects, features and attendant advantages of the present invention will be more fully appreciated as the same becomes better understood by the following detailed description when considered in connection with the accompanying drawings in which like reference characters designate like or corresponding parts throughout the several views, and wherein:
FIG. 1 is an explanatory drawing showing the condition in which the wire wound up in the conventional method rests when it springs back.
FIG. 2 is an explanatory drawing showing one aspect of the present invention.
FIG. 3 is an explanatory drawing showing the condition in which the wire rolled up in a method according to the invention, rests when it springs back.
FIG. 4 is an explanatory drawing showing the condition in which the wire also rolled up in a method according to the invention, rests when it springs back.
FIG. 5 is an explanatory drawing showing the condition in which the wire rolled up in another method according to the invention, rests when it springs back.
FIG. 6 is an explanatory drawing showing the condition in which the wire rolled up in still another method according to the invention, rests when it springs back.
FIG. 7 is a side view showing an apparatus according to the invention, which includes various aspects of constructions, and
FIG. 8 is a plan view of the apparatus according to the invention as shown in FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Welding electrode wires are wound on spools by, for example, the method which is shown in U.S. Pat. Nos. 3,994,058 and 4,019,543 to Kobe Steel Limited. Applicants have conducted various kinds of examinations to see if it is possible to keep the end of the wire from being entwined with other coils when the reeled wire on the spool springs back so that smooth feeding of wire is ensured. As a result, it has been found that this objective can readily be achieved by imparting strain to the end of the wire in the last process of winding, and this finding leads to the present invention.
Namely, the point of the wire winding method according to the present invention lies in the fact that, during the wire winding process, the last coil of wire (or the last group of coils) is strained in such a way that it tends to relax further away from the spool than a coil (or a group of coils wound immediately before the last coil (or the last group of coils).
The construction and effect of the present invention will now be described with reference to the accompanying drawings that show embodiments of this invention. It should be noted that the present invention is not to be restricted by the following description and can be embodied in other forms with modifications without departing from its spirit or essential characteristics.
FIG. 1 is an explanatory drawing showing the condition in which the welding wire 2 wound on the spool 1 in a conventional way rests when it springs back by releasing the wire end. When the wire 2 is wound in such a manner as to make the coil pitch as small as possible and its end is released from a flange 8 of the spool 1, about ten turns of winding spring back and become intertwined with each other forming a knot 4. This makes it difficult to draw out the end of the wire 2 and when the wire end is drawn out with coils entangled the aforementioned problem arises.
FIGS. 2 through 6 are explanatory drawings showing the wires 2 in the spring-back condition which have been strained in the winding process according to the invention. In either case, the end of the wire 2 is not intertwined with other windings so that it can readily be drawn out.
Referring to FIG. 2, a last coil 2a at the end of the wire 2 (or several coils including the last one: the same shall apply hereinafter) is strained so that it tends to expand circumferentially and have a larger diameter than a coil 2b (or several coils including the coil 2b: the same shall apply hereinafter) would immediately before the last coil 2a. Thus, the last coil 2a, when released, springs back and rests further away from the spool 1 than the coil 2b of the wire so that entanglement of the last coil 2a with other coils can be prevented, ensuring smooth drawing out of wire.
In FIG. 3, the last coil 2a at the wire end is strained in such a manner as to cause it to expand and rest in a position which is deviated away from the spool 1 in a direction of the coil pitch when it springs back.
In FIG. 4, the last coil 2a at the wire end is strained to a different degree in such a way as to cause it not only to expand circumferentially but to also project from the spool 1 in the direction of the coil pitch when it springs back.
As in the case with FIG. 2, the last coil 2a at the wire end in FIGS. 3 and 4 is prevented from becoming entangled with other coils, which enables smooth drawing-out of the wire.
FIG. 5 shows another example in accordance with the present invention in which the last coil 2a at the wire end is rolled up with the same coil radius as other coils while the second last coil 2b is strained so that it tends to contract. In this case, since the coil 2b tends to contract, it squeezes the spool with its contractile force and prevents other coils from springing back. This means that only the last coil 2a springs back away from the spool 1 and thus can easily be picked up and drawn out.
FIG. 6 is a modification of the example shown in FIG. 5 in which the last coil 2a at the wire end is strained so that it coils radius tends to become larger, as in the case with FIGS. 2 and 4, and at the same time the second last coil 2b is strained so that its coil radius tends to become smaller.
While FIGS. 2 through 6 show examples where only the last one coil 2a at the end of the wire 2 is strained in such a way that it ends to expand away from the spool 1, the same effect can be obtained if the last two or three coils are strained in the same manner. In the examples of FIGS. 5 and 6 only the second last coil 2b is strained for squeezing the spool 1 but it is desirable to strain the last two or three coils in the same manner so as to make the spring-back preventing effect more reliable.
FIGS. 2 through 6 show only typical examples and any other form of strain can be applied to the coil (or group of coils), provided it projects further away from the spool than other remaining coils.
In the preceding examples, the spool is shown as having regularly wound coils for convenience sake but the same effect can be obtained if the wire is wound crosswise. The cross-winding is a modification of the regular winding. The entanglement among the last several turns of coil is caused when the spring back becomes prominent if the coils are irregularly wound. However, this invention also prevents the entanglement of irregularly wound coils and enables the wire to be easily drawn out.
The concrete method for straining the wire will now be described as follows.
FIGS. 7 and 8 are explanatory drawings showing an apparatus for straining the wire 2, FIG. 7 being a simplified side view and FIG. 8 being a simplified plan view. Reference numeral 5 denotes rectifying rollers, reference numeral 6 designates a roller for straining the wire into coils of normal radius and reference numeral 7 denotes a fixed roller. The wire 2 is led through these rollers and is wound round a rotating spool 8 which is moved up and down during the winding process. The rectifying rollers 5 are mounted on a stand 10 which is pivoted by a cylinder 9 or other means and a coil radius adjusting roller 11 is provided to the pivotable stand 10 on the side of the roller 6. When the adjusting roller 11 is held in a position indicated with a solid line in FIG. 7, this roller 11 does not act upon the wire 2, but when the stand 10 is rotated by actuating the cylinder 9 and the roller 11 is moved forward to a position indicated with an imaginery line in FIG. 7, the wire 2 is strained by the roller 11 so that it tends to reduce its coil radius. Thus, the coil radius of the wire can be controlled by adjusting the position of the roller 11 (i.e., the degree of rotation of the stand 10).
Reference numeral 12 denotes a coil pitch adjusting roller and reference numeral 13 a fixed roller, both of such rollers cooperating for controlling the coil pitch of the wire. As can be seen from the FIG. 8, the coil pitch adjusting roller 12 is so arranged that it can be moved towards and away from the wire 2 by an actuating mechanism such as a cylinder 14'. When the adjusting roller 12 is in a position indicated with a solid line in FIG. 8, the roller 12 does not strain the wire 2. But when the adjusting roller 12 is moved forward to a position indicated with an imaginary line in FIG. 8, the wire 2 is strained in the direction of the coil pitch. Thus, the coil pitch can be controlled by adjusting the position of the roller 12.
Further, provided behind the fixed roller 7 is an adjusting roller 15 for enlarging the coil radius of the wire 2. The roller 15 is so arranged that it can be moved towards and away from the wire 2 by means of an actuating mechanism such as a second cylinder 14. When it is moved toward a position indicated with an imaginary line in FIG. 7, the wire 2 is pressed from the back so that its coil radius becomes larger. Designated by reference numeral 16 in FIG. 7 is a cutter.
The following are the wire winding steps used in this apparatus. Until the wire end approaches, the adjusting rollers 11, 12 and 15 are kept in the positions indicated with solid lines in FIGS. 7 and 8 while the wire 2 is rolled up with the normal coil radius. Just before the wire runs out, these adjusting rollers are moved toward the wire 2 to strain the wire near its end so that the desired coil radius and/or coil pitch can easily be obtained.
It should be noted that FIGS. 7 and 8 illustrate only one example of embodiments according to this invention and that modification can be made without departing from the scope of the invention. For instance, the location of the coil radius adjusting rollers 11 and 15 and the coil pitch adjusting roller 12 can be changed from that described in the drawing, and it is possible to employ as the actuating mechanism for these rollers a rotating arm, a pantograph, a link, and a solenoid mechanism in addition to the cylinder. With these modifications the same effect and result can be obtained.
This invention can not only be embodied in equipment specially designed for this purpose but can also be achieved by providing the coil radius adjusting rollers 11, 12 and 15 to the existing wire winding apparatus, thus reducing the corresponding economical burden.
The present invention which is in general constituted and embodied as explained in the foregoing descriptions is summarized as follows. When the wire rolled up around the spool springs back, only the wire end projects away from the spool, rendering the drawing-out of the wire very easy and at the same time eliminating any possibility of the wire being drawn out with coils entangled. Therefore, there are no such problems such as the wire feeding being obstructed by increased resistance. Because of these characteristics, the invention provides a practical and convenient method of winding various metal wires including wires for automatic or semiautomatic welding.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise that as specifically described herein. | A method of winding a metal wire around a reel structure is disclosed in which the wire is wound about a roller to give the wire a round habit of preselected diameter, at least one of the last few coils of said wire being strained so as to increase the diameter of the round habit, and all of the wire being wound on a reel structure whereby the at least one coil having the larger diameter round habit is coiled about the reel structure in an expanded condition with respect to the remainder of the coils. An apparatus for performing this method is also disclosed. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is a Continuation of U.S. patent application Ser. No. 12/132,989, filed Jun. 4, 2008, the entire contents of which is incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] This invention was made with government support under Contract No. HQ0006-04-C-7092 between the Missile Defense Agency section of the U.S. Department of Defense and Williams-Pyro, Inc. The government has certain rights in the invention.
FIELD OF THE INVENTION
[0003] The present invention relates generally to light weight flexible cabling. More particularly, the present invention relates to providing a flat flexible micro-interconnect cable which provides high speed data transfer.
BACKGROUND OF THE INVENTION
[0004] Conventional wiring harnesses are composed of bundles of mechanically bound individual wires which are attached to the vehicle structure with mechanical tie-downs, and finished on each end with complex and expensive connectors. FIG. 1 shows a conventional satellite wiring harness.
[0005] As shown in FIG. 1 , these conventional cables do not precisely conform to the surface structure on which or in which they are used.
[0006] Sophisticated spacecraft and air craft comprise a multitude of electronic systems which contribute to the volume and weight payload of the craft. The cables, interconnections between electronic components and systems, also contribute significantly to the weight and volume payload of aircraft, satellites, missiles and the like. Similar load constraints and electronic design demands exist in marine and unmanned vehicles.
[0007] For existing aerospace programs to succeed and for new systems to be successfully developed, small flexible cabling is desirable, and could even be necessary. In addition, for avionics based applications, in particular, cables must also be very reliable and meet applicable standards.
[0008] Conventional cabling is labor intensive with respect to engineering and manufacturing. Further, conventional cabling systems are difficult to install in a vehicle and require bulky support brackets and terminations.
[0009] In view of the conventional cabling characteristics and the demands on avionic systems in terms of reliability and minimal contribution to vehicle mass, it is easy to see that small, light, reliable cables are desired.
[0010] There are additional considerations for cables, that is ease of fabrication and ease of interfacing with connectors.
[0011] Applications other than aircraft, spacecraft, and missiles could also benefit from a reduction in the weight and volume of electronic system components while maintaining or even improving system reliability. For, example commercial aircraft now include various electronic services for passengers, even to the individual passenger level. This evolving service can contribute significantly to the weight of the aircraft. A flat flexible cable could, for example, be mounted within the walls of a structure, within a furnishing, or within the casing of a portable system.
[0012] USB is a serial bus standard to interface devices. The prevalence and variety of USB devices, which include human interface devices, has reached astronomic numbers. Consequently, small, flexible, reliable cabling which meets 2.0 USB standards will have a multitude of applications.
[0013] For satellite and other aerospace applications, in particular, yet another need may be a flat cable.
SUMMARY OF THE INVENTION
[0014] The present invention addresses some of the issues presented above by providing a working microscopically small cable, hereafter referred to as “a flexible high speed micro-cable” and method of making the same.
[0015] One aspect the present invention is the limited, microscopic thickness of the cable. One embodiment has a thickness of 350 μm.
[0016] A high speed USB 2.0 compatible cable, in accordance with the present invention is one step towards reducing or eliminating bulky black boxes and cables with a system that can be mounted on or within the structural wall of a vehicle.
[0017] Another aspect of the present invention is its positive contribution to payload mass fraction standards for electronics and cabling for aerospace applications and for other applications where light, reliable, USB connections are desired.
[0018] Another aspect of the present invention is that it provides USB 2.0 transmission capability in a microscopically small cable.
[0019] Another aspect of the present invention is that it provides high speed data transmission in a microscopically small flat cable, comprising parallel conductors in the absence of, for example, a twisted pair.
[0020] Another aspect of the present invention is that it meets USB 2.0 high speed electrical characteristics and USB 2.0 electrical requirements for USB micro-cables. (Universal Serial Bus Micro-USB Cables and Connectors Specification, Rev. 1.01, April 2007).
[0021] Another aspect of the present invention is that its cross section is small enough and its composition is flexible enough along its length that it can conform to bends or turns.
[0022] Another aspect of the present invention is that it employs conductors of only 120 μm diameter and yields a high speed functioning cable having for a cross section of less than 0.75 mm 2 .
[0023] Another aspect of the present invention is that it is light weight reducing bulk and mass in all applications.
[0024] Still another aspect of the present invention is the relative ease its fabrication, which favors ease of automated production and ease of accuracy and consistency in production.
[0025] Still another aspect of the present invention is its combination of ready made materials and ease of manufacturing, in accordance with an embodiment of the present invention, yields a relatively low cost cable.
[0026] Those skilled in the art will further appreciate the above-noted features and advantages of the invention together with other important aspects thereof upon reading the detailed description that follows in conjunction with the drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0027] For 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, wherein:
[0028] FIG. 1 shows a conventional satellite wiring harness;
[0029] FIGS. 2A-2B show cross sectional structures of fabricated microscopic high-speed flexible USB 2.0 cables with a total thickness of 350 um in FIG. 2A and an outer insulation layer in FIG. 2B ;
[0030] FIGS. 2C-2D show cross sectional structures of two exemplary embodiments of fabricated microscopic high-speed flexible USB 2.0 cables with an outer polyimide insulation layer;
[0031] FIGS. 3A-3B show exemplary embodiments of flexible high speed micro-cables with an outermost copper shield and an outermost insulation layer, respectively, in accordance with the present invention;
[0032] FIG. 4 shows the half power point measured in a transmission frequency test on a 25 cm long flat flexible high speed micro-cable made in accordance with an embodiment of the present invention;
[0033] FIG. 5 shows the measured characteristic impedance of a 25 cm long flat flexible high speed micro-cable made in accordance with an embodiment of the present invention; and
[0034] FIG. 6 is an image of a video signal received from a USB 2.0 digital camera through a flexible high speed micro-cable made in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The invention, as defined by the claims, may be better understood by reference to the following detailed description. The description is meant to be read with reference to the figures contained herein. This detailed description relates to examples of the claimed subject matter for illustrative purposes, and is in no way meant to limit the scope of the invention. The specific aspects and embodiments discussed herein are merely illustrative of ways to make and use the invention, and do not limit the scope of the invention.
[0036] FIG. 1 shows a digital image taken of a traditional wiring harness for a satellite 100 . The size and bulk of the conventional cabling 110 is readily apparent. These cables, interconnections between electronic components and systems, contribute significantly to the mass fraction of the satellite. Conventional cabling does not conform to the walls of the structure on which it is secured and its bulk prevents it from mounting flush with walls, contours, or edges 120 .
[0037] FIG. 2 a shows the structure of a fabricated flexible high speed micro-cable, in accordance with an exemplary embodiment of the present invention, with a total thickness of 350 μm 250 . The cable comprises 4 micro copper conductors having a 120 μm diameter 240 . The copper conductors are sandwiched between two layers of polyimide KAPTON® tape 232 , 234 (E.I. Dupont de Nemours and Company, Wilmington, Del., USA). A layer of 50 μm adhesive copper tape 210 , 212 is applied to the outside of each strip of polyimide KAPTON® tape 232 , 234 . The total width of this micro cable is 2 mm. A conventional USB 2.0 cable can have a 5.2 mm diameter including an outer mechanical protection layer, with a cross-sectional area of approximately 22 mm 2 . Referring to FIG. 3 a , a functional flat cable in accordance with the present invention can have a cross sectional area of less than 1 mm 2 , where 0.350 mm thickness and a 2.0 mm width yield a cross sectional area of 0.7 mm 2 . Depending on outer protection applied to the cable, such as standard heat shrink tube, the height of the cable may increase by about 1 mm, while the width can likewise increase. Referring to FIG. 3 b , an outer layer of heat shrink protection 310 increases the protected cable height to 1.5 mm and the width to 5 mm. The outer layer of heat shrink tube 310 surrounds the copper electromagnetic interference (EMI) shielding 212 , 210 , shown in FIG. 2 a . FIG. 2 b shows the heat shrink layers 263 , 265 added on the outer side of EMI shielding 210 , 212 . The flexible high speed USB 2.0 cable, in accordance with the present invention, reduces the bulk of the cable by a factor of 3, in turn, the mass is also greatly reduced.
[0038] FIG. 2 c shows the application of an outer insulation 255 , 257 along the length of an outside the first and second copper tapes, 212 , 210 . An outer layer of polyimide KAPTON® tape 255 , 257 is applied to each exposed side of the first and second copper tape 212 , 210 , wherein the outer layer of KAPTON® tape 255 , 257 has a greater width than a width of the copper tapes; and outer first and second edges of the outer layer polyimide KAPTON® tape, which are beyond the width of the copper tapes, are pressed together 258 . As in cable 200 of FIG. 2 a , the cable 252 in FIG. 2 b comprises 4 micro copper conductors having a 120 μm diameter 240 . The copper conductors are sandwiched between two layers of polyimide kapton tape 232 , 234 . A layer of 50 μm adhesive copper tape 210 , 212 is applied to the outside of each strip of polyimide KAPTON® tape 232 , 234 .
[0039] FIG. 2 d shows the application of an outer insulation 255 , 257 along the length of an outside the first and second copper tapes, 212 , 210 in another exemplary embodiment. A layer of copper tapes 212 , 210 has a greater width than a width of the polyimide tapes 232 , 234 , which surround the conductors 240 . Outer first and second edges of the copper tapes 212 , 210 , are pressed together. An outer layer of polyimide tape 255 , 257 is applied to each exposed side of the first and second copper tape 212 , 210 , wherein the outer layer of polyimide tape 255 , 257 has a greater width than a width of the copper tapes; and outer first and second edges of the outer layer polyimide tape, which are beyond the width of the copper tapes, are pressed together 258 . As in cable 200 of FIG. 2 a , the cable 275 in FIG. 2 b comprises 4 micro copper conductors having a 120 μm diameter 240 . The copper conductors are sandwiched between two layers of polyimide kapton tape 232 , 234 . A layer of 50 μm adhesive copper tape 210 , 212 is applied to the outside of each strip of polyimide KAPTON® tape 232 , 234 .
[0040] FIG. 3 a shows a flexible high speed micro-cable with the copper EMI shielding exposed 312 , while FIG. 3 b shows a flexible high speed micro-cable with an outer layer of heat shrink tube 310 covering the copper EMI shielding, both in accordance with an embodiment of the present invention. The flexible high speed micro-cable has four parallel conductors, as opposed to the inner twisted pair of a conventional USB cable. The result is a flat cable which can be applied in situations where minimal height is desired or needed for clearance purposes. The flatness of the cable is readily discernable in FIGS. 3 a and 3 b , relative to the USB adapters attached to each end of the respective cables.
[0041] FIG. 4 shows the signal strength measured in a 25 cm cable made in accordance with an embodiment of the present invention. The signal strength in decibels 420 is shown as a function of frequency in MHz 410 , on a linear scale, 10%/div. Signal strength for frequencies between 0.030 MHz and 3000 MHz were measured. As shown in FIG. 4 , the cable has a 3 dB bandwidth 430 near 2 GHz 434 . The signal attenuation of a cable in accordance with the present invention surpasses the USB standard for 3.2 dB of cable losses at a frequency of 200 MHz.
[0042] FIG. 5 shows a plot of the characteristic impedance measurements 510 of a 25 cm cable in accordance with the present invention as a function of frequency 520 . Measurements were made for frequencies between 30 kHz 522 and 3 GHz 524 . The characteristic impedance is near 50 ohms. The characteristic impedance 530 , as shown in FIG. 5 , is uniform over the length of the flat cable. Therefore, signal reflection due to impedance mismatch is minimized. As shown in FIG. 5 , the fabricated flat cable has an averaged characteristic impedance 510 of approximately 50Ω 530 , over a frequency range 520 of 0.030 MHz 522 to 2 GHz 524 . The measured impedance exhibits some fluctuation and deviation at frequencies above 2 GHz, this result may be due to non-uniformity in insulation and connector effects of the prototype. Further, performance of a production grade flexible high speed micro-cable, in accordance with the present invention, can be expected to perform even better.
[0043] A cable, such as that shown in FIG. 3 b with the performance of FIG. 5 provides high-speed data transfer. Performance of a flat cable, fabricated in accordance with the present invention, was evaluated by downloading data from a 512 MB USB 2.0 removable disk to a personal computer. All data was successfully downloaded between the removable disk to a personal computer at full USB 2.0 high speed. The structure of this flat cable is illustrated in FIG. 2 b , while FIG. 3 b shows the actual cable used in this performance test.
[0044] FIG. 6 shows an image of a video signal received from a USB 2.0 digital camera through a 2.0 USB cable, which was made in accordance with the present invention. The image shows that a micro cable made in accordance with the present invention can transmit video quality signals.
[0045] Conventional USB cables comprise a twisted pair data cable and have a 90Ω±15% impedance. The twisted pair, D+ and D−, reduce noise and cross-talk. Conventional USB cables use half-duplex differential signaling to combat the effects of electromagnetic noise on longer lines. The two lines usually operate together and are not separate simplex connections. Transmitted signal levels are 0.0 to 300 mV for low and +400 mV for high in high speed 2.0 USB mode. In high speed mode the cable wires have a termination of 45Ω to ground, or 90Ω differential to match the data cable impedance. A High-Speed 2.0 USB cable meets a data transfer rate, frequency, of 480 Mbit/s and a cable fabricated in accordance with the present invention exceeds this data transfer rate, with a 3 dB attenuation not until a frequency of nearly 2000 Megabits/s.
[0046] Mini USB and the micro USB connections have many advantages. The most obvious benefit to this new technology is its smaller size. As cell phones and PDAs become thinner and lighter, consumers are frequently finding the mini USB connector is simply too large for practical use. Micro USB connector and cables will allow manufacturers to push the limits of this trend towards sleeker design. A flexible high speed micro-cable, in accordance with the present invention, will find many applications in personal use products.
[0047] Flexible high speed micro-cables made in accordance with the present invention out perform conventional USB 2.0 cable specifications, as shown by FIG. 4 .
[0048] A cable fabricated in accordance with the present invention will be readily automated, lacking the need for steps such as dipping or curing.
[0049] Off the shelf 50 μm copper tape provides the desired effective EMI shielding, while polyimide kapton tape provides efficient insulation. micro-diameter copper wire combines with the aforementioned to provide a unique combination of materials that yield high speed data transfer, exceeding high speed USB 2.0 specifications.
[0050] Four conductors in parallel contribute to a flat profile, which is particularly suited for satellite and aerospace applications. The small flat flexible cable, in accordance with an embodiment of the present invention, make it ideal for applications requiring tight clearances, low weight, low volume, and conformity to other than flat contours. A cable in accordance with the present invention can positively contribute to the mass fraction payload of, for example, satellites.
[0051] The performance of a cable in accordance with the present invention provides high speed data transfer and video signal transmission capability.
[0052] While specific alternatives to steps of the invention have been described herein, additional alternatives not specifically disclosed but known in the art are intended to fall within the scope of the invention. Thus, it is understood that other applications of the present invention will be apparent to those skilled in the art upon reading the described embodiment and after consideration of the appended claims and drawing. | A flexible high speed micro-cable and method of making the same are described. The parallel conductors incorporated in the present cable contribute to the flat cross section of the cable, while the unique combination of materials yield a flexible cable with a low profile. The data transfer rate and transmission losses of a cable, as provided herein, exceed High Speed Universal Serial Bus (USB) 2.0 specifications and data transmission is achieved from USB devices. The lower volume and mass of the cable make it ideal for applications needing low mass payload, such as satellites. The flexible nature of the cable allow it to readily conform to a desired structure for mounting or routing. A flexible high speed micro-cable is fabricated from a unique combination of materials and fabrication can be readily automated. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 09/168,885 filed Oct. 9, 1998, now abandoned the entire disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to the production of polyclonal and monoclonal antibodies to specific sites of cyclosporine and/or cyclosporine metabolites, derivatives and analogues. The reactivity of these polyclonal and monoclonal antibodies makes them particularly useful for immunoassays for therapeutic drug monitoring (TDM). These immunoassays or TDM kits may include polyclonal or monoclonal antibodies to specific sites of cyclosporine (CSA) and/or metabolites, derivatives and analogues of cyclosporine. These kits may also include various combinations of polyclonal antibodies, polyclonal and monoclonal antibodies or a panel of monoclonal antibodies.
BACKGROUND OF THE INVENTION
Cyclosporine is an 11-amino acid cyclic peptide of fungal origin (isolated from the fungus Tolypocladium inflatum ) that contains two uncommon amino acids: (4R)-4-((E)-2butenyl)-4, N-dimethyl-1-threonine (Bmt) and I-alpha-aminobutyric acid (Abu), as well as several peptide bond N-methylated residues (residues 1, 3, 4, 6, 9, 10, and 11). The structure of cyclosporine is given in FIG. 1 .
Currently, the two immunosuppressive drugs administered most often to prevent organ rejection in transplant patients are cyclosporine (CSA) and tacrolimus (FK-506 or FK). Rapamycin (Rapa) is another known immunnosuppressant. Cyclosporine's primary target appears to be the helper T lymphocytes. Cyclosporine acts early in the process of T cell activation, it has secondary effects on other cell types that are normally activated by factors produced by the T cells. Cyclosporine inhibits the production of interleukin 2 (IL-2) by helper T cells, thereby blocking T cell activation and proliferation (amplification of immune response). It is effective both in the prevention and in the treatment of ongoing acute rejection. The current model for the mechanism of action of CSA suggests that, in the T cell cytoplasm, CSA binds to a specific binding protein called immunophilin. The CSA-immunophilin complex in turn binds to and blocks a phosphatase called calcineurin. The latter is required for the translocation of an activation factor (NF-ATc) from the cytosol to the nucleus, where it would normally bind to and activate enhancers/promoters of certain genes. In the presence of CSA, the cytosolic activation factor is unable to reach the nucleus, and the transcription of IL-2 (and other early activation factors) is strongly inhibited. As a result of this inhibition, T cells do not proliferate, secretion of gamma-interferon is inhibited, no MHC class II antigens are induced, and no further activation of the macrophages occurs.
Various side effects are associated with cyclosporine therapy, including nephrotoxicity, hypertension, hyperkalemia, hypomagnesemia and hyperuricemia. Neuro- or nephrotoxicity has been correlated with certain cyclosporine metabolites. A necessary requirement of cyclosporine drug monitoring assays is to measure the levels of parent cyclosporine drug and metabolite with immunosuppressive and toxic activity. There is a need for improved methods of monitoring levels of CSA and/or CSA metabolites and derivatives.
SUMMARY OF THE INVENTION
The current invention is drawn to methods for the preparation of immunogenic conjugates which elicit antibodies with specificity for cyclosporine related compounds. For the purposes of this application, the term cyclosporine related compound is meant to include any or all of the cyclosporine molecule itself and/or various cyclosporine metabolites and derivatives. Cyclosporine and cyclosporine metabolite conjugate immunogens are prepared and used for the immunization of a host animal to produce antibodies directed against specific regions of the cyclosporine or metabolite molecules. By determining the specific binding region of a particular antibody, immunoassays which are capable of distinguishing between the parent molecule, active metabolites, inactive metabolites and other cyclosporine derivatives/analogues are developed. The use of divinyl sulfone (DVS) as the linker arm molecule for forming cyclosporine/metabolite-protein conjugate immunogen is described.
In a first aspect, the invention provides antibodies which are capable of binding to a cyclosporine related compound. Such antibodies which recognize a specific region of said cyclosporine related compound or the CSA metabolites AM1or AM9 are preferred. Monoclonal antibodies are most preferred. Also provided are methods for producing, an antibody which is capable of recognizing a specific region of a cyclosporine related compound, said methods comprising: a) administering an immunogen comprising a cyclosporine related compound, a linker arm molecule and a protein carrier to an animal so as to effect a specific immunogenic response to the cyclosporine related compound; b) recovering an antibody to said cyclosporine related compound from said animal; and c) identifying the antibody binding region by comparing the reactivity of the antibody to a first cyclosporine related compound to the reactivity of the antibody to a second cyclosporine related compound. Such methods wherein said linker arm molecule is divinyl sulfone and where the cyclosporine related compound is linked to the carrier at amino acid residue 1 or 9 are preferred. The protein carrier may preferably be keyhole limpet hemocyanin or human serum albumin. Use of hybridoma cells to accomplish the above methods is also provided.
In another aspect, the invention provides immunoassay methods for measuring the level of a cyclosporine related compound in a mammal, comprising: a) incubating a biological sample from said mammal with an antibody which is capable of binding to a cyclosporine related compound; and b) measuring the binding of cyclosporine related compound to said antibody. Use of antibodies which recognize a specific region of said cyclosporine related compound or the CSA metabolites AM1 or AM9 in these assays is preferred. Use of monoclonal antibodies is most preferred: Immunoassay kits for measuring the level of a cyclosporine related compound in a biological sample, said kits comprising an antibody as described above are also provided. Also provided are assay methods for determining the amount of a particular cyclosporine related compound in a sample, comprising: a) contacting said sample with a first antibody according to claim 1 ; b) contacting said sample with a second antibody according to claim 1 ; and c) determining the amount of said particular cyclosporine related compound bound to said second antibody.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 [SEQ ID NO.:1] depicts the structure of cyclosporine A (CSA).
FIG. 2 [SEQ ID NO.:2-7] depicts the major metabolites of CSA and routes of its metabolism.
FIG. 3 shows the selectivity of monoclonal antibody AM19-9-5A6 for the CSA metabolite AM1.
FIG. 4 illustrates a monoclonal antibody selective for the AM9 metabolite.
FIG. 5 shows the selectivity of monoclonal antibody AM19-1-7E 12 for the AM1 and AM1c moieties.
FIG. 6 illustrates an example of monoclonal antibodies (MoAbs) with selectivity for the AM1 and AM9 metabolites.
FIG. 7 shows the selectivity of MoAb AM9-9-4F5 for CSA and AM9.
FIG. 8 illustrates a MoAb with greater selectivity for AM1, AM1c, AM9 and AM19 metabolites than for the parent CSA molecule.
FIG. 9 illustrates an MLR assay procedure.
DETAILED DESCRIPTION OF THE INVENTION
The following examples describe the best mode for carrying out the invention. The examples describe isolation of CSA metabolites, preparation of haptens, immunization of animals to ellicit antibody responses, characterization of antibody reactivity, production and selection of polyclonal and monoclonal antibodies to CSA and CSA metabolites or derivatives and assays using the antibodies provided by the present invention.
The following Examples are not intended to limit the scope of the invention in any manner.
EXAMPLE 1
Isolation and Characterization of Cyclosporine Metabolites
Cyclosporine is metabolized in the liver, small intestine and the kidney. The structures of various phase I and II metabolites have been identified by HPLC and mass spectrometry in the literature. The major metabolites of CSA are shown in FIG. 2 . Metabolic reactions include oxidation and cyclisation at amino acid #1 and hydroxylation and demethylation at various amino acid sites.
10 minutes at a low speed. Pour contents into a separatory funnel; discard lower aqueous layer, evaporating the upper ether layer to dryness.
2. Metabolite Isolation:
Add 1.0 mL of HPLC grade methanol to dried down extract, vortex for 30 seconds and centrifuge at 2800 rpm for 2 minutes. Transfer the supernatant to an autosampler vial and inject urine using the following chromatographic conditions:
Column
SPHERISORB ™ (silica-based
10 × 250 mm
spherical packing material
manufactured by Phase
Separations) S5 C8
Guard column
SPHERISORB ™ (silica-based
4.6 × 10 mm
spherical packing material
manufactured by Phase
Separations) S5 C8
Wavelength
214 nm
Run time
90 minutes
Column temperature
60° C.
W600 Gradient Table:
Time
Flow
H 2 O
ACN
MeOH
(min)
(mL)
%
%
%
0.00
4.00
41.0
39.0
20.0
55.00
4.00
41.0
39.0
20.0
55.01
4.00
30.0
50.0
20.0
65.00
4.00
30.0
50.0
20.0
65.01
4.50
5.0
0
95.0
85.00
4.50
5.0
0
95.0
85.01
4.50
41.0
39.0
20.0
89.80
4.50
41.0
39.0
20.0
89.90
4.00
41.0
39.0
20.0
Collect individual metabolites based on the following typical retention times:
Retention
time (min)
Modification
Metabolite species
14.090
hydroxylated on a.a. 1 and 9
AM19
16.118
hydroxylated on a.a. 1 and 9
AM1c9
cyclical on a.a. 1 side chain
22.065
demethylated on a.a. 4
AM4n9
hydroxylated on a.a. 9
32.252
hydroxylated on a.a. 1
AM1
33.852
hydroxylated on a.a. 9
AM9
35.929
hydroxylated on a.a. 1
AM1c
cyclical on a.a. 1 side chain
62.630
demethylated on a.a. 4
AM4n
67.584
NA
CSA
The following are examples of the amounts of various metabolites recovered from 20L urine lots.
Lot P (from
Lot N (from
Lot O (from
20 L urine)
19 L urine)
20 L urine)
Amount
% of
Amount
% of
Amount
% of
Metabolite
(μg)
Total
(μg)
Total
(μg)
Total
AM19
849
5.0
1053
7.7
719
3.9
AM1c9
401
2.4
489
3.6
230
0.12
AM4n9
1323
7.8
1071
7.8
786
4.2
AM1
5640
33.2
4998
36.5
6600
35.5
AM9
3624
21.3
2350
17.1
3852
20.7
AM1c
3814
22.5
2352
17.2
4766
25.6
AM4n
1332
7.8
1395
10.2
1643
8.8
Totals
16,983
13,708
18,596
3. Quantitative Analysis of Metabolites:
Reconstitute isolated metabolite in 1 mL MeOH. Take 25 μL of this mixture and add 25 μL CSG (20,000 ng/mL) and 300 μL mobile phase, vortex and inject 100 μL to the HPLC under the following conditions:
Column
SPHERISORB ™ (silica-based
4.6 × 250 mm
spherical packing material
manufactured by Phase
Separations) C8
Temperature
60° C.
Flow
1.0 mL/min
Wavelength
214 nm
Mobile phase
33% H 2 O/47% ACN/20% MeOH
4. Metabolite Concentration:
(Peak area metabolite÷Peak area internal standard)×0.5 μg×(1/0.025)× dilution factor=μg of Metabolite
Percent purity:
(conc. of metabolite peak μg/mL÷conc. of all peaks μg/mL)×100
5. Final Purification of CSA Metabolites:
The metabolites isolated in the first round of HPLC purification are not usually greater than 97% pure. Therefore, a second round of purification is required using a different HPLC column and mobile phase.
Inject reconstituted metabolites onto the HPLC using the following conditions:
Column
Symmetry Prep C18 7 μm
7.8 × 300 mm
Guard column
SPHERISORB ™ (silica-based
4.6 × 10 mm
spherical packing material
manufactured by Phase
Separations) S5 C8
Wavelength
214 nm
Column temperature
60° C.
A two solvent gradient, comprised of water and methanol, is utilized to purify the metabolites. The key to separation is the addition of methyl-tert-butyl-ether (MTBE) to the methanol portion of the mobile phase (use 70 mL MTBE per 500 mL methanol). The exact gradient utilized varies depending on the metabolite to be purified.
Example 2
Synthesis of CSA-Divinyl Sulfone and Conjugation to a Protein Carrier
1. Preparation of CSA-DVS Hapten:
Cyclosporine (30 mg, 25 mol, U.S. Pharmacopeia, Rockville, Md., Cat #15850-4 USP reference standard), vinyl sulfone (147 mg, 1.3 mmol) and benzyl triethylammonium chloride (11.4 mg, 50 μmol) were stirred in 6 mL dichloromethane and then 0.4 mL of 40% aqueous potassium hydroxide was added. The mixture was rapidly stirred for 1.5 hours, then acidified with 2M hydrochloric acid and diluted with dichloromethane. The organic phase was separated, washed with water, dried over magnesium sulfate and the solvent evaporated.
2. Analysis of CSA-DVS Hapten:
One (1) product with mass corresponding to CSA-DVS was identified by Liquid Chromatography-Electrospray Ionization Mass Spectrometry (LC/MS). The product was purified by HPLC (SPHERISORB™ (silica-based spherical packing material manufactured by Phase Separations) C-8 semi-prep column;80% methanol isocratic;4 mL/min;50° C.;214 nm). The result was 3.3 mg of pure CSA-DVS for which a 600 MHz proton nmr spectrum was obtained.
3. Preparation of CSA-DVS-protein Conjugates:
CSA-DVS (1.0 mg) was dissolved in 350 μL of dimethyl sulfoxide and slowly spiked into a rapidly stirred solution of keyhole limpet hemocyanin (KLH) (1.6 mg) in 1.2 mL of phosphate buffer (pH 7.6). The mixture was stirred at room temperature for 24 hours. This material was then dialyzed overnight against phosphate buffered saline (PBS). The concentration of protein was determined by the Lowry protein assay, the coupling of CSA to the protein was confirmed by gel electrophoresis and western blot analysis. Using human serum albumin (HSA), a CSA-DVS-HSA conjugate was prepared in the same manner. Other protein carriers known in the art may also be used to prepare CSA-DVS conjugates using these methods.
Example 3
Synthesis of AM1-Divinyl Sulfone and Conjugation to a Protein Carrier
1. Preparation of AM1-DVS Haptens:
AM1 (4.0 mg, 3.3 μmol), potassium carbonate (70 mg, 0.51 mmol) and a few crystals of 18-Crown-6 were dissolved in 4 mL of anhydrous acetone and the solution stirred at room temperature for 45 minutes. Vinyl sulfone (31.0 mg, 0.26 mmol) was then added and the reaction stirred overnight at room temperature. The mixture was then diluted with ethyl acetate and washed sequentially with water, dilute aqueous hydrochloric acid and brine (saturated ammonium chloride). The organic phase was then dried over magnesium sulfate and the solvent evaporated. Methanol was added to the residue and the methanol soluble portion was kept for purification. The reaction was repeated several times until sufficient product was obtained for purification and conjugation.
2. Analysis of AM1-DVS Haptens:
Two (2) main products with mass corresponding to AM1-DVS were identified by LC/MS. The products were purified by HPLC (SPHERISORB™ (silica-based spherical packing material manufactured by Phase Separations) C-8 semi-prep column; 80% methanol isocratic; 4 mL/min; 50° C.;214 nm). A 600 MHz proton nmr spectra has been obtained for both AM1-DVS (species 1) and AM1-DVS (species 2).
3. Preparation of AM1-DVS-protein Conjugates:
AM1 -DVS (species 1, 0.2 mg) was dissolved in 300 μL of dimethyl sulfoxide and slowly spiked into a rapidly stirred solution of KLH (1.0 mg) in 1.0 mL of phosphate buffer (pH 7.6). The mixture was stirred at room temperature for 24 hours and then dialyzed overnight against PBS. The concentration of protein was determined by the Lowry protein assay. AM1-DVS (species 2) was conjugated to KLH in the same manner. Human serum albumin (HSA) or other protein carriers known in the art may also be used as carriers to prepare AM1-DVS conjugates.
Example 4
Synthesis of AM19-Divinyl Sulfone and Conjugation to a Protein Carrier
1. Preparation of AM19-DVS Haptens:
AM19 (4.5 mg, 3.6 μmol), potassium carbonate (60 mg, 0.43 mmol) and a few crystals of 18-Crown-6 were mixed together in 5 mL of anhydrous acetone and the solution stirred at room temperature for 45 minutes. Vinyl sulfone (43.0 mg, 0.36 mmol) was then added and the reaction stirred overnight at room temperature. The solvent was evaporated by passing a stream of nitrogen gas through the reaction flask. The residue was immediately quenched with a mixture of 1N aqueous hydrochloric acid and ethyl acetate. The organic phase was then diluted with ethyl acetate, washed sequentially with water and brine, and then dried over magnesium sulfate and the solvent evaporated. Methanol was added to the residue and the methanol soluble portion submitted for LC/MS purification. The reaction was repeated several times until sufficient product was obtained for purification and conjugation.
2. Analysis of AM19-DVS Haptens:
Three (3) products with mass corresponding to AM19-DVS (1375-Na adduct m/z) were identified by LC/MS. These products were assigned AM19-DVS (1), AM19-DVS (2) and AM19-DVS (3) for identification.
i) Identification, Purification and Characterization of AM19-DVS (1) Hapten:
AM19-DVS (1) was purified by HPLC (SPHERISORB™ (silica-based spherical packing material manufactured by Phase Separations) C-8 semi-prep column) as follows: Rotary evaporated AM19-DVS (1) from the crude collection was dissolved in 77% methanol, injected into the HPLC and run using the following conditions: 77% methanol isocratic; 4 mL/min; 35° C.; 214 nm. The collected material was rechromatographed until pure. The purity of AM19-DVS (1) was assessed from a mass spectrum and HPLC. The electrospray fragmentation profile of purified AM19-DVS (1) is consistent with DVS modification through the secondary hydroxyl of amino acid 1. For purposes of this application, this hapten will be referred to as AM19-1-DVS (1).
ii) Identification, Purification and Characterization of AM19-DVS (2) Hapten:
AM19-DVS (2) was purified by HPLC (SPHERISORB™ (silica-based spherical packing material manufactured by Phase Separations) C-8 semi-prep column) in two steps. Step 1: Rotary evaporated AM19-DVS (2) from the crude collection was dissolved in 80% methanol, injected into the HPLC and run using the following conditions: 80% methanol isocratic; 4 mL/min; 35° C.; 214 nm. Step 2: The collected material from Step 1 was freeze dried, dissolved in 64% methanol, injected into the HPLC and run using the following conditions: 64% methanol isocratic; 4 mL/min; 35° C.; 214 nm. The purity of the AM19-DVS (2) hapten was assessed from a mass spectrum and HPLC. The electrospray fragmentation profile of this purified AM19-DVS (2) hapten is consistent with DVS modification through the primary hydroxyl of amino acid 1. For purposes of this application, this hapten will be referred to as AM19-1-DVS (2).
iii) Identification, Purification and Characterization of AM19-DVS (3) Hapten: AM19-DVS (3) was purified by HPLC (SPHERISORB™ (silica-based spherical packing material manufactured by Phase Separations) C-8 semi-prep column) in two steps. Step 1: Rotary evaporated AM19-DVS (3) from the crude collection was dissolved in 60% methanol, injected into the HPLC and run using the following conditions: 76% methanol isocratic; 4 mL/min; 35° C.; 214 nm. The purity of the AM19-DVS (3) hapten was assessed from a mass spectrum and HPLC. The electrospray fragmentation profile of purified AM19-DVS (3) is consistent with DVS modification through the hydroxyl group of amino acid 9. For purposes of this application, this hapten will be referred to as AM19-9-DVS.
3. Preparation of AM19-DVS-protein Conjugates:
AM19-1-DVS (1), 0.4 mg, was dissolved in 250 μL dimethyl sulfoxide and slowly spiked into a rapidly stirred solution of KLH (1.0 mg) in 1.0 mL of phosphate buffer (pH 7.6). The mixture was stirred at room temperature for 24 hours and then dialyzed overnight against PBS. The concentration of protein was determined by the Lowry protein assay. AM19-1-DVS (2), 0.8 mg/KLH, 6.0 mg; AM19-9-DVS, 0.3 mg/KLH, 1.0 mg conjugates, and the corresponding HSA conjugates were prepared in the same manner. Other protein carriers known in the art may also be used as carriers to prepare AM19-DVS conjugates.
Example 5
Synthesis of AM9-Divinyl Sulfone and Coniugation to a Protein Carrier
1. Preparation of AM9-DVS Haptens:
AM9 (11.1 mg, 9.1 μmol), potassium carbonate (80 mg, 0.58 mmol) and a few crystals of 18-Crown-6 were mixed together in 5 mL of anhydrous acetone and the solution stirred at room temperature for 45 minutes. Vinyl sulfone (107.5 mg, 0.911 mmol) was then added and the reaction stirred overnight at room temperature. The solvent was evaporated by passing a stream of nitrogen gas through the reaction flask. The residue was immediately quenched with a mixture of 1N aqueous hydrochloric acid and ethyl acetate. The organic phase was then diluted with ethyl acetate, washed sequentially with water and brine, and then dried over magnesium sulfate and the solvent evaporated. Methanol was added to the residue and the methanol soluble portion submitted for LC/MS purification. The reaction was repeated several times until sufficient product was obtained for purification and conjugation.
2. Analysis of AM9-DVS Haptens:
Two (2) products with mass corresponding to AM9-DVS (1359-Na adduct m/z) were identified by LC/MS. These products were assigned as AM9-DVS (1) and AM9-DVS (2).
i) Identification, Purification and Characterization of AM9-DVS (1) Hapten:
AM9-DVS (1) was purified by HPLC (SPHERISORB™ (silica-based spherical packing material manufactured by Phase Separations) C-8 semi-prep column) as follows: Rotary evaporated AM9-DVS (1) from the crude collection was dissolved in 70% methanol, injected into the HPLC and run using the following conditions: 70% methanol isocratic; 4 mL/min; 35° C.; 214 nm. The purity of AM9-DVS (1) was assessed from a mass spectrum and HPLC. The electrospray fragmentation profile of purified AM9-DVS (1) is consistent with DVS modification through the hydroxyl group of amino acid 9. For purposes of this application, this hapten will be referred to as AM9-9-DVS.
ii) Identification, Purification and Characterization of AM9-DVS (2) Hapten:
AM9-DVS (2) was purified by HPLC (SPHERISORB™ (silica-based spherical packing material manufactured by Phase Separations) C-8 semi-prep column) as follows: rotary evaporated AM9-DVS (2) from the crude collection was dissolved in 70% methanol, injected into the HPLC and run using the following conditions: 70% methanol isocratic; 4 mL/min; 35° C.; 214 nm. The purity of AM9-DVS (2) was assessed from a mass spectrum and HPLC. The electrospray fragmentation profile of purified AM9-DVS (2) is consistent with DVS modification through the secondary hydroxyl group of amino acid 1. For purposes of this application, this hapten will be referred to as AM9-1-DVS.
3. Preparation of AM9-DVS-protein Conjugates:
AM9-9-DVS (0.4 mg) was dissolved in 300 μL of dimethyl sulfoxide and slowly spiked into a rapidly stirred solution of KLH (1.0 mg) in 1.0 mL of phosphate buffer (pH 7.6). The mixture was stirred at room temperature for 24 hours and then dialyzed overnight against PBS. The concentration of protein was determined by the Lowry protein assay. AM9-1-DVS-KLH and the corresponding HSA conjugates were prepared in a similar manner. Other protein carriers known in the art may also be used as carriers to prepare AM9-DVS conjugates.
Example 6
Immunization to Elicit CSA and/or CSA Metabolite/Derivative Specific Antibody Responses
The basic immunization protocols are as follows: Typically, mice are immunized on day 0 (1°—primary immunization), day 7 (2°—secondary immunization), and day 28 (3°—tertiary immunization) by subcutaneous or intraperitoneal injection with CSA/CSA metabolite conjugate immunogens at doses of 5, 10, 15, or 20 μg based on protein content. Mice were bled 7-10 days post 2° and 3° immunization to collect serum to assay antibody responses. Various other immunization schedules are effective, including day 0 (1°), day 7 (2°) and days 14, 21 or 30 (3°); day 0 (1°), day 14 (2°), and days 28 or 44 (3°); and day 0 (1°), day 30 (2°) and day 60 (3°). Thirty days post-tertiary immunization a booster may be injected. Subsequent monthly boosters may be administered.
Immunized mice are I.V. or I.P. injected with immunogen in PBS as a final boost 3-5 days before the fusion procedure. This increases the sensitization and number of immunogen specific B-lymphocytes in the spleen (or lymph node tissues). This final boost is administered 2 to 3 weeks after the previous injection to allow circulating antibody levels to drop off.
Such immunization schedules are useful to immunize mice with CSA/CSA metabolite immunogen conjugates to elicit specific polyclonal antiserum and for the preparation of specific monoclonal antibodies. The immunogen compositions are also useful for immunizing any animal capable of eliciting specific antibodies to CSA and/or a CSA metabolite or derivative, such as bovine, ovine, caprine, equine, leporine, porcine, canine, feline and avian and simian species. Both domestic and wild animals may be immunized. The route of administration may be any convenient route, and may vary depending on the animal to be immunized, and other factors known to those of skill in the art. Parenteral administration, such as subcutaneous, intramuscular, intraperitoneal or intravenous administration, is preferred. Oral or nasal administration may also be used, including oral dosage forms, which are enteric coated.
Exact formulation of the compositions will depend on the species to be immunized and the route of administration. The immunogens of the invention can be injected in solutions such as 0.9% NaCl (w/v), PBS or tissue culture media or in various adjuvant formulations. Such adjuvants could include, but are not limited to, Freund's complete adjuvant, Freund's incomplete adjuvant, aluminum hydroxide, dimethyldioctadecylammonium bromide, Adjuvax (Alpha-Beta Technology), Imject Alum (Pierce), Monophosphoryl Lipid A (Ribi Immunochem Research), Titermax (CytRx), toxins, toxoids, glycoproteins, lipids, glycolipids, bacterial cell walls, subunits (bacterial or viral), carbohydrate moieties (mono-, di-, tri-, tetra-, oligo- and polysaccharide), dextran sulfate, various liposome formulations or saponins. Combinations of various adjuvants may be used with the immunogen conjugates of the invention to prepare a pharmaceutical composition.
The conjugates of this invention may be used as immunogens to elicit CSA and/or CSA metabolite/derivative specific polyclonal antibody, and to stimulate B-cells for specific monoclonal antibody production. They may also be utilized as development and/or research tools; as diagnostic reagents in immunoassay kit development; as prophylactic agents, for example, to block cell receptors; and as therapeutic modalities as immunomodulators and as drug delivery compositions.
Example 7
Assays to Determine Antibody Reactivity to CSA and/or CSA Metabolite Immunogens
The basic direct ELISA protocol (Ag panel ELISA) for determining antibody reactivity to CSA or CSA metabolites used in the Examples was as follows:
Direct ELISA Protocol:
1. Use Falcon Pro-bind immunoplate.
2. Dilute coating antigen (Ag) to 1.0 g/mL in carbonate-bicarbonate buffer. Use glass tubes.
3. Add 100 μL to each well of plate. Store overnight at 4° C.
4. Shake out wells and wash 3× with 200 μL PBS/0.05% TWEEN™ (polyoxyethylene-sorbitol) (v/v) per well.
5. Add blocking buffer, 200 μL per well (PBS/2% BSA (w/v)). Incubate for 60 min at 37° C.
6. Wash 3× as in step 4.
7. Add 100 μL per well of test antibody appropriately diluted in PBS/0.1% Tween (v/v). Incubate 60 min at 37° C.
8. Wash 3× as in step 4.
9. Dilute alkaline phosphatase conjugated anti-mouse IgG (Pierce cat #31322) in PBS/0.1% Tween™ (polyoxyethylene-sorbitol) (v/v) to 1:2000 concentration. Add 100 μL per well and incubate at 37° C. for 60 min.
10. Wash 3× as in step 4.
11. Prepare enzyme substrate using Sigma #104 alkaline phosphatase substrate tablets (1 mg/mL in 10% diethanolamine (v/v) substrate buffer). Add 100 μL per well and incubate in the dark at room temperature. Absorbance can be read at 405 nm at approximately 15-min intervals.
To measure antibody isotype levels (IgM, IgG and IgA isotypes) elicited to CSA or CSA metabolite immunogens the following basic procedure was used:
Isotyping ELISA Protocol:
1. Use Falcon Pro-bind immunoplates.
2. Dilute coating antigen to 1 μg/mL in carbonate-bicarbonate buffer. Add 100 μL per well and incubate overnight at 4° C.
3. Shake out wells and wash 3× with 200 μL PBS/0.05% Tween™ (polyoxyethylene-sorbitol) (v/v) per well.
4. Add 200 μL blocking buffer per well (PBS/2% BSA (w/v)). Incubate 60 min at room temperature.
5. Wash as in step 3.
6. Add 100 μL per well of tissue culture supernatant undiluted or mouse serum diluted to {fraction (1/100)} in PBS/0.1% Tween™ (polyoxyethylene-sorbitol) (v/v). Incubate for 60 min at 37° C.
7. Wash as in step 3.
8. Prepare 1:2 dilution of EIA grade mouse type (rabbit anti-mouse IgM, IgG1, IgG2a, IgG2b, IgG3 and IgA, Bio-Rad) in dilution buffer (PBS/0.1% TWEEN™ (polyoxyethylene-sorbitol) (v/v)). Add 100 μL per well into appropriate wells and incubate 60 min at 37° C.
9. Wash as in step 3.
10. Dilute alkaline phosphatase conjugated anti-rabbit IgG (Tago cat #4620) in PBS/0.1% TWEEN™ (polyoxyethylene-sorbitol) (v/v) to 1:2000 concentration. Add 100 μL per well and incubate at 37° C. for 60 min.
11. Wash as in step 3.
12. Prepare enzyme substrate using Sigma #104 alkaline phosphatase substrate tablets (1 mg/mL in 10% diethanolamine (v/v) substrate buffer). Add 100 μL per well and incubate in the dark at room temperature. Absorbance can be read at 405 nm at approximately 15-min intervals.
13. Absorbance readings may be converted to μg antibody per ml serum using dose-response curves generated from ELISA responses of the rabbit anti-mouse isotype antibodies to various concentrations of mouse class and subclass specific immunoglobulins (Zymed Labs. Inc.).
The following procedure was used to determine antibody binding to specific sites of CSA or CSA metabolites/derivatives and to quantify antibody cross-reactivity to FK-506, rapamycin, and KLH or HSA proteins.
Inhibition ELISA Protocol:
1. Use Falcon Pro-bind immunoplates.
2. Dilute coating antigen to 1 μg/mL in carbonate-bicarbonate buffer. Add 100 μL per well and incubate overnight at 4° C.
3. On the same day prepare inhibiting antigen tubes. Aliquot antibodies into glass test tubes. Prepare appropriate antigen concentration in ethanol and add to aliquoted antibody at 10 μL ethanol solution/250 μL antibody. Vortex tubes and incubate overnight at 4° C.
4. Shake out wells and wash 3× with 200 μL PBS/0.05% TWEEN™ (polyoxyethylene-sorbitol) (v/v) per well.
5. Add 200 μL blocking buffer per well (PBS/2% BSA (w/v)). Incubate 60 min at room temperature.
6. Wash as in step 4.
7. Transfer contents of inhibition tubes to antigen-coated plate, 100 μL per well. Incubate 60 min at 37° C.
8. Wash as in step 4.
9. Dilute alkaline phosphatase conjugated anti-mouse IgG (Pierce cat# 31322) in PBS/0.1 % TWEEN™ (polyoxyethylene-sorbitol) (v/v) to 1:5000 concentration. Add 100 μL per well and incubate at 37° C. for 60 min.
10. Wash as in step 4.
11. Prepare enzyme substrate using Sigma #104 alkaline phosphatase substrate tablets (1 mg/mL in 10% diethanolamine (v/v) substrate buffer). Add 100 μL per well and incubate in the dark at room temperature. Absorbance can be read at 405 nm at approximately 15-min intervals.
Buffers used in the direct, isotyping and inhibition ELISA protocols were:
Coating buffer (sodium carbonate/bicarbonate 0.05 M. pH 9.6)
Sodium carbonate (Fisher, cat # S-233-500)
2.93
g
Sodium bicarbonate (Fisher, cat # S-263-500)
1.59
g
adjust pH to 9.6 using 1 M HCl or 1 M NaOH
store at 4° C.
10× PBS buffer
Potassium phosphate, mono-basic (Fisher, cat P-284B-500)
8.00
g
Sodium phosphate, di-basic (Fisher, cat # S-373-1)
46.00
g
Sodium chloride (Fisher, cat # S-671-3)
320.00
g
Potassium chloride (Fisher, cat # P-217-500)
8.00
g
dissolve in 4 L distilled water
store at room temperature
Dilution buffer (1× PBS/0.1% TWEEN ™ (polyoxyethylene-sorbitol))
10× PBS
50.0
mL
distilled water
450
mL
TWEEN ™ (polyoxyethylene-sorbitol)-20
0.5
mL
(Polyoxyethylene-sorbitol monolaurate
Sigma, cat # P-1379)
adjust pH to 7.2 and store at room temperature
Wash buffer (1× PBS/0.05% TWEEN ™ (polyoxyethylene-sorbitol))
10× PBS
200
mL
distilled water
1800
mL
Tween-20
1.0
mL
adjust pH to 7.2 and store at room temperature
Blocking buffer (1× PBS/2% BSA)
1× PBS
100
mL
Bovine Serum Albumin (Sigma, cat # A-7030)
2.0
g
store at 4° C.
Substrate buffer (10% diethanolamine)
Diethanolamine (Fisher, cat # D-45-500)
97.0
mL
Magnesium chloride (Fisher, cat # M-33-500)
100.0
mg
adjust pH to 9.8 and store at 4° C. (protect from light)
The direct ELISA, isotyping and inhibition ELISA procedures have been described to detect mouse antibodies (poly- and monoclonal antibodies), however these procedures can be modified for other species, including but not limited to antibodies of rabbit, guinea pig, sheep or goat.
Example 8
Polyclonal Antibody Responses to the CSA-DVS-KLH Immunogen
Polyclonal antisera were prepared in mice using the CSA-DVS-KLH immunogen described in Example 2 and the immunization regimes described in Example 6. Individual mouse sera collected 10 days post-secondary and tertiary immunization were assayed for antibody titre by direct ELISA (as described in Example 7) and further screened by inhibition ELISA using CSA, CSA conjugate or KLH inhibitors. Examples of mouse polyclonal sera with good anti-CSA reactivity are shown in Table 1. CSA and CSA-DVS-HSA inhibited antibody binding to a CSA-DVS-HSA ELISA coated plate in a dose dependant manner. KLH or a FK-DVS-KLH conjugate did not inhibit antibody binding.
These mouse sera were further characterized by the antigen panel ELISA assay, results shown in Table 2. These results demonstrate that immunized mouse serum had good reactivity to the CSA-DVS, AM19-1-DVS (1), AM19-1-DVS (2) and AM9-1-DVS HSA conjugates. These sera had low reactivity to the AM19-9-DVS-HSA conjugate. This indicates that the antisera recognized epitopes on the CSA/CSA metabolite molecules and that DVS coupling through the 9 amino acid residue significantly reduced antibody reactivity (i.e., DVS linkage through the 9 amino acid residue blocks the epitope recognition site). These sera had specificity for the CSA antigen and did not react with the FK, Rapamycin or HSA antigens. A significant response to the KLH carrier molecule of the CSA-DVS-KLH conjugate was seen using KLH coated ELISA plates.
To further characterize this polyclonal antibody response, inhibition ELISA's to the CSA-DVS-HSA conjugate were performed. Results are shown in Table 3. The polyclonal sera were inhibited by CSA and all the CSA metabolites (some variability in binding to CSA metabolites was observed). These sera did not bind epitopes on the FK, Rapamycin, KLH or HSA molecules. These results show that the CSA-DVS-KLH immunogen elicits polyclonal antisera to CSA and CSA metabolites.
TABLE 1
Inhibition ELISA Showing CSA Specificity of Mouse Polyclonal Sera (CSA-DVS-
KLH immunogen)
Inhibiting
Mouse 1
Mouse 2
Ag conc
CSA-DVS-
FK-DVS-
CSA-DVS-
FK-DVS-
(μg/100 μL)
CSA
HSA
KLH
KLH
CSA
HSA
KLH
KLH
10
82.9
85.4
0
0
86.8
83.3
0
0
5
80.4
83.2
0
0
85.9
70.7
0
0
2.5
75.9
80.3
0
0
73.3
54.4
0
0
1.25
72.1
68.3
0
0
66.8
47.4
0
0
0.625
56.5
62.0
0
0
48.8
28.4
0
0
0.313
43.4
43.3
0
0
19.6
10.1
0
0
0.156
23.0
30.3
0
0
6.9
2.2
0
0
(results expressed as percent inhibition)
TABLE 2
Mouse Polyclonal Antibody Reactivity (CSA-DVS-KLH immunogen)
to CSA, CSA Metabolite, FK, Rapamycin, KLH or HSA Antigens
Antigen
Mouse 1
Mouse 2
Panel
OD
%*
OD
%
CSA-DVS-HSA
0.991
100
0.977
100
AM9-1-DVS-HSA
1.304
>100
1.218
>100
AM19-9-DVS-HSA
0.290
29.3
0.453
46.4
AM19-1-DVS-HSA (1)
1.099
>100
1.462
>100
AM19-1-DVS-HSA (2)
1.212
>100
1.128
>100
FK-DVS-HSA
0.005
0
0.010
1.0
Rapa-suc-HSA
0
0
0
0
HSA
0
0
0
0
*Percent reactivity = OD to test antigen/OD to CSA-DVS-HSA × 100
TABLE 3
Percent Inhibition of Mouse Sera (CSA-DVS-KLH immunogen) with
CSA/CSA Metabolites, Rapamycin, FK, KLH and HSA Antigens
Inhibiting antigen
Mouse sera
CSA
65.1
AM1
96.2
AM1c
98.0
AM4n
59.5
AM1c9
60.5
AM19
57.2
AM9
70.7
FK
31.9
Rapamycin
28.2
KLH
30.2
HSA
24.9
Example 9
Polyclonal Antibody Responses to the AM1-DVS-KLH Immunogen
Polyclonal antisera was prepared in mice using the AM1 immunogens described in Example 2 and the immunization regimes described in Example 6. Individual mouse sera collected 10 days post-secondary and tertiary immunizations were assayed for antibody titre by direct ELISA. Mice having high anti-CSA titres were assayed for specificity by antigen panel reactivity. Results are shown in Table 4.
These results show that mice immunized with the AM1-DVS antigen conjugated to KLH carrier displayed good antibody reactivity to the CSA antigen and cross-reactivity with the AM19-1-DVS (1), AM19-1-DVS (2) and AM9-1-DVS antigens. These sera had lower reactivity to the AM19-9-DVS antigen. As with the previous example, this indicates that the antisera recognized epitopes on the CSA/CSA metabolite conjugates when DVS coupling was through the 1 amino acid residue, but that DVS binding through the 9 amino acid residue significantly reduced antibody reactivity (i.e., masking antibody epitope recognition site). These sera were CSA/CSA metabolite epitope specific and did not react with the FK, Rapamycin or HSA antigens. These mice mounted a significant response to the KLH carrier of the immunogen conjugate.
To further characterize these polyclonal antibody responses, inhibition ELISA's to the CSA-DVS-HSA conjugate were performed as described in Example 7. Results are shown in Table 5. These polyclonal sera were inhibited by CSA and CSA metabolites. However, inhibition varied from 39-100%, depending on the inhibiting molecule. The polyclonal antisera were specific to CSA/CSA metabolites as no inhibition with FK, Rapamycin, HSA or KLH antigens was observed.
TABLE 4
Mouse Polyclonal Antibody Reactivity (AM1-DVS-KLH immunogens)
to CSA, CSA Metabolite, FK, Rapamycin, KLH or HSA Antigens
Antigen
Mouse 1
Mouse 2
Panel
OD
%*
OD
%
CSA-DVS-HSA
0.780
100
0.622
100
AM9-1-DVS-HSA
1.037
>100
0.966
>100
AM19-9-DVS-HSA
0.483
61.9
0.583
93.7
AM19-1-DVS-HSA (1)
1.075
>100
1.244
>100
AM19-1-DVS-HSA (2)
0.982
>100
1.187
>100
FK-DVS-HSA
0
0
0
0
Rapa-suc-HSA
0
0
0
0
HSA
0
0
0
0
*Percent reactivity = OD to test antigen/OD to CSA-DVS-HSA × 100
TABLE 5
Percent Inhibition of Mouse Polyclonal Sera (AM1-DVS-KLH
immunogen) with CSA/CSA Metabolites, Rapamycin, FK, KLH and
HSA Antigens
Inhibiting antigen
Mouse 1
Mouse 2
CSA
96.6
56.2
AM1
100
96.7
AM1c
96.9
99.5
AM4n
86.8
72.6
AM1c9
75.6
92.7
AM19
39.2
84.7
AM9
87.9
88.6
FK
3.5
13.0
Rapamycin
0
12.4
KLH
8.9
5.8
HSA
1.8
14.9
Example 10
Polyclonal Antibody Response to AM19-DVS-KLH Immunogens
Serum samples were collected 10 days post-secondary and tertiary immunization (as described in Example 6) with AM19-1-DVS (1), AM19-1-DVS (2) or AM19-9-DVS KLH conjugates (as described in Example 4). These serum samples were assayed by direct ELISA for antibody titre to specific haptens. Sera showing high antibody reactivity to AM19 were further characterized by antigen panel ELISA (Table 6).
Sera from mice 1 and 2 (AM19-1-DVS (1) hapten) had good reactivity to CSA/CSA metabolite epitopes and did not cross-react to Rapamycin, FK or HSA epitopes. Sera from Mice 3 and 4 (AM19-1-DVS (2) hapten) also reacted to CSA/CSA metabolite epitopes. Modification of amino acid #9 (DVS coupled to amino acid 9) decreased antibody binding. These sera did not cross-react with epitopes on the Rapamycin, FK or HSA molecules. All mice displayed significant antibody titres to the KLH carrier protein.
Inhibition ELISA results (Table 7), demonstrate variable polyclonal antibody reactivity to the CSA metabolites and little or no inhibition with the CSA parent molecule.
TABLE 6
Mouse Polyclonal Antibody Reactivity (AM19-1-DVS-KLH immunogens)
to CSA, CSA Metabolite, FK, Rapamycin, KLH or HSA Antigens
Antigen
Mouse 1*
Mouse 2*
Mouse 3**
Mouse 4**
Panel
OD
%***
OD
%
OD
%
OD
%
CSA-DVS-
2.135
65.1
2.741
90.5
0.994
70.4
1.534
59.6
HSA
AM9-1-
2.683
81.8
2.920
96.4
1.372
97.2
2.134
82.9
DVS-HSA
AM19-9-
3.17
96.6
2.409
79.6
0.646
45.8
1.091
42.4
DVS-HSA
AM19-1-
3.281
100
3.028
100
1.181
83.7
2.351
91.4
DVS-
HSA(1)
AM19-1-
3.020
92.0
3.188
>100
1.411
100
2.573
100
DVS-
HSA(2)
FK-DVS-
0
0
0
0
0
0
0
0
HSA
Rapa-suc-
0
0
0.036
1.2
0
0
0
0
HSA
HAS
0
0
0
0
0
0
0
*AM19-1-DVS (1)-KLH immunogen
**AM19-1-DVS (2)-KLH immunogen
***Percent reactivity = OD to test antigen/OD to AM19-1-DVS (1) or (2) × 100
TABLE 7
Percent Inhibition of Mouse Polyclonal Sera (AM19-1-DVS-KLH
immunogen) with CSA/CSA Metabolites
Inhibiting antigen
Mouse 1*
Mouse 2*
Mouse 3**
Mouse 4**
CSA
4.9
23.4
0.2
4.7
AM1
35.3
53.6
58.3
64.7
AM1c
76.6
87.2
76.8
82.7
AM4n
26.3
50.1
44.1
47.3
AM1c9
75.0
88.2
61.5
69.0
AM19
68.5
85.6
42.3
60.8
AM9
57.9
75.9
46.1
50.3
FK
0
0
0
0
Rapamycin
0
0
0
0
KLH
0
0
0
0
HAS
0
0
0
0
*AM19-1-DVS (1) HSA coated plate
**AM19-1-DVS (2) HSA coated plate
The AM19-1-DVS (1) conjugate was also used to immunize rabbits. Reactivity of the polyclonal sera is shown in the inhibition ELISA results of Table 8 (AM19-1-DVS (1) HSA coated plate). As seen with the mouse serum, this rabbit sera did not recognize the CSA molecule and showed variable reactivity to the CSA metabolites and strongly bound to AM1c, AM1c9, AM19 and AM9 metabolites. There was no cross-reactivity to Rapamycin, FK, KLH or HSA antigens.
TABLE 8
Percent Inhibition of Rabbit Polyclonal Sera (AM19-1-DVS-KLH
(1) immunogen) with CSA/CSA Metabolites
Inhibiting antigen
Rabbit sera
CSA
0
AM1
55.2
AM1c
89.5
AM4n
55.2
AM1c9
97.2
AM19
97.2
AM9
94.7
FK
0
Rapamycin
0
KLH
0
HAS
0
Sera from mice immunized with the AM19-9-DVS immunogen showing high reactivity to the AM19-9-DVS hapten were further characterized by antigen panel ELISA (Table 9). Significant antibody titres to the KLH carrier was observed.
Sera from mice 5 and 6 (AM19-9-DVS hapten) recognized epitopes on AM19-9-DVS hapten. Modification of the amino acid#1 (CSA-DVS, AM9-1-DVS or AM19-1 (2)) inhibited antibody binding. It is assumed that the antibody recognition site is on or near the amino acid 1 face of the molecule.
Polyclonal sera, when tested by inhibition ELISA using AM19-9-DVS-HSA coated plates, showed different results. Sera from mouse 5 demonstrate recognition of CSA and CSA metabolite epitopes. As this is a polyclonal serum the immunogen may elicit antibodies to epitopes of the parent CSA molecule as well as modified epitopes of the metabolites. With mouse 6, it appears the immunogen elicited only antibodies to the modified epitopes of the metabolites, no antibody to CSA epitopes was produced. With both sera there was no cross-reactivity to Rapamycin, FK, KLH or HSA antigens. Results are presented in Table 10.
TABLE 9
Mouse Polyclonal Antibody Reactivity (AM19-9-DVS-KLH
immunogens) to CSA, CSA Metabolite, FK, Rapamycin, KLH
or HSA Antigens
Antigen
Mouse 5
Mouse 6
Panel
OD
%*
OD
%
CSA-DVS-HSA
0.002
0
0.017
0
AM9-1-DVS-HSA
0.232
7.2
0.457
14.0
AM19-9-DVS-HSA
3.231
100
3.267
100
AM19-1-DVS-HSA (1)
3.411
>100
3.022
92.5
AM19-1-DVS-HSA (2)
0.167
5.2
0.968
29.6
FK-DVS-HSA
0.033
1.0
0.032
0
Rapa-suc-HSA
0.020
0
0.033
0
Has
0.012
0
0.007
0
*Percent reactivity = OD to test antigen/OD to AM19-9-DVS-HSA × 100
TABLE 10
Percent Inhibition of Mouse Polyclonal Sera (AM19-9-DVS-KLH
immunogen) with CSA/CSA Metabolites
Inhibiting antigen
Mouse 5
Mouse 6
CSA
87.9
19.9
AM1
96.2
67.6
AM1c
92.5
58.7
AM4n
77.9
36.3
AM1c9
91.0
30.2
AM19
97.8
55.4
AM9
95.1
52.5
FK
0
0
Rapamycin
0
0
KLH
0
0
HAS
0
0
Example 11
Polyclonal Antibody Response to AM9-DVS-KLH Immunogens
Polyclonal antisera was prepared in mice using the AM9-1-DVS or AM9-9-DVS conjugates described in Example 5 and the immunization regimes as described in Example 6. Individual serum samples were collected 10 days post-secondary and tertiary immunization and assayed by direct ELISA for antibody titre to the corresponding hapten. Titres to the KLH carrier molecule were also quantified by direct ELISA.
Sera from mice immunized with the AM9-1-DVS conjugate which showed high antibody (Ab) reactivity to the specific hapten were then further characterized by antigen panel ELISA (Table 11). Sera from these mice recognized the CSA hapten, the AM9-1, AM19-1 (1) and (2) hapten conjugates (i.e., the AM9-1-DVS hapten would present the modified (hydroxylated) a.a. #9 face of the molecule for immune recognition). No reactivity to Rapamycin, FK, KLH or HSA epitopes was observed. The reduction in antibody binding to the AM19-9 hapten is presumed to be due to masking of the epitope recognition site, (i.e., blocking the modified a.a. #9 residue with the DVS linker arm would thereby block Ab/Ag interaction). The results of the inhibition ELISA (Table 12, AM9-1-DVS-HSA coated plate) demonstrate that the polyclonal antisera do not strongly recognize epitopes on the CSA, parent molecule, and show variable reactivity for the CSA metabolites. The AM9-1 DVS immunogen may be used to prepare and isolate MoAbs to various CSA metabolites. Screening for specific anti-AM9 MoAbs can also be achieved.
TABLE 11
Mouse Polyclonal Antibody Reactivity (AM9-1-DVS-KLH
immunogen) to CSA, CSA Metabolites, FK, Rapamycin,
KLH or HSA Antigens
Antigen
Mouse 1
Mouse 2
Panel
OD
%*
OD
%
CSA-DVS-HAS
1.486
76.6
1.702
69.7
AM9-1-DVS-HAS
1.941
100
2.443
100
AM19-9-DVS-HAS
1.119
57.7
1.644
67.3
AM19-1-DVS-HSA (1)
2.683
>100
2.750
>100
AM19-1-DVS-HSA (2)
2.171
>100
2.859
>100
FK-DVS-HAS
0
0
0
0
Rapa-suc-HAS
0
0
0
0
HAS
0
0
0
0
*Percent reactivity = OD to test antigen/OD to AM9-1-DVS-HSA × 100
TABLE 12
Percent Inhibition of Mouse Polyclonal Sera (AM9-1-DVS-KLH
immunogen) with CSA/CSA Metabolites
Inhibiting antigen
Mouse 1
Mouse 2
CSA
3.2
17.8
AM1
61.5
41.6
AM1c
94.3
75.4
AM4n
25.1
43.8
AM1c9
70.7
80.8
AM19
57.9
74.2
AM9
47.7
74.6
Sera from mice immunized with the AM9-9-DVS immunogen which reacted strongly to the AM19-9-DVS hapten were further characterized by antigen panel ELISA (Table 13). Sera from these mice recognize epitopes on the AM19-9-DVS-HSA molecule. However, DVS coupling through amino acid #1 appears to abrogate or significantly reduce antibody binding, as seen with the CSA, AM9-1, AM19-1 (1) and AM19-1 (2)-HSA conjugates. The reduction in antibody binding to panel antigens coupled through the a.a.#1 residue is presumed to be due to masking of the Ab epitope recognition site. As the AM9-9-DVS immunogens would present the a.a. #1 face of the molecule for immune recognition, blocking the a.a. #1 residue with the DVS linker arm would thereby block Ab/Ag interaction. Mouse sera did not cross-react with Rapamycin, FK or HSA antigens, significant antibody titres to the KLH carrier protein was observed.
The results of the inhibition ELISA (Table 14, AM19-9-DVS-HSA coated plate) demonstrate that these polyclonal sera recognize epitope sites on the CSA parent molecule and the CSA metabolites. The AM9-9-DVS hapten may be used to prepare and isolate MoAbs to CSA parent and various CSA metabolites.
TABLE 13
Mouse Polyclonal Antibody Reactivity (AM9-9-DVS-KLH
immunogen) to CSA, CSA Metabolites, FK,
Rapamycin, KLH or HSA Antigens
Antigen
Mouse 1
Mouse 2
Mouse 3
Panel
OD
%*
OD
%
OD
%
CSA-DVS-HSA
0.032
1.0
0
0
0
0
AM9-1-DVS-HSA
0.252
8.2
0
0
0
0
AM19-9-DVS-HSA
3.077
100
0.618
100
1.802
100
AM19-1-DVS-HSA (1)
0.018
0
0
0
0.777
43.1
AM19-1-DVS-HSA (2)
0.015
0
0
0
0
0
FK-DVS-HSA
0.016
0
0
0
0.046
2.6
Rapa-suc-HSA
0.048
1.6
0
20.2
0
0
HSA
0.001
0
0.060
9.7
0
0
*Percent reactivity = OD to test antigen/OD to AM19-9-DVS-HSA × 100
TABLE 14
Percent Inhibition of Mouse Polyclonal Sera (AM9-9-DVS-KLH
immunogen) with CSA/CSA Metabolites
Inhibiting antigen
Mouse 1
Mouse 2
CSA
65.4
83.9
AM1
66.2
83.9
AM1c
71.9
78.9
AM4n
51.9
57.7
AM1c9
60.8
65.9
AM19
32.7
69.0
AM9
82.3
88.1
FK
24.2
34.5
Rapamycin
16.9
24.1
KLH
12.3
35.8
HSA
24.6
26.8
Example 12
A Method for Monoclonal Antibody Production (MoAb)
The steps for monoclonal antibody production are summarized below:
Immunize mice with parent drug or metabolite conjugates
(1, 2, 3 & boost)
⇓
Recover Ab secreting B cells from mouse spleen
+
Myeloma cell lines (NS-1, SP-2, and P3X63-Ag8.653)
⇓
Hybridization (using PEG)
⇓
Propagation
⇓
Screening (Immunoblot, ELISA, automated assays)
⇓
Cloning (3x)
⇓
Screening
⇓
Propagation
⇓
Characterization (metabolite cross-reactivity)
⇓
Tissue culture MoAb production
⇓
Ascites MoAb production
Although there are many suitable reagent suppliers, we have found the following to be most preferred for obtaining a high yield of fusion products, for isolating stable clones and for the production of monoclonal antibodies.
Dulbecco's Modified Eagles Medium: (DMEM) from JRH BIOSCIENCES, Cat #56499-10L+3.7 g/L NaHCO3.
HAT supplement: (100×—10 mM sodium hypoxanthine, 40 mM aminopterin, 1.6 mM thymidine) from CANADIAN LIFE TECHNOLOGIES, Cat #31062-037.
HT stock: (100×—10 mM sodium hypozanthine, 1.0 mM thymidine) from CANADIAN LIFE TECHNOLOGIES, Cat #11067-030.
FCS: CPSR-3 Hybrid-MAX from SIGMA, Cat#C-9155.
Polyethylene glycol (PEG): Use PEG 4000, SERVA #33136. Autoclave PEG, cool slightly and dilute to 50% w/v with serum free DMEM. Make fresh PEG the day before the fusion, and place in 37° incubator.
Fusion Procedure:
Myeloma cells should be thawed and expanded one week before fusion and split the day before the fusion. Do not keep the myeloma cell line in continuous culture. This prevents the cells from becoming infected with mycoplasma and also from any changes, which may result from repeated passaging.
For example:
SP2/0 can be split back to 1×10 4 cells/mL, freeze at least 5×10 6 cells/vial
NS-1 can be split back to 1×10 4 cells/mL, freeze at least 5×10 6 cells/vial
P3X63-Ag8.653 can be split back to 1×10 4 cells/ml, freeze at least 5×10 6 cell/vial Culture the myeloma cell line so that you will have at least 0.5×10 7 cells (in log phase growth) on the day of the fusion. Three to five days prior to fusion, boost the immunized mouse. The mouse must be genotypically compatible with the myeloma cell line. Myeloma cell drug sensitivity should be confirmed.
Serum should be tested for its ability to support growth of the parental myeloma cell line. To test batches of serum, clone the parental myeloma cells (as outlined under cloning) in 10%, 5%, 2.5%, and 1% FCS. No feeder layer is required. Check growth and cell viability daily for 5 days.
Fusion Day
1. Place fresh medium, FCS to be used in fusion in water bath.
2. Harvest myeloma cells and wash 3× with serum-free medium (DMEM, RPMI or other commercially available tissue culture media may be used).
3. Remove spleen (lymph node cells may also be used) from immunized mouse; resterilize instruments or use new sterile instruments between each step, i.e., cutting skin, cutting abdominal muscle, removing spleen.
4. Rinse outside of spleen 3× by transferring to plastic petri plates containing sterile medium; use sterile forceps between each step.
5. Place spleen in plastic petri dish with serum-free medium in it, cut into 4 pieces and push gently through screen with sterile glass plunger to obtain a single cell suspension.
6. Centrifuge spleen cells in 50-mL conical centrifuge tubes at 300×g (1200 rpm in silencer) for 10 minutes.
7. Resuspend in 10 ml medium. Dilute an aliquot 100× and count cells.
8. Centrifuge rest of spleen cells, resuspend and recentrifuge. Myeloma cells can be washed at the same time. The NS-1, SP2/0 and P3X63Ag8 myeloma cell lines are most preferred, however other myeloma cell lines known in the art may be utilized. These include, but are not limited to, the mouse cell lines: X63Ag8.653, FO, NSO/1, FOX-NY; rat cell lines; Y3-Ag1.2.3, YB2/0 and IR983F and various rabbit and human cell lines.
9. Add myeloma and spleen cells together in 5:1 or 10:1 ratio with spleen cells in excess.
10. Recentrifuge: spleen cells and myeloma have now been washed 3×.
11. Gently flick pellet and place in incubator for 15 minutes to reach 37° C.
Fusion Protocol:
1. Add 1 mL of 50% PEG (w/v) solution over 1 minute stirring (add 0.25 mL {fraction (1/15)} sec) holding tube in 37° C. water bath (beaker with warm water). PEG fuses membranes of myeloma with antibody secreting (B) cells.
2. Stir 1 minute holding in 37° C. water bath. Solution will turn lumpy.
3. Add 1 mL medium at 37° C. over 1 minute stirring.
4. Add another mL medium over 1 minute stirring.
5. Add 8 mL medium over 2 minutes stirring.
6. Centrifuge for 10 minutes at 300×g (1200 rpm in silencer) and pipet off supernatant.
7. Add 10 mL medium +20% FCS (v/v) to cells in tube and pour into plastic petri dish.
8. Leave in incubator with 5% CO 2 at 37° C. for 1-3 hours. This enhances stability of fusion products.
9. Plate cells out at a concentration of 2×10 5 cells per well in medium (100 μL/well).
10. Feed cells 100 μL of 2×HAT in medium the next day.
No feeder layer is necessary at this time
Feed fusion products 100 μL medium+HAT selection additive on day 3.
Hybridoma cells (myeloma:spleen cell hybrids) are selected by the addition of the drug aminopterin which blocks the de novo synthesis pathway of nucleotides. Myeloma:spleen hybrid cells can survive by use of the salvage pathway. Unfused myeloma cells and myeloma:myeloma fusion products have a defect in an enzyme of the salvage pathway and will die. Unfused spleen cells from the immunized mouse do not grow in tissue culture. Other drugs known in the art may be used to select myeloma:spleen cell hybrids, such as methotrexate or azaserine.
Feed fusion products 100 μL medium+HAT+spleen/thymus feeder layer if necessary on day 5 (1×10 5 cells/well). Fibroblasts, RBC's or other cell types may also be used as feeder layers.
Continue to feed cells medium+HAT for 1 week, by day 7 post-fusion, change to medium+HT. Clones should appear 10-14 days after fusion.
Note:
1. Washing of the spleen cells, myeloma cells and steps 1-6 of the fusion protocol are performed with serum-free medium.
2. Thymocytes die in about 3 days, non-fused spleen cells in about 6 days.
3. Hybrids are fairly large and almost always round and iridescent.
4. T-cell and granulocyte colonies may also grow. They are smaller cells.
To Clone Hybrid Cells:
1. Resuspend the 200 μL in the well with a sterile eppendorf pipet tip and transfer to a small 5-mL sterile tube.
2. Add 200 μL medium (20% FCS v/v) to the original well. This is a safety precaution of the cloning procedure. Parent cells may also be transferred to 24 well plates as a precaution.
3. Take 20 μL of the hybrid cell suspension from step 1 and add 20 μL of eosin or trypan blue solution. Under 40× magnification hybrid cells appear to be approximately the same size and morphology as the myeloma cell line.
4. Clone viable cells by limiting dilution with:
20% FCS (v/v) used in fusion medium
1×HT
1×10 6 thymocytes per ml
clone 1400 cells per cloning protocol
Dilution Cloning Procedure:
Make 10 mL of thymocyte cloning suspension in DMEM with 20% FCS (v/v). Take 1400 hybrid cells and dilute to 2.8 mL.
Row 1: Plate 8 wells (200 μL/well)→100 cells/well.
To the remaining 1.2 mL add 1.2 mL medium.
Row 2: Plate 8 wells (200 μL/well)→50 cells/well.
To the remainder add 2.0 mL medium.
Row 3: Plate 8 wells (200 μL/well)→10 cells/well
To the remainder add 1.2-mL medium.
Row 4: Plate 8 wells (200 μL/well)→5 cells/well.
To the remainder add 2.8 mL medium.
Rows 5 & 6: Plate 16 wells (200 μL/well)→1 cell/well.
After cloning and screening for positive wells, re-clone the faster growing, stronger reacting clones. To ensure that a hybridoma is stable and single-cell cloned, this cloning is repeated 3 times until every well tested is positive. Cells can then be grown up and the tissue culture supernatants collected for the monoclonal antibody. Other limiting dilution cloning procedures known in the art, single-cell cloning procedures to pick single cells, and single-cell cloning by growth in soft agar may also be employed.
Monoclonal Antibody Production:
Monoclonal antibodies can be readily recovered from tissue culture supernatants. Hybrid cells can be grown in tissue culture media with FCS supplements or in serum-free media known in the art. Large-scale amounts of monoclonal antibodies can be produced using hollow fibre or bioreactor technology. The concentration, affinity and avidity of specific monoclonal antibodies can be increased when produced as ascitic fluid.
Ascitic Fluid Production:
1. Condition mice by injecting (I.P.) 0.5 mL pristane (2, 6, 10, 14-tetramethylpentadecane) at least 5 days before hybrid cell are injected. Mice should be genotypically compatible with cells injected, i.e., Balb/c mice should be used with NS-1 or SP2/0 fusion products. Mice of non-compatible genotype may be used if irradiated before cells are injected. However, Balb/c pristane treated mice are the best to use.
2. Inject (I.P.) 10 6 (or more) hybrid cells in PBS. Wash cells 3× prior to injection to remove the FCS.
3. Mice will be ready to tap in about 7-14 days. Use an 18½ G needle to harvest ascites cells and fluid.
4. Transfer at least 10 6 ascites cells from these mice to more pristane treated mice.
5. Ascites cells can be frozen in 10% DMSO (v/v), 20% FCS (v/v), DMEM medium. Freeze about 5×10 6 cells per vial.
Monoclonal antibodies prepared in tissue culture or by ascitic fluid may be purified using methods known in the art.
Example 13
Isolation and Characterization of Monoclonal Antibodies to Specific Sites of CSA and/or CSA Metabolites/Derivatives
The steps to isolate and characterize monoclonal antibodies with reactivity to a specific site(s) of CSA or CSA metabolites are outlined below:
Steps to Identify MoAb to Specific Sites of CSA or CSA Metabolites
Immunization regime (collect polyclonal sera)
⇓
Direct ELISA (Ab to CSA or CSA metabolites)
⇓
Antigen panel ELISA
⇓
Inhibition ELISA
(specificity to CSA or CSA metabolite/derivative epitopes, cross-reactivity
to FK, Rapamycin, KLH or HSA inhibitors)
⇓
Direct ELISA (CSA metabolite, FK, Rapamycin or HSA cross-reactivity)
⇓
Fusion procedure
⇓
Screening of parent fusion products
Immunodot
Direct ELISA
Inhibition ELISA
Ab Isotyping
⇓
Cloning and screening (3x)
⇓
Characterization of Ab in tissue culture supernatant
Direct ELISA (IgG isotypes only)
Ag panel ELISA (CSA metabolites, FK, Rapamycin or HSA
cross-reactivity)
Inhibition ELISA (Rapamycin, FK, CSA and CSA metabolite inhibitors)
⇓
Ascites production
Direct ELISA (Ab titre and isotype)
Inhibition ELISA (Rapamycin, FK, CSA and CSA metabolite inhibitors)
⇓
Ab purification
Characterize antibody reactivity
Immunodot Assay
1. Dot 5-10 μL of antibody onto nitrocellulose paper, which has been gridded for reference.
2. Air-dry and immerse nitrocellulose in PBS/0.1% TWEEN™ (polyoxyethylene-sorbitol) (v/v)/5% Milk (w/v) to block non-specific binding sites. Incubate at room temperature for 60 min with shaking.
3. Rinse twice with PBS/0.05% TWEEN™ (polyoxyethylene-sorbitol) (v/v) and wash with shaking for 10 min.
4. Dilute alkaline phosphatase conjugated anti-mouse IgG (Tago cat #AMI4405) in PBS/0.1% TWEEN™ (polyoxyethylene-sorbitol)(v/v) to 1:2000. Place nitrocellulose on parafilm or saran wrap and add diluted conjugated antibody until nitrocellulose is covered. Incubate covered at 37° C. for 60 min. Do not allow nitrocellulose to dry out between steps.
5. Wash as in step 3.
6. Prepare enzyme substrate using BCIP/NBT (Canadian Life Technologies, cat #18280-016; 88 μL NBT and 66 μL BCIP in 20 mL substrate buffer, 100 mM Tris, 5 mM MgCl 2 , 100 mM NaCl). Place nitrocellulose in substrate solution and shake at room temperature for 10-30 min, watching for color development.
7. Rinse nitrocellulose with water to stop reaction.
Once antibody secreting parent fusion products were identified, the tissue culture supernatants were further characterized for CSA/CSA metabolite reactivity by the direct, isotyping and inhibition ELISA assays as described in Example 7. Tissue culture supernatants from clones (3×) of CSA/CSA metabolite positive parent fusion products were then characterized by isotyping ELISA to isolate IgG producing clones, by direct ELISA to determine antibody titre, by Ag panel ELISA to determine CSA/CSA metabolite reactivity and to determine FK and HSA cross-reactivity, and by inhibition ELISA using Rapamycin, CSA, FK and CSA metabolites to further demonstrate specificity and determine CSA site reactivity.
Using the immunodot and direct ELISA assays many parent fusion products were identified which have strong reactivity to the CSA and metabolite antigens. We have now isolated many IgM and IgG secreting clones with reactivity to the CSA and metabolite antigens by direct, Ag panel, inhibition and isotyping ELISA assays.
Example 14
Monoclonal Antibodies Elicited to the CSA-DVS Immunogen
Spleen cells from mice immunized with the CSA-DVS conjugate have been used to prepare monoclonal antibody secreting hybridoma clones. IgM and IgG anti-CSA secreting clones have been isolated. Table 15 illustrates the reactivity of tissue culture supernatants (TCS) from two of these anti-CSA MoAbs (CSA-1H6 and CSA-2G9).
These two MoAbs show good reactivity (high OD's) to CSA-DVS, AM9-1-DVS, AM19-1-DVS (1) and AM19-1-DVS (2) panel antigens (i.e., haptens coupled through the #1 amino acid residue). Reduction in MoAb binding to the AM19-9-DVS hapten indicates that DVS coupling through the #9 amino acid residue reduces Ab/epitope binding (i.e., this area of the CSA molecule is important or part of the epitope recognition site). CSA-1H6 and CSA-2G9 were specific to CSA epitopes and did not cross-react to epitopes on the FK, Rapamycin, KLH or HSA molecules.
To further characterize the specificity of CSA-1H6 and CSA-2G9 MoAbs, inhibition ELISA assays to the CSA-DVS-HSA conjugate were performed. Table 16 shows that TCS from CSA-1H6 and CSA-2G9 are inhibited by the parent CSA molecule (CSA-2G9 more strongly inhibited) and the AM1 and AM1c metabolites. Inhibition with the AM4n, AM1c9, AM19 and AM9 metabolites is significant. TCS from CSA-1H6 and CSA-2G9 MoAb clones are specific to CSA/CSA metabolite epitopes and do not cross-react with Rapamycin, FK, KLH and HSA. CSA-1H6 and CSA-2G9 can be used in a TDM assay to measure CSA parent molecule and CSA metabolite levels.
Table 15
Mouse Monoclonal Antibody (CSA-1H6, CSA-2G9) Reactivity to
CSA, CSA Metabolites, FK, Rapamycin, KLH or HSA Antigens
Antigen
CSA-1H6
CSA-2G9
Panel
OD
%*
OD
%
CSA-DVS-HSA
1.515
100
2.752
100
AM9-1-DVS-HSA
1.904
>100
2.978
>100
AM19-9-DVS-HSA
0.511
33.7
0.323
11.7
AM19-1-DVS-HSA (1)
1.390
91.7
2.731
>100
AM19-1-DVS-HSA (2)
1.870
>100
3.219
>100
FK-DVS-HSA
0
0
0.029
1.1
Rapa-suc-HSA
0
0
0.006
0
HSA
0.006
0
0
0
KLH
0
0
0.026
0
(CSA-1H6 and CSA-2G9 are both IgG1 antibody isotypes)
*Percent reactivity = OD to test antigen/OD to CSA-DVS-HSA × 100
TABLE 16
Percent Inhibition of TCS from CSA-1H6 and CSA-2G9 MoAb Clones
with CSA/CSA Metabolites, Rapamycin, FK, KLH and HSA Antigens
Inhibiting Antigen
CSA-1H6
CSA-2G9
CSA
62.5
92.6
AM1
98.0
98.2
AM1c
99.1
98.8
AM4n
98.8
64.3
AM1c9
72.7
79.4
AM19
62.4
76.4
AM9
78.3
71.4
Rapamycin
0
10.4
FK
0
10.8
HSA
0
1.5
KLH
0
4.8
Example 15
Monoclonal Antibodies Elicited to the AM1-DVS Immunogens
Spleen cells from mice immunized with the AM1-DVS conjugates have been used to prepare monoclonal antibody secreting hybridoma cells. IgM and IgG anti-CSA MoAbs have been isolated by direct ELISA to CSA-DVS-HSA conjugates. Table 17 illustrates the reactivity of TCS from two of these monoclonal antibody clones (AM1-2E10 and AM1-7F5).
As with the monoclonal antibodies elicited by the CSA-DVS hapten, the MoAbs elicited to the AM1-DVS haptens have good affinity for CSA-DVS, AM9-1-DVS, AM19-1-DVS (1) and AM19-1-DVS (2) panel antigens (i.e., haptens coupled with the DVS linker through the #1 amino acid residue). Similarly, reduction in MoAb binding to the AM19-9-DVS hapten demonstrates that DVS coupling through the #9 amino acid residue decreases Ab/epitope binding. These results indicate that AM1-2E10 and AM1-7F5 are specific to CSA and CSA metabolite epitopes, they do not recognize epitopes on FK, Rapamycin, KLH or HSA molecules.
The specificity of TCS from AM1-2E10 and AM1-7F5 MoAb clones was further characterized by inhibition ELISA to the CSA-DVS-HSA conjugate. Table 18 demonstrates that AM1-2E10 is inhibited by the parent CSA molecule and all CSA metabolites. This MoAb does not cross-react with any epitope on Rapamycin, FK, KLH or HSA molecules. AM1-2E10 can be utilized in a TDM assay to measure CSA parent molecule and all CSA metabolite levels.
With AM1-7F5, the AM1 and AM1c metabolites strongly inhibit MoAb binding to the CSA-DVS-HSA coated plate. Less but significant inhibition was found with the CSA parent molecule and AM4n, AM1c9, AM19 and AM9 metabolites. Rapamycin, FK, KLH and HSA showed no significant inhibition. This result demonstrates that AM1-7F5 can be used in a TDM assay to measure CSA and CSA metabolite levels. Under certain TDM assay conditions (i.e., MoAb dilution), AM1-7F5 may also be used to selectively measure the levels of AM1 and AM1c metabolites.
TABLE 17
Mouse Monoclonal Antibody Reactivity (AM1-DVS-KLH
immunogen) to CSA, CSA Metabolites, FK, Rapamycin,
KLH or HSA Antigens
Antigen
AM1-2E10
AM1-7F5
Panel
OD
%*
OD
%
CSA-DVS-HSA
1.546
100
1.971
100
AM9-1-DVS-HSA
1.750
>100
2.465
>100
AM19-9-DVS-HSA
0.270
17.5
0.790
40.1
AM19-1-DVS-HSA (1)
1.546
100
2.283
>100
AM19-1-DVS-HSA (2)
1.793
>100
3.372
>100
FK-DVS-HSA
0.015
0
0
0
Rapa-suc-HSA
0.015
0
0.008
0
KLH
0.061
3.9
0
0
HSA
0.006
0
0
0
(AM1-2E10 is an IgG2b and AM1-7F5 is an IgG1 antibody isotype)
*Percent reactivity = OD to test antigen/OD to CSA-DVS-HSA × 100
TABLE 18
Percent Inhibition of TCS from AM1-2E10 and AM1-7F5 MoAb
Clones with CSA/CSA Metabolites, Rapamycin,
FK, KLH and HSA Antigens
Antigen
AM1-2E10
AM1-7F5
CSA
81.9
53.8
AM1
100
99.5
AM1c
100
100
AM4n
85.7
57.5
AM1c9
100
56.2
AM19
100
60.0
AM9
100
62.3
Rapamycin
0
25.4
FK
0
26.0
KLH
0
22.5
HSA
0
16.1
Example 16
Monoclonal Antibodies Elicited to the AM19-DVS Immunopens
Spleen cells from mice immunized with the AM19-1-DVS (1) conjugate have been used to prepare MoAb secreting hybridoma cells. Anti-AM19-1-DVS (1) ELISA reactive IgM and IgG MoAb isotypes have been isolated. Table 19 illustrates the reactivity of TCS from two of these anti-AM19-1-DVS MoAbs (AM19-1-7E12-1 and AM19-1-7E12-2).
These two MoAb TCSs have high reactivity to the CSA-DVS, AM9-1-DVS, AM19-9-DVS, AM19-1-DVS (1) and AM19-1-DVS (2) panel antigens. These monoclonals did not cross react to Rapamycin, FK, KLH or HSA antigens. Using the more specific inhibition ELISA with AM19-1-DVS (1) coated ELISA plates, the CSA parent molecule did not inhibit antibody binding, the AM1c metabolite strongly inhibited binding of these MoAbs, AM1 and AM1c9 significantly inhibited MoAb binding, AM4n, AM19 and AM9 moderately inhibited binding, and Rapamycin, FK, KLH and HSA showed no inhibition of MoAb binding (Table 20).
Under specific TDM assay conditions (i.e., MoAb dilution) the level of AM1c metabolite may be quantified; the assay parameters may also be modified to selectively identify all CSA metabolite levels while not reacting to the CSA parent molecule.
TABLE 19
Mouse Monoclonal Antibody Reactivity (AM19-DVS-KLH
immunogen) to CSA, CSA Metabolites, FK, Rapamycin, KLH
or HAS Antigens
Antigen
AM19-1-7E12-1
AM19-1-7E12-2
Panel
OD
%*
OD
%
CSA-DVS-HSA
3.229
100
3.477
>100
AM9-1-DVS-HSA
3.268
>100
3.167
95.5
AM19-9-DVS-HSA
2.883
89.4
2.132
64.3
AM19-1-DVS-HSA (1)
3.226
100
3.316
100
AM19-1-DVS-HSA (2)
3.405
>100
3.504
>100
FK-DVS-HSA
0.029
0
0
0
Rapa-suc-HSA
0
0
0
0
HAS
0.009
0
0
0
KLH
0.023
0
0
0
(AM19-1-7E12-1 and AM19-1-7E12-2 are both IgG1 antibody isotypes)
*Percent reactivity = OD to test antigen/OD to AM19-1-DVS (1)-HSA × 100
TABLE 20
Percent Inhibition of TCS from AM19-1-7E12-1 and
AM19-1-7E12-2 MoAb Clones with CSA/CSA Metabolites,
Rapamycin, FK, KLH and HSA Antigens
Antigen
AM19-1-7E12-1
AM19-1-7E12-2
CSA
0
0
AM1
59.2
67.3
AM1c
99.6
99.8
AM4n
30.4
36.8
AM1c9
64.6
71.6
AM19
35.2
49.5
AM9
43.0
44.3
Rapamycin
7.7
8.6
FK
6.3
3.2
KLH
3.8
4.3
HSA
3.5
1.5
Similarly, MoAbs were prepared using the AM19-1-DVS (2) and AM19-9-DVS hapten-protein conjugate immunogens. For example, the AM19-1-DVS (2) and AM19-9-DVS conjugates were used to develop specific MoAbs to AM1 or AM9 metabolites. The ability of the AM19-1 and AM19-9 immunogens are not limited to MoAb development of AM1or AM9 metabolite residues; they may also be used to prepare MoAbs to other CSA metabolite residues and epitopes on the parent CSA molecule. Examples of MoAb's reactivity elicited to AM19-9 haptens is shown in Table 21.
TABLE 21
Percent Inhibition of TCS from AM19-9-1E11, AM19-9-5A6 and
AM19-9-2G9 MoAb Clones with CSA/CSA Metabolites
Antigen
AM19-9-1E11
AM19-9-5A6
AM19-9-2G9
CSA
96
72
28
AM1
99
95
80
AM1c
99
68
20
AM4n
93
58
25
AM1c9
96
61
47
AM19
99
74
82
AM9
99
44
85
*These TCS had no cross-reactivity to Rapamycin, FK, KLH or HSA.
Example 17
Monoclonal Antibodies Elicited to the AM9-DVS Immunogens
Using the methods disclosed in this application, spleen cells from mice immunized to the AM9-DVS-KLH conjugates can be used to prepare monoclonal antibody secreting hybridoma cells. The AM9-1-DVS-KLH and AM9-9-DVS-KLH immunogens can be used to elicit MoAbs with specificity for the AM1, AM1c and AM9 metabolite moieties. MoAbs to other CSA/CSA metabolite antigens may also be prepared using these immunogens (Table 22)
TABLE 22
Percent Inhibition of TCS from AM9-1-9H5, AM9-1-2A11,
AM9-9-4F5 and AM9-9-6C3
Antigen
AM9-1-9H5
AM9-1-2A11
AM9-9-4F5
AM9-9-6C3
CSA
6
18
36
57
AM1
45
53
25
58
AM1c
94
82
13
52
AM4n
21
15
22
50
AM1c9
41
28
6
40
AM19
24
19
6
37
AM9
21
40
99
99
*These TCS had no cross-reactivity to Rapamycin, FK, KLH or HSA.
Example 18
Selectivity of Purified Monoclonal Antibodies
To confirm the reactivity and selectivity of MoAbs of this invention, purified MoAb was prepared from tissue culture supernatants. To purify MoAbs the following procedure was used:
Antibody Purification Protocol:
Thaw a frozen vial of monoclonal cells and grow to 200 ml in DMEM+Supplements (10% CPSR-3, 1%Penicillin/Streptomycin, 1% L-Glutamine, 1% Sodium pyruvate) until confluent. Incubate at 37° C., 5% CO 2 incubator.
1. Harvest concentrated supernatant by centrifuging at 1200 RPM, 10 minutes, 4° C. Balance pH of concentrated supernatant to pH 7.
2. Prepare Protein G column according to instructions (GammaBind Plus Spharose, Code No. 17-0886-02, Pharmacia Biotech).
3. Load concentrated supernatant on Protein G column at R/T.
4. Wash column with 25 ml of Binding buffers (0.01 M sodium phosphate, 0.15 M NaCl, 0.01 EDTA, pH 7.0).
5. Elute column with 15-20 ml of Elution buffer (0.5 M acetic acid pH 3.0).
6. Collect fractions using fraction collector (ISCO, FOXY Jr.).
7. Neutralize the eluted fractions with 0.5 ml of Neutralizing buffer (1 M Tris-HCl, pH 9.0)
8. Measure optical density of eluted fractions at 280 ηm wavelength (BECKMAN SpectrophotometerDU640i).
9. Pool fractions together in Spectra/Por membrane MWCO: 6-8000 (SPECTRUM, #132653)
10. Dialyze against 1×PBS at 4° C., O/N.
11. Do protein assay using BSA as standards (0, 200, 400, 600, 800, 1000 mg/ml). Read O.D. at 280 ηm wavelength.
Other antibody purification methods known in the art can be used. Using the competitive inhibition ELISA, MoAb cross-reactivity to a panel of hydroxylated or demethylated CSA metabolites was determined. The MoAbs to metabolite hapten conjugates of this invention can be separated into at least six groups based on their selectivity. Selectivity of various MoAbs purified from tissue culture supernatant is shown in Table 23.
TABLE 23
Purified MoAb Selectivity
Clone Reference
Purified MoAb Selectivity*
Gp I:
AM1-2E10
AM1
AM19-9-5A6
AM1 (FIG. 3)
AM9-1-6D4
AM1
Gp II:
AM9-1-7D2
AM9 (FIG. 4)
AM9-9-11G9
AM9
AM9-9-6C3
AM9
Gp III:
AM1-3A6
AM1, AM1c
AM19-1-7E12
AM1, AM1c (FIG. 5)
AM9-1-2A11
AM1, AM1c
Gp IV:
AM19-9-1E11
AM1, AM9
AM19-9-1D8
AM1, AM9
AM19-9-2G9
AM1, AM9 (FIG. 6)
Gp V:
AM9-9-11H11
CSA, AM1, AM9
AM9-9-4F5
CSA, AM9 (FIG. 7)
Gp VI:
AM9-1-4D6
AM1, AM1c, AM9, AM19 (FIG. 8)
*This selectivity was determined by inhibition ELISA format.
MoAbs in group I are selective for the AM1 metabolite, FIG. 3 shows the selectivity of MoAb AM19-9-5A6 for the AM1 metabolized residue.
Example 19
Monoclonal Antibodies to CSA Derivatives
The specificity of the CSA-1H6, CSA-2G9, AM1-2E10, AM1-7F5 and AM19-7E12-1 MoAbs were also analyzed using CSA, CSA derivative and CSG inhibitors (Table 24).
As demonstrated previously, these MoAbs were inhibited by the parent CSA molecule. Deuteration of the amino acid #1 residue of the CSA molecule did not affect Ab epitope site recognition. Their binding to the ELISA plate was inhibited by this CSA derivative. MoAbs CSA-1H6 and CSA-2G9 have good affinity for the cyclosporine G (CSG) molecule. The AM1 MoAbs show moderate (AM1-2E10=61% inhibition) to low (AM1-7F5=28.8% inhibition) affinity for CSG.
This data demonstrates that CSA-1H6, CSA-2G9, AM1-2E10 and AM1-7F5 have good affinity for the CSA molecule and a CSA derivative modified on the amino acid #1 residue. CSA-1H6 and CSA-2G9 also have good affinity for the CSG molecule. None of these MoAbs are cross-reactive with epitopes of derivatives of Rapamycin or FK.
TABLE 24
Percent Inhibition of CSA and AM1 MoAbs with CSA, CSG and CSA
Derivatives
Antigen
CSA-1H6
CSA-2G9
AM1-2E10
AM1-7F5
I
100
100
100
100
II
0
23.1
12.7
16.6
III
5.5
21.9
17.8
16.6
HSA
6.0
9.4
15.4
13.6
CSA
100
100
90.4
77.5
CSG
88.6
89.8
61.2
28.8
Inhibiting Derivatives:
Species Identification
Modification
I
CSA - deuterated on #1 amino acid
II
Rapamycin - deuterated and methylated on
#7 amino acid
III
oxime of FK (#22 amino acid)
This example demonstrates that, using CSA or CSA metabolite conjugates of this invention, antibodies can be elicited which recognize epitopes on the CSA parent molecule, CSG or other derivatives/analogues of CSA.
Example 20
Measuring the Biological Activity of CSA and CSA Metabolites by in vitro Mixed Lymphocyte Reaction (MLR) Assay
The MLR assay is useful for identifying CSA metabolites with biological (immunosuppressive) activity and to quantify this activity relative to the immunosuppressive activity of the parent CSA molecule.
An example of a mixed lymphocyte proliferation assay procedure useful for this purpose is presented graphically in FIG. 9 and is performed as follows:
Two-way Mixed Lymphocyte Reaction Assay:
1. Collect blood from two individuals (20 mls each) and isolate lymphocytes using Ficoll-Paque (Pharmacia Biotech).
2. Count lymphocytes at 1:10 dilution in 2% acetic acid (v/v).
3. Prepare 10 mls of each lymphocyte populations (A+B) at 1×10 6 cells/ml in DMEM/20% FCS (v/v).
4. Set up a 96 well sterile tissue culture plate, flat bottom (Sarstedt, cat #83.1835). To each well add:
5. Aliquot 100 μl per well lymphocyte population A
6. Aliquot 100 μl per well lymphocyte population B
7. Aliquot 20 μl per well of drug (CSA and CSA metabolites) at 0, 2.5, 5, 10, 25, 50 and 100 μg/L in triplicate in DMEM with no supplements.
8. To measure the effect of drug on proliferation, incubate the plate for 5 days at 37° C. in 5 % CO 2 atmosphere.
9. On day 6, prepare 3.2 mls of 1:50 dilution of Methyl- 3 H-Thymidine (Amersham Life Science, cat # TRK 120) in DMEM with no supplements. Add 30 μl per well and incubate for 18 hours at 37° C. in 5% CO 2 atmosphere.
10. On day 7 cells are harvested onto glass microfiber filters GF/A (Whatman, cat #1820024) using a Cell-Harvestor (Skatron, cat #11019). Wash cells 3× with 1.0-ml sterile distilled water.
Note: All procedures are done using sterile techniques in a biological flow hood.
11. Place filters in Scintillation vials and add 1.5 mls of SciniSafe Plus 50% scintillation fluid (Fisher, cat # SX-25-5).
12. Measure the amount of radioactivity incorporated in the lymphocytes using a beta counter (Micromedic System Inc., TAURUS Automatic Liquid Scintillation Counter) for 1.0 minute.
13. Calculate averages and standard deviations for each drug and express results as: % Inhibition = 1 - [ Ave CPM of test drug Ave CPM of zero drug ] × 100
% Proliferation=100−% Inhibition
Other mixed lymphocyte reaction assays known in the art can also be used.
The MLR assay can be utilized to select antibodies of the invention which bind biologically active CSA metabolites and/or the parent CSA molecule. Antibodies could also be selected for reactivity to biologically inactive metabolite moieties. Examples of MoAbs displaying such reactivity/selectivity are shown in Table 25.
TABLE 25
Ability of Anti-CSA Metabolite MoAbs to Block CSA Inhibition
of MLR
Purified MoAbs
% Inhibition of MLR
Media Control (no CSA, no MoAbs)
0
CSA 100 ug/L (no MoAbs)
49.1
AM1-3A6
3.6
AM1-7F5
0
AM9-1-7D2
5
AM9-1-2A11
46.7
AM9-9-6C3
0
AM9-9-11G9
0
AM19-1-7E12
0
AM19-1-4E8
0
AM19-9-1D8
0
AM19-9-5A6
41.5
AM19-9-1E11
0
AM19-9-2G9
42.5
As shown in Table 25, a 100 ug/L concentration of CSA inhibited MLR by 49.1% (the IC 50 value), media alone caused no inhibition of MLR. A number of MoAbs blocked the CSA inhibition of MLR, indicating MoAb binding (or cross-reactivity) to epitopes of the CSA molecule. All MoAbs were control tested in this MLR assay (with no CSA drug) to determine non-specific suppressive effects. No MoAbs showed any suppression of MLR. Three MoAbs (AM9-1-2A11; AM19-9-5A6; AM19-9-2G9) showed no ability to block CSA inhibition of MLR. This result confirms the inhibition ELISA results which demonstrate selectivity to metabolite moieties. AM9-1-2A11 is selective for AM1 and AM1c; AM19-9-5A6 is selective for AM1; and AM19-9-2G9 for AM1 and AM9. These MoAbs do not bind or cross-react with epitopes of the CSA molecule.
Example 21
Immunoassay Kits Using Polyclonal and Monoclonal Antibodies to Specific Sites of Cyclosporine
The polyclonal and monoclonal antibodies to specific sites of CSA of the invention may be used for development of immunoassays or TDM kits. Such assays could include, but are not limited to, direct, inhibition, competitive or sandwich immunoassays (ELISA or other assay systems), RIA, solid or liquid phase assays or automated assay systems.
In an automated assay format, the CSA-2G9 MoAb can significantly inhibit a CSA- enzyme conjugate (27.6%; maximal inhibition in this assay format is 30%). This inhibition can be modulated (blocked) by free CSA. Other MoAbs elicited using conjugates of this invention which can be optimized for CSA quantification in automated TDM assays, include (but not limited to) MoAbs CSA-1H6; AM1-7F5 produced by the hybridoma cell line deposited with ATCC as designation PTA-4142 on Mar. 13, 2002; AM1-3B1 produced by the hybridoma cell line deposited with ATCC as designation PTA-4154 on Mar. 30, 2002; AM1-2E10 produced by the hybridoma cell line deposited with ATCC as designation PTA-4141 on Mar. 13, 2002; AM9-1-3C1 produced by the hybridoma cell line deposited with ATCC as designation PTA-4155 on Mar. 30, 2002; AM19-1-5D2 produced by the hybridoma cell line deposited with ATCC as designation PTA-4163 on Mar. 30, 2002; AM19-1-4E8; AM19-1-5B3 produced by the hybridoma cell line deposited with ATCC as designation PTA-4147 on Mar. 13, 2002; AM9-9-11H 11 produced by the hybridoma cell line deposited with ATCC as designation PTA-4159 on Mar. 30, 2002 and AM9-9-4F5 produced by the hybridoma cell line deposited with ATCC as designation PTA-4145 on Mar. 13, 2002.
A further aspect of the invention is to use metabolite, selective MoAbs to mop-up or block metabolites in patient samples; thereby reducing anti-CSA metabolite cross-reactivity. This would allow for more accurate determination of levels of the parent CSA molecule in samples. MoAbs of this invention most preferred for this purpose include, but not limited to, MoAbs AM1-2E10 produced by the hybridoma cell line deposited with ATCC as designation PTA-4141 on Mar. 13, 2002; AM19-9-5A6 produced by the hybridoma cell line deposited with ATCC as designation PTA 4150 on Mar. 13, 2002; AM9-1-6D4 produced by the hybridoma cell line deposited with ATCC as designation PTA-4157 on Mar. 30, 2002; AM9-1-7D2 produced by the hybridoma cell line deposited with ATCC as designation PTA-4144 on Mar. 13, 2002; AM9-9-11G9 produced by the hybridoma cell line deposited with ATCC as designation PTA-4158 on Mar. 30, 2002; AM9-9-6C3 produced by the hybridoma cell line deposited with ATCC as designation PTA-4146 on Mar. 13, 2002; AM1-3A6; AM19-1-7E12 produced by the hybridoma cell line deposited with ATCC as designation PTA-4161 on Mar. 30, 2002; AM9-1-2A11 produced by the hybridoma cell line deposited with ATCC as designation PTA-4143 on Mar. 13, 2002; AM19-9-1E11 produced by the hybridoma cell line deposited with ATCC as designation PTA-4149 on Mar. 13, 2002; AM19-9-1D8 produced by the hybridoma cell line deposited with ATCC as designation PTA-4148 on Mar. 13, 2002; AM19-9-2G9 produced by the hybridoma cell line deposited with ATCC as designation PTA-4160 on Mar. 30, 2002; and AM9-1-4D6 produced by the hybridoma cell line deposited with ATCC as designation PTA4156 on Mar. 30, 2002.
Another aspect of this invention is that CSA or metabolite hapten conjugates can be used to prepare antibodies to CSA epitopes outside the region of a.a. #1. Other antibodies can be prepared to CSA epitopes outside the region of the a.a. #9. Using antibodies from two different species, sandwich assays for TDM can be developed. For example, mouse polyclonal or monoclonal antibodies (Ab A) prepared with the AM9-9-DVS hapten conjugate would bind CSA; rabbit polyclonal or monoclonal antibodies (Ab B) prepared with CSA-DVS or AM1-DVS hapten would bind epitopes on the other face of the CSA molecule to provide a sandwich assay. This invention also provides methods to prepare polyclonal or monoclonal antibodies to various epitopes of CSA metabolites. Methods to block, bind or remove specific metabolites with these MoAbs can be developed using methods known in the art.
TDM assays may also be designed to measure levels of the CSA parent molecule and certain biologically active and/or toxic metabolites using combinations of MoAbs. For example, a combination of a MoAb (specific for the parent CSA molecule), with a MoAb (specific for AM1 and AM1c metabolites), and a MoAb (specific for AM9 metabolite) could be used to measure CSA, AM1, AM1c and AM9 metabolite levels. Such MoAbs could also be used alone to quantify levels of CSA or specific CSA metabolites.
The examples disclosed in this application demonstrate the preparation of polyclonal-and monoclonal antibodies useful in TDM assays to measure parent CSA/CSA derivative levels; or parent CSA/CSA derivative and all CSA metabolite levels, or parent CSA/CSA derivative and specific metabolite levels (i.e., AM1 and/or AM1c and/or AM9), or for the development of TDM assays to measure specific CSA metabolite levels. This invention is not limited to production of monoclonal antibodies using immunogens described in Examples 2-5, as these are presented merely as proof of principle of the invention. This invention also encompasses the preparation of immunogens using CSA derivatives or any CSA metabolites and the production of polyclonal and monoclonal antibodies to all CSA metabilites (i.e., phase I, II , etc. metabolites).
Upon reading the present disclosure, modifications of the invention will be apparent to one skilled in the art. These modifications are intended to be encompassed by the present disclosures, Examples and the claims appended hereto.
7
1
11
PRT
Tolypocladium inflatum
MOD_RES
(1)
Position 1 is xaa wherein xaa =
N-methyl-(4R)-4-but-2E-en-1-yl-4-methyl-(L)-threonine.
1
Xaa Xaa Gly Leu Val Leu Ala Ala Leu Leu Val
1 5 10
2
11
PRT
Tolypocladium inflatum
MOD_RES
(1)
Position 1 is xaa wherein xaa =
N-methyl-(4R)-4-but-2E-en-1-yl-4-methyl-(L)-threon
ine.
2
Xaa Xaa Gly Leu Val Leu Ala Ala Leu Leu Val
1 5 10
3
11
PRT
Tolypocladium inflatum
MOD_RES
(1)
Position 1 is xaa wherein xaa =
N-methyl-(4R)-4-but-2E-en-1-yl-4-methyl-(L)-threon
ine.
3
Xaa Xaa Gly Leu Val Leu Ala Ala Leu Leu Val
1 5 10
4
11
PRT
Tolypocladium inflatum
MOD_RES
(1)
Position 1 is xaa wherein xaa =
N-methyl-(4R)-4-but-2E-en-1-yl-4-methyl-(L)-threon
ine.
4
Xaa Xaa Gly Leu Val Leu Ala Ala Leu Leu Val
1 5 10
5
11
PRT
Tolypocladium inflatum
MOD_RES
(1)
Position 1 is xaa wherein xaa =
N-methyl-(4R)-4-but-2E-en-1-yl-4-methyl-(L)-threon
ine.
5
Xaa Xaa Gly Leu Val Leu Ala Ala Leu Leu Val
1 5 10
6
11
PRT
Tolypocladium inflatum
MOD_RES
(1)
Position 1 is xaa wherein xaa =
N-methyl-(4R)-4-but-2E-en-1-yl-4-methyl-(L)-threon
ine.
6
Xaa Xaa Gly Leu Val Leu Ala Ala Leu Leu Val
1 5 10
7
11
PRT
Tolypocladium inflatum
MOD_RES
(1)
Position 1 is xaa wherein xaa =
N-methyl-(4R)-4-but-2E-en-1-yl-4-methyl-(L)-threon
ine.
7
Xaa Xaa Gly Leu Val Leu Ala Ala Leu Leu Val
1 5 10 | This invention relates to the production of polyclonal and monoclonal antibodies to specific regions of cyclosporine (CSA) and/or CSA metabolites/derivatives. The reactivity of these polyclonal and monoclonal antibodies make them particularly useful for immunoassays for therapeutic drug monitoring (TDM). These immunoassays or TDM kits may include polyclonal or monoclonal antibodies to specific sites of CSA and/or CSA metabolites. These kits may also include various combinations of polyclonal antibodies, polyclonal and monoclonal antibodies or a panel of monoclonal antibodies. Cyclosporine or CSA metabolite conjugate immunogens are prepared for the immunization of a host animal to produce antibodies directed against specific regions of the CSA or CSA metabolite molecule. By determining the specific binding region of a particular antibody, immunoassays which are capable of distinguishing between the parent molecule, active metabolites, inactive metabolites and other structurally similar immunosuppressant compounds are developed. The use of divinyl sulfone (DVS) as the linker arm molecule for forming cyclosporine and cyclosporine metabolite protein conjugate immunogens is described. | 8 |
TECHNICAL FIELD
[0001] The present invention relates to a carrier for loading a bicycle, in particular, to a hitch carrier for loading a bicycle on a rear of a vehicle.
BACKGROUND ART
[0002] As a hitch carrier configured to load a bicycle, a hanging type that includes two arms is conventionally known. The hitch carrier with such a configuration puts the two arms through a triangle constituted with a top tube, a down tube, and a sheet tube as a bicycle frame, then secures the top tube with belts disposed on the respective arms.
[0003] As the hitch carriers related to such a configuration, structures disclosed in Patent Documents 1 and 2 are known. The hitch carrier disclosed in Patent Document 1 includes an arm disposed to extend laterally using a brace member as a base point. This brace member and the lateral arm include respective hangers for locking a bicycle. The basic configuration thereof is to support a top tube with the hanger disposed on the lateral arm and secure a sheet tube with the hanger disposed on the brace member.
[0004] The hitch carrier disclosed in Patent Document 2 includes a plurality of multifunctional brackets on one or two arms, which are put through to an empty space within a frame constituted with a top tube, a down tube, a sheet tube, and similar member. The basic configuration thereof is to sandwich and secure the top tube and the sheet tube with each of the multifunctional brackets.
Patent Document 1: U.S. Pat. No. 5,067,641 Patent Document 2: U.S. Pat. No. 5,573,165
DISCLOSURE OF THE INVENTION
Problems to be Solved by the Invention
[0007] The conventional hitch carrier with a configuration of disposing two arms horizontally in parallel has a problem that a bicycle is not loadable unless the bicycle includes a frame that is constituted to have a relatively large empty space within the frame and a straight top tube, therefore the versatility is poor.
[0008] Patent Document 2 discloses a configuration that ensures loading a bicycle even in the case where the empty space within the frame is small by including multifunctional brackets (cradles) that includes supporting portions at two positions on one arm. However, in this case, the multifunctional brackets possibly rotate using the arm as a base point, thus generating a problem in stably holding the bicycle.
[0009] Therefore, the objective of the present invention is to provide a hitch carrier that is highly versatile for a bicycle that is loadable and that ensures stable loading of a bicycle.
Solutions to the Problems
[0010] A hitch carrier according to the present invention to achieve the above-described objective is a hitch carrier for loading a bicycle including a frame that includes a top tube, a down tube, and a sheet tube. The hitch carrier includes a first arm engaged with a first cradle including a supporting portion that supports the top tube, a second arm engaged with a second cradle including a supporting portion that supports the down tube, and a post supporting in a cantilever manner both the first arm and the second arm separated in a vertical direction. Fastening belts are disposed on the first cradle and the second cradle to fasten the top tube and the down tube, respectively.
[0011] In the hitch carrier including a feature as described above, the first cradle and the second cradle include respective through holes that engage with the first arm and the second arm, and a plurality of the supporting portions disposed in a peripheral area using the through hole as a base point on an outer periphery in a direction intersecting with a direction where the through hole is formed. Respective distances between the through hole and the plurality of supporting portions are configured to be different.
[0012] Including such features allows changing of a loading height and a loading angle of the frame, which constitutes the bicycle, by rotating the cradle. In view of this, in the case where the plurality of bicycles are loaded, interference of a large width portion such as a handlebar and a pedal is avoidable.
[0013] In the hitch carrier including features as described above, the first arm and the second arm are preferred to include a turning mechanism configured to turn using a supporting portion of the post as a base point. Including such a feature allows the arms to be folded in the post side when in an unused state.
[0014] The hitch carrier including features as described above, preferably includes a link mechanism that links turning movements of the first arm and the second arm. Including such a feature allows switching of a used state and a stored state to be performed in one action. A mechanism for keeping a posture of the arm such as a locking mechanism is sufficient by being disposed on only one of the first arm or the second arm, thus simplifying the configuration.
Effects of the Invention
[0015] According to the hitch carrier including features as described above, a hitch carrier that is highly versatile for a bicycle that is loadable and that ensures stable loading of a bicycle can be constituted.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a diagram illustrating a configuration when a hitch carrier according to the embodiment is installed on a vehicle is viewed from a vehicle side surface.
[0017] FIG. 2 is a perspective view illustrating the configuration of the hitch carrier according to the embodiment.
[0018] FIG. 3 is a partial cross-sectional view illustrating a used state in a state where a brace member that constitutes a post of the hitch carrier according to the embodiment is divided.
[0019] FIG. 4 is a partial cross-sectional view illustrating a stored state in a state where the brace member that constitutes the post of the hitch carrier according to the embodiment is divided.
[0020] FIG. 5 is a perspective view illustrating a configuration of a cradle employed in the hitch carrier according to the embodiment.
[0021] FIG. 6 is a diagram for describing an exemplary of a specific configuration of a fastening belt and a buckle that constitute the cradle.
[0022] FIG. 7 is a diagram illustrating a configuration when the hitch carrier with a bicycle loaded is viewed from a vehicle side surface side.
[0023] FIG. 8 is a diagram illustrating a configuration when the hitch carrier with the bicycle loaded is viewed from a vehicle rear side.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0024] The following describes embodiments according to a hitch carrier of the present invention in detail with reference to the drawings. FIG. 1 is a diagram illustrating a configuration when a hitch carrier is installed on a vehicle is viewed from a vehicle side surface. FIG. 2 is a perspective view of the hitch carrier.
[0025] A hitch carrier 10 according to the embodiment is basically constituted with a post 12 , a first arm 18 , and a second arm 24 . The post 12 is a member that supports the first arm 18 and the second arm 24 in a cantilever manner (supports one end portions of the first arm 18 and the second arm 24 ). The post 12 is connected to a rear of a vehicle via an adapter 14 (the vehicle is not illustrated). The post 12 includes a turning mechanism 16 having a locking function in a connecting portion with the adapter 14 . In the used state, the post 12 keeps a state of being disposed standing upright to be approximately perpendicular with respect to the adapter 14 , which is disposed to extend approximately horizontally to the rear of the vehicle, as illustrated in FIG. 1 and FIG. 2 . On the other hand, a vehicle of a hatchback type cannot open a hatch with the post 12 standing upright. In view of this, when the hatch is opened, the post 12 is turned in a direction to which the adapter 14 is extended using the connecting portion with the adapter 14 as a base point. Therefore, the turning mechanism 16 has the locking function to prevent an unwanted turning in the used state.
[0026] The post 12 according to the embodiment is constituted with a pair of brace members 12 a . The brace members 12 a forming the pair are configured to sandwich the adapter 14 , and the first arm 18 and the second arm 24 , which will be described in detail later. With such a configuration, the configuration to store the first arm 18 and the second arm 24 between the brace members 12 a forming the pair can be employed. Rotation axes 22 d and 28 (see FIG. 3 and FIG. 4 ) to support the one end portions of the first arm 18 and the second arm 24 may be disposed so as to bridge across the brace members 12 a forming the pair. Therefore, the rotation axes 22 d and 28 can be stably held.
[0027] The first arm 18 is a support rod disposed on a top end side of the post 12 . The first arm 18 includes a plurality of cradles (first cradles 20 ) engaged. The first arm 18 according to the embodiment is constituted with a cylindrical member or a columnar member, and its base end portion includes a turning mechanism 22 that serves as a connecting portion with the post 12 .
[0028] The turning mechanism 22 is constituted with a turning member 22 a , a locking means 22 b , and a casing 22 c as a main body, as the cross-sectional structures in FIG. 3 and FIG. 4 illustrate. The turning member 22 a is a member that supports the one end portion of the above-described first arm 18 and supports its rotation and locking. A rotating member 22 a supports the first arm 18 in a state where the first arm 18 is shifted upward (a direction to which the post 12 extends) with respect to the rotation axis 22 d for a shift amount L. Such a configuration ensures preventing interference between the first arm 18 and the second arm 24 when the first arm 18 and the second arm 24 are turned to be stored because positions of the first arm 18 and the second arm 24 are mutually shifted as illustrated in FIG. 4 .
[0029] The turning member 22 a includes a locking groove 22 a 1 . Cooperating with the locking means 22 b , which will be described later, ensures keeping a state where the first arm 18 is projected out (used state) or a state where the first arm 18 is folded (stored state).
[0030] The locking means 22 b is a mechanism used for keeping the first arm 18 in the used state or the stored state as described above. In this embodiment, a lever 22 b 2 including a rotation axis 22 b 1 and a convex-shaped portion 22 b 3 included in this lever 22 b 2 constitute the locking means 22 b . Here, the plurality of locking grooves 22 a 1 of the turning member 22 a are formed toward a side of the rotation axis 22 b 1 on an outer periphery of the turning member 22 a . Positions to form the locking grooves 22 a 1 are a portion where the convex-shaped portion 22 b 3 of the lever 22 b 2 positions when the first arm 18 is in the used state and a portion where the convex-shaped portion 22 b 3 of the lever 22 b 2 positions when the first arm 18 is in the stored state. The lever 22 b 2 preferably is biased to a side of the rotation axis 22 d of the turning member 22 a with, for example, a spring, which is not illustrated.
[0031] The casing 22 c is a cover covering the turning member 22 a , the first arm 18 , the locking means 22 b , or similar part. The casing 22 c includes a guide groove 22 c 1 for avoiding interference with the rotation axis 22 b 1 of the lever 22 b 2 fixed to the brace member 12 a.
[0032] Such a configuration ensures turning of the first arm 18 by turning the lever 22 b 2 in a direction of an arrow A to release an engagement of the locking groove 22 a 1 and the convex-shaped portion 22 b 3 . When the first arm 18 turns to a predetermined position (a position in the used state or a position in the stored state), the convex-shaped portion 22 b 3 of the lever 22 b 2 biased to the rotation axis 22 d side of the turning member 22 a engages with the locking groove 22 a 1 formed in the predetermined position.
[0033] The second arm 24 is a support rod disposed on a base end side of the post 12 with respect to the first arm 18 described above. Therefore, the first arm 18 and the second arm 24 have their arrangement at upper and lower positions in the used state. The second arm 24 also includes a plurality of cradles (second cradles 26 ) engaged, similar to the first arm 18 .
[0034] The second arm 24 according to the embodiment includes the rotation axis 28 on the one end portion, and includes a connecting member 30 in between with the turning member 22 a supporting the one end portion of the first arm 18 . Thus disposing the connecting member 30 can constitute a link mechanism that links a turning movement of the second arm 24 with a turning movement of the first arm 18 . When the first arm 18 is in a locked state, the second arm 24 can also be in the locked state. In view of this, the second arm 24 has no necessity of including the locking means 22 b , thus the configuration can be simplified.
[0035] The cradles (the first cradle 20 and the second cradle 26 ), which is engaged to the first arm 18 and the second arm 24 , are not necessarily plural for both the first arm 18 and the second arm 24 . The same number as the number of the bicycle loaded may be disposed each.
[0036] The first cradle 20 and the second cradle 26 (hereinafter collectively and simply referred to as the cradles 20 and 26 ) basically include a through hole 32 and a supporting portion 34 ( 34 a and 34 b ), and a fastening belt 36 , as a perspective view in FIG. 5 illustrates. The through hole 32 is an engaging portion to engage with the above-described first arm 18 or second arm 24 . The supporting portion 34 is a loading surface to support a top tube 52 (see FIG. 8 ) or a down tube 54 (see FIG. 8 ) of a bicycle 50 (see FIG. 7 and FIG. 8 ). The fastening belt 36 is a holding member that holds the top tube 52 or the down tube 54 loaded on the supporting portion 34 so as to prevent the top tube 52 or the down tube 54 from slipping from the loading surface.
[0037] The cradles 20 and 26 including such a basic element according to the embodiment have their side surface shaped in oval (track-like shape). On the side surface, the above-described through hole 32 is formed from one side surface toward the other side surface. The cradles 20 and 26 according to the embodiment include the through hole 32 that is formed being biased to one circular arc side of the oval-like shape. A whole outer peripheral surface connecting a pair of side surface, which forms the oval, constitutes the supporting portion 34 for supporting the bicycle. In view of this, the plurality of supporting portions 34 on the cradles 20 and 26 are arranged around the peripheral area using the center of the through hole 32 as the base point. The supporting portion 34 , such as the supporting portion 34 a and the supporting portion 34 b , has a different distance from the center of the through hole 32 depending on its position. In view of this, the distance from the center of the through hole 32 (the first arm 18 or the second arm 24 ) to the supporting portion 34 , that is, a height of the supporting portion 34 can be changed by rotating the cradles 20 and 26 engaged with the first arm 18 or the second arm 24 using the through hole 32 as the base point. This ensures changing of the height when the bicycle 50 (see FIG. 7 and FIG. 8 ) is loaded, thus preventing interference when the plurality of bicycles 50 are loaded.
[0038] The supporting portion 34 is constituted to have its center portion dent in a drum shape from the one side surface to the other side surface. Such a configuration improves a holdability of the frame (the top tube 52 or the down tube 54 ) when the bicycle 50 is loaded, and ensures the prevention of the frame slippage.
[0039] The circular arc side on the opposite side of the side where the through hole 32 is disposed in the cradles 20 and 26 includes a buckle 38 for fastening the fastening belt 36 . The buckle 38 is disposed to form a pair on both the one side surface side and the other side surface side. The specific configuration of the buckle 38 does not matter as long as the configuration ensures the effective fastening of the fastening belt 36 . The configuration may omit the buckle 38 itself as long as the configuration allows the frame in contact with the supporting portion 34 to be effectively held with the fastening belt 36 . For example, in the case where the fastening belt is constituted with a member having a stretch property such as a rubber, it is not necessary to dispose the buckle 38 because the fastening belt 36 alone can fasten and hold.
[0040] On the other hand, in the case where a configuration includes the buckle 38 , the following configuration, for example, may be employed. That is, in the case where a stopper 36 a in a sawtooth shape is disposed in a fastening portion of the fastening belt 36 as illustrated in FIG. 6 , the buckle 38 is preferably constituted to be in a ratchet shape having a base 38 a , a lever 38 b , a bias spring 38 c , and similar part. Such a configuration enables a fastening belt 38 to be pulled only to a fastening side indicated by an arrow E when a leading end of the lever 38 b of the buckle 38 is biased to the fastening belt 36 side, and when the fastening belt 36 is pulled to a loosening side (an arrow F side), an engagement occurs between the leading end of the lever 38 b and the stopper 36 a , thus the fastening belt 36 cannot be pulled. When the fastening belt 36 is loosen, pushing a rear end of the lever 38 b to the fastening belt 36 side releases the engagement of the leading end and the stopper 36 a.
[0041] The buckle 38 having the configuration as described above is turnable around the axis connecting the one side surface and the other side surface as indicated by an arrow D (see FIG. 5 ). Such a configuration enables the frame to be held even in the case where the position of the supporting portion 34 , which contacts the frame, is changed in association with the rotation of the cradles 20 and 26 using the through hole 32 as a base point at each contacting position by turnably disposing the fastening belt 38 such that the fastening belt 38 straddles over the supporting portion 34 that is in contact with the frame.
[0042] The hitch carrier 10 having such a configuration allows the first arm 18 and the second arm 24 to be in the stored state by turning in a direction of an arrow B (see FIG. 3 ) or to be in the used state by turning in a direction of an arrow C (see FIG. 4 ), by turning the lever 22 b 2 of the locking means 22 b in the direction of the arrow A as described above. In the stored state, the first arm 18 and the second arm 24 , which include the plurality of cradles 20 and 26 engaged are stored in the post 12 constituted with the brace members 12 a forming the pair, thus making the stored state compact.
[0043] Next, loading of the bicycle using the hitch carrier as described above will be described with reference to FIG. 7 and FIG. 8 . FIG. 7 is a diagram illustrating a state where the bicycle is loaded is viewed from the vehicle side surface side in a state where the hitch carrier 10 is installed on the vehicle. FIG. 8 is a diagram illustrating a state when viewed from the vehicle rear portion side.
[0044] The hitch carrier 10 according to the embodiment is basically loaded by the bicycle 50 including the frame forming a triangle with the top tube 52 , the down tube 54 , and a sheet tube 56 as illustrated in FIG. 8 .
[0045] The first cradle 20 is located under the top tube 52 , supports the top tube 52 with the supporting portion 34 , and holds the top tube 52 with the fastening belt 36 . The second cradle 26 is located under the down tube 54 , supports the down tube 54 with the supporting portion 34 , and holds the down tube 54 with the fastening belt 36 .
[0046] The employed configuration holds the bicycle 50 by disposing only the first cradle 20 in the triangle constituted with the frame and supporting the down tube 54 with the second cradle 26 from outside the triangle. Thus the bicycle 50 with a frame having a small triangle constituted with the top tube 52 , the down tube 54 , and the sheet tube 56 can also be held. The configuration holds the frame of the bicycle 50 vertically by disposing the first cradle 20 and the second cradle 26 in a vertical direction, therefore a wobble of the loaded bicycle can be stopped.
[0047] Rotating the cradles 20 and 26 using the first arm 18 or the second arm 24 as the base point ensures changing a distance between the first arm 18 or the second arm 24 and the supporting portion 34 . That is, a height and an angle to support the frame are changeable. In view of this, the loading height and angle of the frame are changeable in order to avoid the interference at a large width portion such as a handlebar 58 and a pedal 60 when the plurality of bicycles 50 are loaded.
[0048] While the hitch carrier 10 according to the embodiment is described that the first arm 18 and the second arm 24 are disposed to be in a vertical position, the vertical positions of the first arm 18 and the second arm 24 do not necessarily match one another, and may be disposed with a shift of approximately the width of the member constituting the arm. Such a configuration ensures avoiding the interference between the first arm and the second arm even in a case where the shift amount L is not disposed between the rotation axis 22 b 1 and the support position of the first arm.
[0049] The hitch carrier 10 according to the above-described embodiment employs the configuration that the first arm 18 and the second arm 24 are vertically disposed on the post 12 , and the cradles 20 and 26 disposed on both the arms support and hold the frame, thus the bicycle 50 basically cannot shake in a front-rear direction of the vehicle (not illustrated). However, a member to reduce the shaking of the bicycle 50 (wobble stop member) may be disposed separately from the cradles 20 and 26 in consideration of safety.
DESCRIPTION OF REFERENCE NUMERAL
[0050] 10 : hitch carrier, 12 : post, 12 a : brace member, 14 : adapter, 16 : turning mechanism, 18 : first arm, 20 : first cradle, 22 : turning mechanism, 22 a : turning member, 22 a 1 : locking groove, 22 b : locking means, 22 b 1 : rotation axis, 22 b 2 : lever, 22 b 3 : convex-shaped portion, 22 c : casing, 22 c 1 : guide groove, 22 d : rotation axis, 24 : second arm, 26 : second cradle, 28 : rotation axis, 30 : connecting member, 32 : through hole, 34 ( 34 a , 34 b ): supporting portion, 36 : fastening belt, 36 a : stopper, 38 : buckle, 38 a : base, 38 b : lever, 38 c : bias spring, 50 : bicycle, 52 : top tube, 54 : down tube, 56 : sheet tube, 58 : handlebar, 60 : pedal | Provides a hitch carrier that is highly versatile for a bicycle that is loadable and that ensures stable loading of a bicycle. A hitch carrier for loading a bicycle including a frame that includes a top tube, a down tube, and a sheet tube, includes a first arm engaged with a first cradle including a supporting portion that supports the top tube, a second arm engaged with a second cradle including a supporting portion that supports the down tube, and a post supporting in a cantilever manner both the first arm and the second arm separated in a vertical direction. Fastening belts are disposed on the first cradle and the second cradle to fasten the top tube and the down tube, respectively. | 1 |
RELATED APPLICATION
[0001] This continuation application claims the priority benefit of application Ser. No. 09/242,845, filed Jul. 7, 1999, which is a national stage application of international application number PCT/EP97/04520, filed Aug. 20, 1997, which claims the priority benefit of German Application No. 196 35 429.3, filed Sep. 2, 1996.
FIELD OF THE INVENTION
[0002] The present invention relates to a database system and a method of organizing a data set existing in an n-dimensional cube with n>1.
BACKGROUND OF THE INVENTION
[0003] The so-called B tree (or also B* tree or prefix B tree) is known as the data structure to organize extensive one-dimensional volumes of data in mass memories such as magnetic disk memories. The data structure of the B tree over that of a simple search tree has the advantage that lower search times are required for data access. The resulting search time to locate certain data involves at least log 2 (n) steps with a simple search tree with n nodes. With a search tree with 1,000,000 nodes, log 2 (1,000,000)≈20 disk access operations must therefore be expected. Assuming a mean access figure of 0.1 sec., the search of one node will require 2 secs. This value is too large in practice. With the data structure of the B tree, the number of disk access operations is reduced by transferring not one single node, but a whole segment of the magnetic disk allocated to a node to the main memory and searching within this segment. If, for example, the B tree is divided into areas of seven nodes each and if such an area is transferred into the main memory with each disk access operation, the number of disk access operations for the search of a node is reduced from a maximum of 6 to a maximum of 2. With 1,000,000 nodes, only log 8 (1,000,000)=7 access operations are therefore required. In practice, the search tree is normally divided into partial areas with a size of 2 8 -1 to 2 10 -1 nodes. With an area size of 255 nodes, log 6 (1 m)≈2.5 disk access operations are required for the search of a node in a tree with 1,000,000 nodes so that the search for a given value takes only around 0.3 secs. The search time within a partial area with 255 nodes located in the main memory can be neglected in comparison with the disk access operation. The B tree is a vertically balanced tree in which all leaves are located at the same level.
[0004] The so-called dd trees are known from K Mehlhorn: Multidimensional searching and computational geometry, Springer, Heidelberg 1984, to organize a multidimensional data set. With the dd trees, three types of queries can be performed in principle, namely point queries, area queries and queries where some intervals are given as (−infinite, +infinite). However, the data structure of a dd tree only allows fast access for point queries, as then only one path in the tree needs to be searched. With the other queries, it is possible that the whole tree has to be searched. Moreover, dd trees are static, i.e. the whole object volume to be organized must already be known before the dd tree can be set up. However, in most applications in practice, the object volume is dynamic, i.e. it must be possible for objects to be inserted into or deleted from the tree in any order and at any time without the whole tree having to be set up again from the start. Furthermore, dd trees are only suitable for main memory applications, but not for peripheral memories which are needed to store very large volumes of data.
[0005] In “The Grid File” by Nievergelt et al, ACM TODS, Vol 9, No. 1, March 1984, so-called grid files are described to organize multidimensional data where queries for points and areas are performed on the basis of an index structure, the so-called grid. Although this data organization allows a fast search for point and area queries, it is a static procedure so that the total index structure has to be completely reorganized regularly when data objects are inserted or deleted dynamically. This method is thus not suitable for many applications, in particular not for online applications.
[0006] So-called R trees are known as the data structure to organize multidimensional data from A. Guttmann: A dynamic index structure for spatial searching, Proceedings ACM SIGMOD, Intl. Conference on Management of Data, 1984, pages 47-57. These trees, which are used mainly for so-called geo-databases, are vertically balanced like B trees and also allow the dynamic insertion and deletion of objects. However, no fast access times are guaranteed for the response to queries, because under certain circumstances any number of paths in the corresponding tree, in extreme cases even the whole tree, have to be searched to answer a query. As a result, these R trees are not suitable for most online applications.
[0007] From Y. Nakamura et al: Data structures for multi-layer n-dimensional data using hierarchical structure, 10th International Conference on pattern recognition, Volume 2, Jun. 16, 1990, IEEE Computer Society Press, New Jersey, USA, pages 97-102, a splitting method is known for a multidimensional rectangular space. In the known method, a given multidimensional rectangular space is split into two sub-spaces as soon as the number of data points in the space exceed the capacity of one data page. The splitting of the starting space is performed by cutting out a partial rectangular. The spatial structures newly created by this splitting, namely a cut-out rectangular and the rest of the starting space are structured as layers in a BD tree with the tree structure being created depending on the sequence of the cutting out of the individual partial spaces in the event of multiple cut-out partial spaces. The BD tree structure created in such a way represents a binary tree in which it is determined at each branch node which rectangle will be cut out as the new BD partial space. This successive cutting out has the consequence that the BD tree grows downwards so that in the insertion, deletion and searching of data points, i.e. data objects, in the total space a path has to be passed through from the tree root to a leaf (branch end). Here, it is necessary to check at every intermediate node whether a point being searched for is located in the associated cut-out partial space or in the complementary rest space. The search effort can thus grow proportionally with the size of the data set, which leads to a poor efficiency behavior with large and very large data sets.
[0008] The most widespread method in practice today to organize a multidimensional data set is based on the original one-dimensional B trees, with one B tree in each case being used for each dimension of the starting data set so that area queries in an n-dimensional data set are supported by n B trees. In an area query, all objects are thus obtained from the peripheral memory for each dimension whose values are located in the interval specified in the query for this dimension. These data objects form the hit number in the corresponding dimension. To determine the desired answer number, a mean number of the hit numbers of all dimensions must be computed, which will normally first require the sorting of these numbers. When a data object is inserted or deleted, n B trees must also be searched and modified correspondingly.
OBJECTS AND SUMMARY OF THE INVENTION
[0009] On this basis, the object of the invention is to provide a database system and a method of organizing an n-dimensional data set which, thanks to improved access times, is, in particular, suited for use in online applications and which allows a dynamic insertion and deletion of data objects.
[0010] In accordance with the invention a database system and a method to organize an n-dimensional data set is proposed to solve this object. The database system in accordance with the invention comprises a computing apparatus, a main memory and a memory device, which is in particular a peripheral memory device. The basic idea of the invention is to place a multidimensional data set to be organized in a multidimensional cube and to perform a repeated iterative division of the multidimensional cube in all dimensions into sub-cubes to index and store this data set by means of the computing apparatus. The division is repeated so often here until successive sub-cubes can be combined into regions which each contain a set of data objects which can be stored on one of the memory pages of given storage capacity of the in particular peripheral memory device. As the regions of successive sub-cubes are combined, the regions are also successive so that they form a one-dimensional structure. Thus, in accordance with the invention, when data objects are inserted or deleted, only the modification of one single data structure, for example, a tree, is necessary.
[0011] In one embodiment of the invention, the storing of the data objects of a region on one memory page of given storage capacity is performed while allocating a pointer to the memory page and an address defining the region borders. Thus, each region to be stored has allocated to it clear addresses defining the region borders and a pointer pointing to the memory page on which the corresponding region is stored. In this way, the locating of the region and the data objects contained in the region is simplified in organizational routines such as the answering of queries and the deletion or insertion of data objects.
[0012] In another embodiment of the invention, the storage of the pointer and the address is made in a B tree, B* tree or prefix B tree so that in an address search, a simple search, which can be performed quickly, can be made in a B tree to identify the required region through the pointer allocated to the address and pointing to the memory page of the required region.
[0013] In another embodiment of the invention, the storage of the data objects themselves is made in the leaf pages of the B tree, B* tree or prefix B tree.
[0014] In an advantageous embodiment of the invention, the address defining the region borders consists of data on the last of the sub-cubes forming the region. A database system has proved to be very advantageous in which the address comprises data on the number of sub-cubes contained in each division stage in the region. A region is thus clearly defined if the last sub-cube fully contained in the region is also clearly defined by the address data. The start of the region is here given by the address data on the last of the sub-cubes forming the previous region.
[0015] In an embodiment of the method in accordance with the invention, a method is proposed. With the method in accordance with the invention, to index and store a multidimensional data set, said data set is placed in an n-dimensional cube with n>1. This cube forms in its totality a starting region containing all data objects of the data set. If the number of existing data objects is smaller than or equal to that of the number of data objects corresponding to the given storage capacity of a memory page, the starting region is stored on one memory page. Otherwise, the starting region is split along a splitting address, with the splitting address being chosen so that two new partial regions are generated roughly along the data center. Each of these partial regions is then treated in the same way as before with the starting region, i.e. the number of data objects contained in the partial region in each case is determined and compared with the number corresponding to the given storage capacity of a memory page. If the data set is not larger than the number corresponding to that of the given storage capacity, then the corresponding region is stored on one memory page, otherwise it is again split along the data center and the process begins afresh.
[0016] Advantageously, the storage of the data objects of a region or partial region is made in parallel with the storage of an address allocated to the corresponding region and of a pointer allocated to the address and pointing to the memory page on which the stored data objects are contained. The address to be stored in parallel can advantageously be the splitting address giving the end of the one and the beginning of the other region.
[0017] In an embodiment of the invention, the storage of the address and the pointer is made in a B tree, B* tree or prefix B tree, with in each case regions being defined by successive addresses, the data objects of which regions are each stored on one memory page of given storage capacity.
[0018] In an embodiment of the method in accordance with the invention, a method is proposed for the insertion of data objects. Advantageously, the stored n-dimensional data set is a data set indexed and stored in accordance with the method in accordance with the invention described above. In accordance with the invention, a region of the n-dimensional data set containing the data object and the memory page on which this region is stored is determined on the basis of the coordinates of the data object to be inserted. Subsequently, the data objects stored on this memory page are counted. If the number of data objects stored is smaller than the number corresponding to the given storage capacity of the memory page, the data object to be inserted is also stored on this memory page. Otherwise a splitting address is selected for the region stored on this memory page in such a way that by splitting the region along this splitting address, a first and second partial region are generated in which in each case less than around half the number of data objects corresponding to the given memory capacity is contained. Then, the data object to be inserted is inserted in that partial region in which the coordinates of the data object lie whereupon the first and the second partial regions are stored on one memory page each.
[0019] In accordance with the invention, the dynamic insertion of data objects in the given data structure is thus possible without the totality of the data structure having to be modified or created anew. If as a result of the insertion of the new data object, the region in which the insertion was made can no longer be stored on one memory page, this region is split into two further regions, whereby only the corresponding region to be split into two further regions or the partial regions newly created by the splitting have to be modified and stored anew.
[0020] Advantageously, the locating of the memory page is made in the method in accordance with the invention for the insertion of data objects by means of addresses and pointers stored in a B tree, B* tree or prefix B tree and allocated to the memory pages. In this way, the locating of the desired memory page can be particularly simple and fast. Accordingly, it has proved to be advantageous if the storing of the newly created partial regions is made while replacing the prior pointer and the address of the split region by in each case the addresses and pointers allocated to the first and second partial regions. Here, for example, the splitting address can be used as the limiting address for the first partial region and the limiting address of the split region can be used for the second partial region.
[0021] It has proven to be particularly advantageous if the storage of the address and the pointer is performed in a B tree, B* tree or prefix B tree, with regions being defined in each case by successive addresses, the data objects of which regions are stored in each case on a memory page of given storage capacity.
[0022] In an embodiment of the method in accordance with the invention, a method is proposed for the deletion of data objects. Accordingly, on the basis of the coordinates of the data object to be deleted, that region of the n-dimensional data set containing the data object and the memory page on which this region is stored is determined and the object to be deleted is deleted from this memory page. Subsequently, the number of the data objects stored on this memory page is determined and the region is merged with one of its two neighboring regions if the number of stored data objects is smaller than roughly half the number corresponding to the given storage capacity of the memory page. Then, in turn, the number of the data objects present in the region newly created by the merger is determined. If this number is not greater than the number corresponding to the given storage capacity of a memory page, the region is stored on one memory page, otherwise a splitting address is selected for the region in such a way that by splitting along the splitting address, a first partial region and a second partial region are generated which each contain around half of the data objects contained in the region to be split, whereupon the partial regions created are stored on one memory page each.
[0023] Advantageously, in this method, too, the locating of the memory page is made by means of addresses and pointers stored in a B tree, B* tree or prefix B tree and allocated to the memory pages.
[0024] In an embodiment of the method in accordance with the invention, a method is proposed for the performance of a data query on the basis of a given n-dimensional query area.
[0025] Accordingly, the coordinates of the lowest and the highest point of intersection of the given query area with the n-dimensional data set are determined as is that region in which the lowest point of intersection lies. Then, the memory page is located on which the determined region is stored and all data objects stored on this memory page which form a set of intersection with the query area are determined. The data objects determined are then output. Then, the sub-cube of the determined region which is the last in the sequence is determined, which sub-cube intersects the query area, and the data query is ended if the highest point of intersection of the query area is in this sub-cube. Otherwise, the next sub-cube of the same plane and of the same next higher cube is determined which intersects the query area, and the coordinates of the lowest point of intersection of the query area with the newly determined sub-cube are determined, whereupon the process is continued with the determining of that region in which the lowest point of intersection lies if a sub-cube was determined. Otherwise, the next sub-cube of the plane of the next higher cube is determined which intersects the query area and the determination of the next sub-cube of the same plane and of the same next higher cube intersecting the query area is performed with the sub-cubes of the newly determined cube. If no sub-cube of the plane of the next higher cube is determined, the next higher cube assumes the role of the sub-cube and then the next sub-cube of this plane and of the same next higher cube which intersects the query area is determined. Thus, in accordance with the invention, the sub-cubes of all relevant next higher cubes and in turn, their next higher cubes are examined successively with respect to intersection sets of data objects with the query area.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The invention is shown in the drawings by means of embodiments and is described below in detail by reference to the drawings.
[0027] [0027]FIG. 1 shows a two-dimensional cube in which there lies a two-dimensional data set, not shown in any detail, and which is divided into four sub-cubes of equal size.
[0028] [0028]FIG. 2 shows a three-dimensional cube in which there lies a three-dimensional data set, not shown in any detail, and which is divided into eight sub-cubes of equal size.
[0029] [0029]FIGS. 3. 1 to 3 . 4 serve to illustrate the address allocation of sub-cubes in a two-dimensional cube.
[0030] [0030]FIG. 4 serves to illustrate the address allocation of sub-cubes in a three-dimensional cube.
[0031] [0031]FIG. 5 illustrates the storage of addresses and pointers.
[0032] [0032]FIGS. 6. 1 and 6 . 2 illustrate the modification and storage of addresses and pointers in the splitting of a region for the insertion of data objects.
[0033] [0033]FIG. 7 shows a two-dimensional cube divided into a plurality of regions with a data set not shown in any detail.
[0034] [0034]FIG. 8 shows a query area for the two-dimensional case.
[0035] [0035]FIG. 9 shows the query area of FIG. 8 with a sub-cube in the query area.
[0036] [0036]FIG. 10 shows the query area of FIGS. 8 and 9 with multiple sub-cubes lying in the query area and intersecting the query area.
[0037] [0037]FIG. 11 shows a data set by way of the example of an extended object.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] To organize an n-dimensional database, it is assumed in accordance with the invention that the data space in which the data objects to be organized are located is an n-dimensional cube or is enclosed by such a cube, with n being any natural number where n>1. This cube is called an enclosing cube.
[0039] The enclosing cube is divided into 2 n sub-cubes of equal size by halving each dimension of the cube. These sub-cubes are numbered in an order to be determined from 1 to 2 n . FIG. 1 shows a two-dimensional cube, that is a square, for the case of a two-dimensional data space, divided into 2 2 =4 sub-cubes of equal size which are numbered beginning at the top left from left to right and from top to bottom.
[0040] [0040]FIG. 2 shows an enclosing cube of a three-dimensional data space with 2 3 =8 sub-cubes of equal size which are also numbered, in this case beginning at the back left from left to right, from top to bottom and from back to front. Accordingly, the sub-cube with the number 3 is positioned at the back left in the drawing of FIG. 2 and is not visible.
[0041] Each of the sub-cubes of the starting cube shown in FIGS. 1 and 2 can be divided in turn using the same method into 2 n sub-cubes with a numbering from 1 to 2 n , and this division can be continued as often as desired recursively (or iteratively). In the practical application of the invention, the dividing process is repeated until regions can be formed by sub-cubes lying together, the number of data objects of which regions can be stored on a memory page of given storage capacity.
[0042] If the starting cube has a side length l, then after s divisions, the sub-cubes have a side length of ({fraction (1/25)} s ) *l. To identify the cubes, these are ordered in accordance with the corresponding division in a stage s. Accordingly, the starting cube has the stage 0 , the sub-cubes shown in FIGS. 1 and 2 have the stage 1 , etc.
[0043] An area A is now a special sub-space of the starting cube which is created as follows:
[0044] At stage 1 , the first a, sub-cubes belong fully to the area a, where 0<=α 1 <2 n ;
[0045] At stage 2 , the first α 2 sub-cubes of the sub-cube α 1 +1 of the first stage belong to area A;
[0046] And so on, up to stage i, where the first α 1 sub-cubes of the sub-cube α i−1 +1 of the ith stage belong to area A.
[0047] An area A defined in this way is clearly described by the sequence of numbers α 1 α 2 α 3 . . . α i . This sequence of numbers is called the clear address alpha(A) of area A. This is illustrated by means of FIGS. 3. 1 to 3 . 4 for the two-dimensional case, that is n=2.
[0048] [0048]FIG. 3. 1 shows a two-dimensional cube divided into four sub-cubes of equal size which are in turn divided twice. The gray hatched area in FIG. 3. 1 forms an area A which has the address alpha(A)=03, because the first two-dimensional sub-cube at stage 1 does not fully belong to A, which is indicated by the number 0 at the first position of the address. Of this sub-cube, however, then the first 3 sub-cubes of stage 2 belong to A, which is indicated by the number 3 at the second position of the address.
[0049] [0049]FIG. 3. 2 shows the cube of FIG. 3. 1 with another gray hatched area which forms the area B. This has the address alpha(B)=132, as the first sub-cube is completely contained in the area B (number 1 at first position); however, of the second sub-cube only the first three sub-cubes of stage 2 are contained (number 3 at second position) and of the fourth sub-cube of stage 2 only the first two sub-cubes of stage 3 are contained (number 2 at third position).
[0050] [0050]FIG. 3. 3 again shows the two-dimensional sub-cube of FIGS. 3. 1 and 3 . 2 with a different gray hatched area which forms the area C which has the address alpha(C)=2331.
[0051] In FIG. 3. 4 , the total (gray hatched) two-dimensional cube forms an area D with the address alpha(D)=4. This special case is allocated, for example, epsilon as the address (alpha(D)=epsilon).
[0052] To further illustrate the address allocation, in FIG. 4 a section forming an area E of a three-dimensional data set cube is shown which has the address alpha(E)=541.
[0053] The sub-cubes which still belong to an area become smaller exponentially by the factor 2 n at each division stage. In this way, the addresses remain very short. In one implementation, for example, of a map of the state of Bavaria, an area whose smallest sub-cube is 8×8 meters in size has an address of a length of around 32 bits.
[0054] The areas described are ordered in strictly linear fashion according to their being contained according to set theory: for an area A, which is contained spatially in an area B, we can write:
[0055] A contained in B
[0056] Furthermore, the addresses belonging to the areas are ordered lexicographically like words by alphabetical order. If, for example, an address α is smaller than the address β, then it can be defined as
α<<β.
[0057] Thus, for example,
132 << 2331 and 2331 << 32
[0058] applies.
[0059] The areas and addresses described above are now organized in such a way that the following relationship applies:
[0060] Area (α) contained in area (β) precisely when α<<β.
[0061] Since the areas are, as explained, ordered in a linear fashion, the difference can always be formed between the larger and the smaller area. If the address α is smaller than the address β, that is α<<β, then a region reg (α,β) is defined as the difference between area(β) and area(α). This is equivalent in meaning to:
reg(α,β)=area(β)−area(α)
[0062] Regions have the property that they are clustered in very special patterns in the given n-dimensional space. FIG. 7 shows an example of such a clustering of a two-dimensional cube into multiple regions. Thus, the first region, defined as 01 , exactly comprises the first sub-cube of the first sub-cube of the total cube. The second region, defined as 023 , comprises the complete second sub-cube of the first sub-cube and the three first sub-cubes of the following third sub-cube. In FIG. 7, this region is shown in white. The region thus begins after the sub-cube with the address 01 and ends with the sub-cube with the address 023 . By giving these two addresses, the rule explained above, namely reg( 01 , 023 )=area ( 023 )−area ( 01 ), is clearly defined.
[0063] The other regions drawn in the sub-cube of FIG. 7 are formed accordingly using the addresses given in the individual regions. Here, it is very possible that sub-cubes which form a connected region appear as not connected due to the method of numbering and presentation. This is precisely the case when a region is made up of sub-cubes in which a jump exists in the numbering from 2 to 3 or from 4 to 1 . In FIG. 7, for example, this is the case in the region reg( 01 , 023 ) drawn in white and already explained as there the sub-cube 02 and parts of the sub-cube 03 form a region, but due to the change in numbering from 02 to 03 there is a jump in the representation. This may also be the case, for instance, in the region reg( 023 , 101 ) adjacent to region reg( 01 , 023 ), where the former extends from the sub-cube 04 to the sub-cube 11 .
[0064] The described regions of an n-dimensional cube play a central role in the storage of objects in an, in particular, peripheral computer memory. These memories are divided into so-called pages whose contents are collected in an input/output procedure with a memory access operation into the random access memory of the computer or are written back into the peripheral computer memory from there. The regions are designed in the following so that the data objects to be stored which lie in one region or intersect it can be stored on one page of the peripheral computer memory. The memory page belonging to region reg(α, β) can, for example, be defined as page (αβ).
[0065] In all computer applications, the resolution of the space, i.e. the smallest still distinguishable spatial elements, plays an essential role. In the two-dimensional case, they are also called pixels (from picture element) and in the n-dimensional case voxels (from volume elements). The number of elements which can be distinguished per dimension can be termed pix. If the Cartesian coordinates of a point in n-dimensional space are (x 1 , x 2 , . . . x n ), then the equation applies 0<=x i <pix for i=1, 2, . . . , n.
[0066] The area whose last sub-cube just reaches the point (x 1 , x 2 , . . . x n ) is clearly defined and has a certain address which can be computed easily and clearly from (x 1 , x 2 , . . . x n ). We identify this function or computation rule with alpha(x 1 , x 2 , . . . x n ). Vice versa, from the address α of an area, the Cartesian coordinates of the last point can be computed which still belongs to this area. We identify this function by cart(α). alpha and cart are inverse functions to each other, i.e. the following applies:
cart ( alpha (x 1 , x 2 , . . . x n )) = (x 1 , x 2 , . . . x n ) alpha ( cart (α)) = α
[0067] As described, in the data organization in accordance with the invention, an n-dimensional space is partitioned fully into regions in the form of a cube by a set of areas, with the addresses of the areas being sorted lexicographically and a region being defined just by the difference between two successive areas or by their addresses. The smallest possible area is the smallest pixel of the “data universe” and has the address 00 . . . 01. This address is identified here by sigma. The biggest address is 4 in the two-dimensional case and 2 n in the n-dimensional case and, as described above, is identified here by epsilon.
[0068] The sorted addresses of the areas are stored in accordance with the invention in a conventional B tree, B* tree or prefix B tree. Advantageously, in the B tree a pointer (also termed a reference) is stored between two successive addresses α i−1 and α i , which exactly define the region reg(α i−1 , α i ), on that page of the peripheral memory on which the data objects of the region reg(α i−1 , α i ) are stored. This pointer is identified with p i .
[0069] [0069]FIG. 5 illustrates such a storage procedure, where in the plane at the top in the representation of FIG. 5 alternately an address and a pointer are stored in each case. By means of the two addresses each allocated to a pointer, the borders of a region are given to whose data objects the pointer positioned between the two addresses refers. Thus, in the example of FIG. 5, the pointer p i points by means of the arrow drawn in to a memory page in which the data objects (here the identifiers of the data objects) of the region reg(α i−1 , α i ) formed by the addresses to the left and right of the pointer in each case are located.
[0070] The case described here relates to a B* tree for addresses in which tree the pointer p i points to so-called leaf pages. The data objects themselves or their identifiers are located on these leaf pages, with—in the latter case—the data objects themselves being restored on other pages and being able to be found in the peripheral memory by means of their identifiers.
[0071] The data structure in accordance with the invention described above is defined in the following as an FB tree.
[0072] In the following, the method in accordance with the invention is described for the example of the organization of point objects in n-dimensional space. A point object P is given by its Cartesian coordinates (x i , x 2 , . . . x n ). From this, the address β=alpha (x i , x 2 , . . . x n ) is computed. The point P is in the clearly defined region reg(α j−1 , α j ) with the property that
α j−1 <<β<<α j .
[0073] This region is determined by a tree search in the FB tree where the reference p j to the page page (α j−1 , α j ) is found. The point P, i.e. its identifier together with its coordinates (x 1 , x 2 , . . . x n ), is then stored on the page page (α j−1 , α j ) of the peripheral memory. Alternatively, only the identifier of the point can be stored on page (α j−1 , α j ) and the point itself, i.e. its coordinates and other information about it, is restored again on another page.
[0074] The pages of the peripheral memory have only a certain given storage capacity and can therefore only accept a certain number M of objects. As soon as further objects are to be inserted into a region, but the page belonging to the region cannot accept any more objects, the contents of the page have to be divided onto two pages and the region must accordingly be split into two regions.
[0075] Below, we first describe the splitting of the region: let us assume the region reg(α j−1 , α j ) and the associated page page (Ε j−1 , α j ). From the definition of a region, it then follows that: α j−1 <<α j . Now a splitting address β is selected with the property that β is between the two area addresses α j−1 and α j and splits the region reg(α j−1 , α j ) roughly in the middle, i.e. that around half of the objects are contained in the region reg(α j−1 , β) each contain less than ½M+eps objects, where eps is a small given number and could, for example, be around {fraction (1/10)} of M.
[0076] Subsequently, the objects are divided from the page page(α j−1 , α j ) onto the two pages page (α j−1 , β) and page (β, α j ), where one of the two pages can be identical to the original page page(α j−1 , α j ).
[0077] When the region reg(α j−1 , α j ) is split, the modification of the FB tree shown in FIGS. 6. 1 and 6 . 2 is performed. FIG. 6. 1 shows the starting structure of the FB tree with a plane (at the top in the drawing representation) which contains the stored addresses α j−1 , α j and α j+1 and the pointers p j and p j+1 between these addresses. Here, the pointer p j points to the page page(α j−1 , α j ) and the pointer p j+1 to the page page(α j , α j+1 ). After the splitting of the page page (α j−1 , α j ), the tree structure visible from FIG. 6. 2 exists, with there having been inserted in the next higher plane in the drawing representation between the pointer p j and the address α j the address β corresponding to the splitting address and the pointer p′ referring to the new memory page page(β, α j ). The previous pointer p j now refers to the amended sheet pages(α j , β) and the pointer p j+1 which is unchanged, refers to the also unchanged page page(α j , α j+1 ).
[0078] Due to the insertion of β and p′ into the next higher node, it may become necessary also to split the next higher page, if too many address and pointer data exist due to this insertion. However, these splitting procedures then run exactly as usual in the B trees known in the prior art. Due to these repeated splitting procedures on the insertion of objects into the existing data universe, the FB trees are created which have a growth very similar to that of the known B trees.
[0079] For the further explanation of the method, in the following the deletion of data objects from the existing data universe and the adaptation of the regions after the performance of the deletion is described.
[0080] If a point object (x 1 , x 2 , . . . x n ) has to be deleted again, first—as in the insertion procedure—the region in which the point is located and the associated memory page are determined. The point is deleted from the page and so also disappears from the region. If the number of the objects in the page falls as a result to less than ½M−eps, then the region is merged with one of the two neighboring regions. If the region thus created contains too many objects, it is again split at the middle as already described above.
[0081] As an example, the region reg(α i−1 , α j ) could, if it does not contain enough objects after a deletion operation, be merged with the region reg(α i , α i+1 ) to form region reg(α i−1 , α i+1 ). If reg(α i−1 , α i ) then contains too many objects, it is split again into reg(α i−1 , β) and reg(β, α i+1 ), where naturally β is chosen as suitable and
α i−1 ,<<β<<α i+1
[0082] must apply, with in addition a i−1 <<β so that more objects are contained in the first region. When an object is deleted from the region reg(α i−1 , α i ), the following 3 cases thus result:
[0083] Case 1: reg(α i−1 , α i ) still has at least ½ M−eps objects after the deletion. Then the region and the associated page remain in existence.
[0084] Case 2: reg(α i−1 , α i ) can be merged with one of the two neighboring regions reg(α i−2 , α i−1 ) or reg(α i , α i+1 ) to the new region reg(α i+2 , α i ) or reg(α i−1 ).
[0085] Case 3: The region reg(α i−1 , α i ) is first merged with a neighboring region as in Case 2, but must then be split again, and the two regions reg(α i−2 , β) and reg(β, α i ) or reg(α i−1 , β) and reg(β, α i+1 ) are created.
[0086] By means of such deletion operations, neighboring regions can at some time be fully merged again so that the FB tree shrinks again and shows exactly the reverse behavior as in the splitting of regions and pages and in the growth caused thereby. If, finally, all objects have been deleted from the universe, then the FB tree has become empty again.
[0087] For the further explanation of the method in accordance with the invention, the response to point queries is explained below.
[0088] In a point query, the Cartesian coordinates (y 1 , . . . , y n ) are given for the point P to be located for which additional information such as height or temperature or stock exchange value or similar should then be determined. This additional information is stored with the point object itself.
[0089] First, the address pp of the point P is computed from the Cartesian coordinates (y 1 , . . . , y n ). The point is in the clearly determined region reg(α i−1 , α i ), ad with the property
α i−1 <<pp<<=α i .
[0090] This region and the page page(α i−1 , α i ) belonging to this region is found and retrieved by means of a search in the FB tree and by means of the pointer p i stored there. On the page reg(α i−1 , α i ), there is then located the complete, desired information on the point P (and naturally on further points and objects belonging to this region).
[0091] As an FB tree in accordance with the invention is balanced exactly like a B tree with regard to height, the tree search and thus the locating of the point P can be performed in a time 0 (log k N).
[0092] One fundamental query type in all database systems is that of so-called area queries in which an interval is given with regard to every dimension. In this case, no interval data with regard to one dimension is interpreted as the interval (−infinite, +infinite). By means of the product of these intervals, an n-dimensional cuboid is determined which represents the query area. In the following, this query area is called query box q.
[0093] [0093]FIG. 8 shows by way of example a query box q for the two-dimensional case in which the n-dimensional cuboid is a rectangle. The query range of the query box q shown in
[0094] [0094]FIG. 8 is given by the values (ql 1 , ql 2 ) for the lowest value (1 for low) and (qh 1 , qh 2 ) for the highest point (h for high).
[0095] The answer to an area query is the set of those points or objects which are within the query box q or intersect this.
[0096] In the general n-dimensional case, the query box is given by the 2 *n values ql i and qh i where i=1, 2, . . . , n, where naturally in accordance with the example of FIG. 8 explained above ql i <qh i applies (for the case ql i =qh i for all i values, the special case of the point query which has already been treated is produced).
[0097] The smallest point of the query box q thus has the Cartesian coordinates (ql 1 , ql 2 , . . . , ql n ) and lies in an exactly defined region reg(α j−1 , α j ). To locate this region, first the address
λ=alpha( ql 1 ,ql 2 , . . . ,ql n )
[0098] of the smallest point q is computed. This operation represents internal computations in the main memory which do not require any access operations in peripheral memories. The computation effort is negligibly small for this reason.
[0099] Then the region reg(α j−1 , α j ) with the property
α j−1 <<λ<<α j
[0100] is determined. This requires a search in the FB tree with the effort 0 (log k N). Here, O (log k N) disk access operations may also become necessary. The last page of this tree search is the page page (α j−1 ,α j ) which contains the identifiers of all data objects or the complete data objects themselves which are within or intersect the region reg(α j−1 , α j ). For these data objects, an individual determination is now made as to whether they intersect the query box q or not. It should be noted that the data objects can only intersect q if their associated region intersects the query box q (this is a necessary, but not sufficient condition). Thus, first a part of the data objects is found in the query box q.
[0101] The region reg(α j−1 , α j ) found is built up, as described above, of sub-cubes whose addresses are ordered. Here, the region reg( 023 , 101 ) of FIG. 7 should serve as an example, which region consists of the cubes 024 , 04 , 101 in that order. If any region intersects the query area, it is naturally not necessary for all sub-cubes of this region also to intersect the query area.
[0102] The address of the last sub-cube of the region reg(α j−1 , α j ) which intersects the query area is assumed to be β. Furthermore, β is assumed to have the form β′l, where l is the index of β at the stage at which β is located. For example, for the cube 024 of the region reg( 023 , 101 ) of FIG. 7 the relationship applies:
for 024 at stage 3, l= 4.
[0103] β=024 can thus be represented in the form β′l where β′=02 and l=4 where the number of digits in the address representation gives the stage.
[0104] The same applies for the other cubes 04 and 101 contained in the given region reg ( 023 , 101 ):
for 04 at stage 2, l= 4
for 101 at stage 3, l= 1.
[0105] It should be noted that l=0 cannot occur, as in accordance with the address structure in accordance with the invention no address can end in 0.
[0106] After the region reg(α j−1 , α j ) has been worked through in the area query as described above, now the next region has to be found which intersects the query area. For this purpose, the position of cube β is considered in relation to the query box q and its next higher cube in which β itself is contained. This is shown by way of example in the representation of FIG. 9 in which the query box q of FIG. 8 is shown with the cube β within it, where the other cubes belonging to the next higher cube of the cube β being shown in dots. These dotted sub-cubes of the same stage belonging to one and the same next higher cube are called brothers here. All sub-cubes of stage s of a next higher cube of stage s-l are thus brothers. A sub-cube of the same stage s with a smaller index l is thus a smaller brother; a sub-cube of the same stage s with a bigger index l is thus a bigger brother. In the example shown in FIG. 7, the big brother of sub-cube 023 is the sub-cube 024 , where these two brothers are not in the same region.
[0107] In the continuation of the area query, the next data objects which had previously not yet been found in the region reg(α j−1 , α j ), which had been worked through, and which are in the query box q, are thus contained in a bigger brother of β or in the father of β or in another predecessor of β.
[0108] [0108]FIG. 10 shows by way of example some possible situations for a cube β of the form β′ 2 for the two-dimensional case.
[0109] If no bigger brother of the cube β intersects the query box q (last case in FIG. 10), then the father of cube β does not contain any more objects either which have not yet been found (by a previous working through of the smaller brothers), but which could lie in the query box q. For this reason, the bigger brothers of the father of the cube β must be investigated to see whether they intersect the query box q. If not, it will be necessary in accordance with an analog consideration to switch to the grandfather of the cube β and to check its bigger brothers for intersection with the query box q. In this way, finally the whole data universe will be covered and all objects in the query box q found.
[0110] It is to be noted: if the cube β is located at the stage s, then we can switch to the father s times at the most and check its bigger brothers (of which there are at most 2 n −1) in each case for intersection with the query box q. Furthermore s<=ld(pix) and in the switch to the father node and in the check of the intersection of the bigger brothers in each case with the query box q, only internal main memory computations are performed; there are thus no input/output processes or disk access operations required. For this reason, this method of finding the next cube which intersects the query box q is extremely fast and can be neglected in the balance for the total time in the answering of an area query.
[0111] As soon as, in accordance with this method, the first cube is determined which intersects the query box q, the Cartesian coordinates of the smallest pixel in intersection with the query box q (in FIG. 10 the small black squares) are computed, these being produced as follows:
[0112] Let one cube have with regard to its dimension i the extension of xl i (smallest coordinate) to xh i (biggest coordinate) based on the designations for the values ql or qh.
[0113] The condition for this cube not intersecting query box q is:
there exist: i: xh i <ql i or xl i >qh i
[0114] The condition for this cube intersecting query box q is the negation of the above formula:
not there exist: i: xh i <ql i or xl i >qh i
[0115] or, according to the laws of mathematical logic:
for all i: xh i >ql i and xl i <qh i
[0116] Then the coordinates of the smallest intersection point sp with the query box q is produced as follows with regard to the ith dimension:
if xl i >=ql i then sp i :=xl i else sp i :=ql i
[0117] The point of intersection sp then has the Cartesian coordinates
sp = ( sp 1 , sp 2 , . . . , sp n )
[0118] and its address is:
sigma:=alpha(sp 1 , sp 2 , . . . sp n ).
[0119] It should be noted that up to this step, our method to determine sp did not require any input/output procedures or any disk access operations.
[0120] To find the clear region belonging to the point of intersection sp, a point query is now required with the address sigma, exactly as was already described above. It requires a time effort of the order O (log k N), as also analysed above.
[0121] However, it now follows from this that in answering an area query processing costs are only incurred for those regions which actually intersect the query box q. For each such region, the costs are of the order O (log k N), a total therefore of r*0 (log k N) when r regions intersect the query box q.
[0122] Below, the method of answering area queries is given for an n-dimensional query box q with coordinates ql i and qh i for i=1, 2, . . . , n:
Initialize: sigma : = alpha (ql 1 , ql 2 , ..., ql n ) ; RegionLoop: begin co for each region which intersects q oc find by tree search in the FB tree the reg(α j−1 , α j ), in which sigma lies, i.e. where α j−1 <<sigma<<= α j ; get page page (α j−1 , α j ); ObjectLoop: begin for all objects Q on page page (α j−1 , α j ) check: if Q intersects q then output Q as part of the answer end ObjectLoop ; find last sub-cube with address β of reg(α j−1 , α j ), so that sub-cube (β) intersects q; if (qh 1 , qh 2 , ..., qh n ) contained in sub-cube (β) then co finished oc goto Exit else FatherLoop: begin co β have the form β = β′.i oc i: tail (β), BrotherLoop: for k: = i+1 to 2 n do if sub-cube (β′.k) intersects q then begin sp : = smallest intersection with q: sigma : = alpha (sp); goto RegionLoop co loop is safely left here because q is not yet worked through oc end od co for all bigger brothers of β intersection with q is empty oc; β: = father (β), goto FatherLoop end FatherLoop; end RegionLoop; Exit: co end of program oc
[0123] Below, the method in accordance with the invention is described by means of the organization of generally extended objects.
[0124] A generally extended object is one important case of a data object. Here, it is, for example, a question of a lake in a geographical map as is shown in FIG. 11.
[0125] The extended object 0 is surrounded first by an axis-parallel cuboid corresponding to the dimension, which cuboid is selected in its dimensions so small that it just surrounds the extended object. In the example of FIG. 11, this is shown by means of the lake and a two-dimensional cuboid bb (=rectangle) just surrounding the lake shown there. In the literature, the cuboid surrounding the extended object is termed the bounding box.
[0126] For an extended object, only the identifier Id(O) is stored in the FB tree, with said storing of the identifier actually being performed several times, said is for each region intersecting the extended object. The extended object itself is stored remotely from the FB-tree in another memory sector or in a database.
[0127] The bounding box for an extended object O is designated here with bb(O). The identifier Id(O) for the extended object O is now stored in the FB tree with each region which intersects the extended object O. Here, it should be noted that the extended object O can only intersect those regions which are also intersected by the bounding box bb. This is a necessary condition, but not a sufficient one, which is used to accelerate substantially the algorithms to implement the method in accordance with the invention.
[0128] When inserting a general extended object O, first the associated bounding box bb(O) is computed. Then the following method is performed:
[0129] for all regions R which intersect bb(O) do
[0130] if R intersects O then insert Id(O) into R
[0131] co this can naturally lead to a—generally even to multiple—splittings of R oc
[0132] Note: To find the regions R which intersect bb(O), bb(O) is treated exactly like a query box q. This leads to the following detailed process:
Initialize: Compute bb(O): q:= bb(O) sigma : = alpha (ql 1 , ql 2 , ..., ql n ); RegionLoop: begin co for each region which intersects q oc find by tree search in the FB tree the reg(α j−1 , α j ), in which sigma lies, i.e. where α j−1 <<sigma<<= α j ; get page page (α j−1 , α j ); if O intersects R then insert ID(O) into R, i.e.: if number of objects intersecting R is <= M then save ID(O) on page (α j−1 , α j ) else split R and page(α j−1 , α j ) as described above to split regions and pages; find last sub-cube with address β of reg(α j−1 , α j ), so that sub-cube (β) intersects q, if (qh 1 , qh 2 , ..., qh n ) contained in sub-cube (β) then co finished oc goto Exit else FatherLoop: begin co β have the form β = β′.i oc i: tail (β), BrotherLoop: for k: = i+1 to 2 n do if sub-cube (β′.k) intersects q then begin sp : = smallest intersection with q: sigma := alpha (sp), goto RegionLoop co loop is safely left here because q is not yet worked through oc end od co for all bigger brothers of β intersection with q is empty oc; β: = father (β); goto FatherLoop end FatherLoop; end RegionLoop; Exit: co end of program oc
[0133] To delete an extended object O, a bounding box bb(O) is again used to find all regions which could intersect O. The identifier ID(O) is contained in the regions and stored on the associated pages which actually intersect the extended object (O) and is deleted from this. Here, merging of regions and associated pages can again occur as was already described above.
[0134] The database system in accordance with the invention and the methods in accordance with the intention to organize multidimensional data thus allow a fast and secure access to data of a multidimensional data set with the data structure in accordance with the invention allowing in particular a dynamic addition to or modification of the multidimensional data set. In accordance with the invention, only the modification of a single tree is necessary for the insertion or deletion of objects.
[0135] In answering queries, the FB tree method in accordance with the invention shows the following performance characteristic: for this purpose we assume that p i % of the values of the data set lie with regard to the ith dimension in the query interval [ql i :qh i ] of the query box q, then
( p 1 %* p 2 %* . . . * p n %)* N
[0136] objects lie in the query box q. As not all regions which intersect q lie completely within q, but can extend out of it, generally more objects must be fetched from the peripheral memory than lie in the query box. On average, however, these are less than twice as many objects as lie in q, i.e. 2 * (p 1 % * p 2 % * . . . * p n %) * N objects.
[0137] We therefore have a multiplying rather than an additive process (as in the methods known from the prior art) of fractions of N, which leads to clear improvements. This is illustrated by means of a simple computation example:
Let p 1 = 2% p 2 = 5%, p 3 = 4% p 4 = 10% then sum of p i = 21% = 21 * 10 −2 and product of p i = 400 * 10 −8 = 4 * 10 −6
[0138] If the total data universe observed contains 10,000,000 objects—for typical database applications a realistic, rather small data universe—then in the prior art, 2,100,000 objects have to be fetched from the peripheral memory; but with the new method of FB trees only 2*10 7 *4*10 −6 =80 objects, an improvement by around the factor of 2,500 over the known prior art.
[0139] Naturally, the present invention is not restricted to the embodiments described, but other embodiments are possible which are within the scope of one skilled in the art. For example, the type of numbering of the sub-cubes and the structure of the addresses of sub-cubes and regions is thus also possible in other ways without leaving the scope of the invention. | The invention concerns a database system and method of organizing a multidimensional data stock. The database system comprises a computing arrangement, a main memory and an in particular peripheral memory arrangement. In order to index and store the data stock present in multidimensional cube on memory pages of the peripheral memory device with a given storage capacity, the multidimensional cube is divided iteratively in all dimensions into sub-cubes until successive sub-cubes can be combined to form regions each containing an amount of data objects which can be stored on one of the memory pages with a given storage capacity. The method according to the invention for organizing, insert, deleting and searching for data objects is designed as a dynamic data structure known as an “FB tree”, which improves access times and is therefore suitable for use in on-line applications. | 8 |
RELATED APPLICATIONS
Reference is made to my Provisional Application No. 60/167,376, filed Nov. 24, 1999, entitled “Guitar”.
BACKGROUND AND SUMMARY OF THE INVENTION
Desirable characteristics for stringed instruments, such as base viols, cellos, guitars, and violins, etc., include the provision of sharp, clear tones, and substantial resonance.
Prior art guitars often do not produce such tones, and typically have resonance periods of only about 8 seconds.
The present invention provides a guitar having a polyurethane foam body and an interfitting hardwood base member, with a sound reservoir defined by a cavity in a hardwood member wherein a foam core is disposed, in which electromagnetic pick-ups are disposed.
The entire guitar is encased in a fiberglass shell, except for the sound reservoir, wherein the pick-ups are disposed. Resonance of about 28 seconds is produced. Substantially all musical notes produced by the strumming of the strings of the guitar are conducted via the hardwood and polyurethane foam components to exit the guitar via the sound reservoir.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a guitar according to the invention;
FIG. 2 is a bottom view of a body portion of the guitar of FIG. 1;
FIG. 3 is a perspective view of the guitar body of FIG. 2, showing the top of the body prior to assembly of operating components;
FIG. 4 is a sectional view taken at line 4 — 4 in FIG. 1;
FIG. 5 is an exploded perspective view showing a foam insert of FIGS. 3 and 4 in relation to a hardwood base member; and
FIG. 6 is a perspective top view of a modified embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates generally to stringed musical instruments, and in particular to guitar structures.
Referring to the drawings, a preferred embodiment 10 of the invention comprises a hardwood base member 12 , preferably of mahogany, and a foam body 14 , typically of high density closed cell polyurethane foam. As shown, hardwood base member 12 is interfitted with the foam body 14 , in which a rectilinear cavity 16 is defined and which comprises a sound reservoir or resonator bay 18 , wherein a core 20 of polyurethane foam is disposed. Although shown as rectilinear, the sound reservoir may be of different configurations, such as oval, circular, etc.
Defined in the foam body 14 are cavities to accommodate electronic components and connectors (not shown), a generally oval cavity 22 containing conventional three-way switch equipment (not shown), and a tear-shaped larger cavity 24 accommodating electronic components and connectors (not shown). The components in these cavities are preferably encased in polyester resin or the like.
Electromagnetic pick-ups 26 , 28 are disposed in cavities in foam core 20 in the sound reservoir 18 . Each pick-up has a casing thereabout. The pick-ups extend preferably about three-quarters the depth of the foam core 20 . A plurality of pick-ups may be provided in each cavity (not shown), and various combinations of respective pick-up types may be utilized.
The pick-ups are covered by bezels 31 , 33 to which they are connected. The bezels are mounted by threaded fasteners, and certain threaded fasteners (not shown) are rotatable for raising and lowering the pick-ups 26 , 28 to provide desired sound effects.
The guitar is substantially entirely sealed, except for the sound reservoir 18 , by being wrapped in fiberglass 29 (FIG. 4 ), typically fiberglass cloth or matting of preferably 3 oz. to 12 oz. weight. Carbon fiber or Kevlar might be utilized.
The sound reservoir is an important feature of the present invention. The guitar foam body being encased in a fiberglass shell, except for the sound reservoir, musical sounds and notes, cannot escape the guitar except by passing through the sound reservoir.
When the guitar strings 34 are strummed at neck 36 , the musical tones produced pass via the bridge 30 and tail piece 32 into the hardwood base member 12 , and thence to the foam care 14 in the sound reservoir, and to the pick-ups. The musical sounds have essentially no exit from the guitar except via the sound reservoir and the pick-ups. All other areas or exits are sealed and closed by the fiberglass shell 29 .
The polyester foam body 14 is secured to the interfitting hardwood base member 12 by a hard adhesive, because a soft adhesive would absorb musical sounds, and it is desired to provide as brittle musical tones as possible. The surfaces of the polyester foam are not coated with adhesive or other coating.
The fiberglass shell 29 provides strength, rigidity, and also provides clear, high-end frequency, bright tones. The hardwood base member 12 provides rich, dark tones, or bottom end bass tones.
The foam components typically of 4-8 lb. density, provide sustained resonance and a resonant quality whereby each note reverberates for a substantial period of time, without electrical amplification, thus to provide increased duration of resonance.
It is believed that the cumulative effect of the vast number of foam cells, expanding and contracting somewhat in the manner of miniature diaphragms, generate tiny audible pulses in response to musical vibrations. The cells are closed-cell foam plastic, preferably polyurethane foam, and vibrations or air pressure waves pass from one closed cell to adjacent closed cells via cell walls. The cumulative effect is to produce resonant, audible output via the pick-up devices, air trapped in the cells of the plastic foam being alternately pressurized and depressurized in accordance with musical tones and notes generated, according to the invention. The foam body typically has a density of 4-8 lbs. to provide sustained resonance and a resonant quality, whereby each note vibrates for a substantial time period without electrical amplification.
FIG. 6 illustrates a modified form of the invention wherein a wood base member 40 has defined therein two cavities 42 , 44 wherein electromagnetic pick-ups or transducers are mounted (not shown). No foam member is provided in either cavity, and the pick-ups or transducers are in direct contact with wood base member 40 . Musical notes are transmitted through the foam body and the wood to the pick-up transducers.
It will be understood that various changes and modifications may be made from the preferred embodiment discussed above without departing from the scope of the present invention, which is established by the following claims and equivalents thereof. | A stringed musical instrument or guitar has a plastic foam body substantially covered by a shell of thermoplastic material, a wood base on the plastic foam body, a plurality of strings supported to extend above the wood base, and at least one electromagnetic pick-up at the base. Musical vibrations produced by strumming the strings are conducted via the plastic foam body and wood base are largely sensed by the electromagnetic pick-up. | 6 |
TECHNICAL FIELD OF THE INVENTION
[0001] Embodiments of the present invention relates to a method and apparatus for avoiding erosion and high friction loss for power cable deployed electric submersible pump (ESP) systems.
BACKGROUND OF THE INVENTION
[0002] For certain production wells, artificial lift systems can become necessary when the natural pressure within the underground reservoir is no longer adequate to naturally push produced fluids to the surface. Electric submersible pumps (ESPs) are often used in these situations. Electric power is transmitted from the surface via an umbilical power cable to the downhole ESP. Conventionally, ESPs were deployed at the end of production tubing, with the power cable installed outside the production tubing. However, electrical failures were often associated with this type of setup, and anytime there was an electrical failure, a rig had to be brought in to pull out the production tubing and the ESP.
[0003] In an effort to overcome this problem, alternative ESP systems were developed. One such system is a power cable deployed ESP system. In this system, the power cable is used to transmit power, as well as to support the ESP itself. In this alternate setup, both the power cable and the ESP are installed inside the production tubing.
[0004] In order to improve overall safety for a power cable deployed ESP system, well control can employ a deep set surface controlled subsurface safety valve (SCSSV). The SCSSV is installed in the production tubing below the ESP. The SCSSV is designed to be fail-safe, so that the wellbore is isolated in the event of any system failure or damage to the surface production-control facilities. An example of a prior art setup is shown in FIG. 1 .
[0005] In FIG. 1 , production tubing 40 is disposed within casing 20 . ESP 90 is supported by power cable 100 , as well as production tubing 40 via isolation member 120 . Casing 20 has perforations 22 in a producing region 30 of an underground reservoir. Produced fluids enter casing 20 through perforations 22 . The produced fluids then travel through the safety valve 80 into an inner volume 105 of production tubing 40 , and flow through a narrow gap between ESP 90 and production tubing 40 . The produced fluid then enters ESP 90 via intake slots 97 , travels through medial pump body portion 98 , and exits ESP 90 above isolation member 120 via discharge slots 111 . The produced fluid is now back within production tubing 40 (at a point above isolation member 120 ), where it can be pumped to the surface. Lower packer 50 prevents produced fluids from traveling up the annular region formed between production tubing 40 and casing 20 .
[0006] In these types of setups, the fluid velocity of the production fluids can get quite high due to the narrow gap between the production tubing and the ESP. In typical installations, the narrow gap can range from 0.079 inch to 0.225 inch, depending on the size of the production tubing and chosen ESP. For a typical target rate of 6,000 barrels per day (bpd) production using production tubing of 4½ inch, the fluid velocity of the produced fluid coming through this gap can be 70 ft/s. For 5½ inch tubing, the velocity can still reach 40 ft/s. However, at fluid velocities in this range, the ESP system can fail quickly due to erosion. Additionally, at high velocities such as these, the frictional losses are quite significant. Overcoming frictional losses is usually achieved using longer motors and longer pumps; however, doing this increases the capital costs. Additionally, longer equipment increases installation difficulties, particularly for live well deployment with a surface lubricator. As such, ESP systems are typically only operated at 1,000 to 2,000 bpd.
[0007] Therefore, it would be advantageous to provide an ESP system that did not suffer from erosion or high friction losses at production rates higher than 2,000 bpd.
SUMMARY OF THE INVENTION
[0008] The present invention is directed to a method and apparatus that provides one or more of these benefits. In one embodiment, the invention provides for an ESP assembly for use in a wellbore, wherein the ESP assembly includes a pump and a tubing section adapted for insertion within casing of the wellbore thereby defining an annulus between the tubing section and the casing. The tubing section circumferentially surrounds a portion of the pump. The tubing section includes fluid openings that are operable to allow fluid from the wellbore to flow radially outward, thereby occupying a greater volume, and therein reducing the bulk fluid velocity of the fluid. The pump can include a fluid inlet, a seal section, a pump discharge and a pump motor coupled to the pump.
[0009] In one embodiment, the tubing section can be integral within a string of production tubing that is adapted for insertion into the wellbore. In another embodiment, the ESP assembly further includes a safety valve positioned at a lower end of the tubing section. The safety valve has an open and closed position, and the safety valve is positioned such that fluid from the wellbore enters the tubing section through the safety valve when the safety valve is in an open position. In another embodiment, the ESP assembly can further include a safety valve control line that is in communication with the safety valve.
[0010] In one embodiment, the fluid openings are selected from the group consisting of slots, holes, perforations, and combinations thereof. Those of ordinary skill in the art will recognize that the fluid openings can be of any size, shape, and pattern so long as the integrity of the production tubing is maintained. In one embodiment, the fluid openings are perforations having diameters in the range of ¼ inch to ½ inch. In another embodiment, the ESP assembly can include a lower packer and an upper packer, wherein the lower packer is connected to the casing and the production tubing, the lower packer being positioned proximate the lower end of the production tubing, the lower packer being operable to support the positioning of the production tubing within the casing. The upper packer is connected to the casing and the production tubing, and the upper packer is positioned at a point above the lower packer thereby forming a first interstitial space in the annulus between the upper packer and the lower packer. A second interstitial space is also formed in the annulus between the upper packer and the surface.
[0011] In another embodiment, the ESP assembly for use in a wellbore can include casing, production tubing, the lower packer, the upper packer, the safety valve, and the safety valve control line in communication with the safety valve. The casing is positioned within a hydrocarbon wellbore and is in fluid communication with a producing region of a reservoir such that produced fluid can enter the casing. The production tubing is positioned within the casing to provide a pathway for produced fluids dispersed from the hydrocarbon well. The production tubing has a diameter that is less than the diameter of the casing such that an annulus is formed between an outer wall of the production tubing and an inner wall of the casing, wherein the production tubing has a lower end that is distal from the surface. The lower packer is connected to the casing and the production tubing and is positioned proximate the lower end of the production tubing. The lower packer is operable to support the positioning of the production tubing within the casing. The upper packer is connected to the casing and the production tubing. The upper packer is positioned at a point above the lower packer, thereby forming the first interstitial space in the annulus between the upper packer and the lower packer. The second interstitial space is formed in the annulus between the upper packer and the surface. The safety valve is positioned on an inner wall of the production tubing proximate the lower packer, and the safety valve has an open position and a closed position. The first interstitial space is in fluid communication with the production tubing, such that the assembly is operable to allow produced fluid from the producing region of the reservoir to flow from the production tubing into the first interstitial space. This causes the fluid velocity of the produced fluid to be less than the fluid velocity of the produced fluid if the first interstitial space was not in fluid communication with the production tubing.
[0012] In another embodiment, the ESP assembly can also include an absence of perforations in the casing in areas other than proximate the producing region of the reservoir. In another embodiment, the casing does not allow produced fluids to reenter the reservoir. In another embodiment, the second interstitial space is not in fluid communication with the production tubing.
[0013] In another embodiment, the assembly is operable to house an ESP within the production tubing. The ESP can include a pump intake, a pump discharge, a medial pump body portion, an isolation member, a motor, and a seal section. The pump intake can be positioned above the safety valve so that the produced fluids enter the pump intake. The pump discharge can be positioned above the upper packer and within the production tubing so that the produced fluids are discharged within inner walls of the production tubing and sent to the surface. The medial pump body portion can extend between the pump intake and the pump discharge and can also provide a pathway through which the produced fluids flow from the pump intake to the pump discharge. The isolation member can be positioned at an upper portion of the ESP, and the isolation member is operable to isolate the pump intake from the pump discharge. The motor is connected to the ESP and provides power to the ESP. The seal section can be connected between the motor and a distal end portion of the pump intake, with the seal section being operable to prevent produced fluids from entering the motor. In another embodiment, the second interstitial space is not in fluid communication with the ESP.
[0014] In another embodiment, the portion of the tubing between the upper packer and safety valve can include fluid openings for allowing the produced fluids to enter the first interstitial space. In another embodiment, the perforations fluid openings can have diameters in the range from ¼ inch to ½ inch. In another embodiment, the casing can extend through the producing region of the reservoir. In one embodiment, the fluid velocity of the produced fluid can be maintained below 20 fps when producing more than 2,000 bpd. In another embodiment, the fluid velocity of the produced fluid is maintained between 10 to 20 fps when producing up to 6,000 bpd. In another embodiment, the fluid velocity of the produced fluid is maintained below 20 fps when producing up to 32,000 bpd for 4½ inch tubing (7 inch casing). In another embodiment, the fluid velocity of the produced fluid is maintained below 20 fps when producing up to 45,000 bpd for 7 inch tubing (9⅝ inch casing).
[0015] Embodiments of the present invention also include a method for enhanced well control of high fluid velocity wells. In one embodiment, the method can include providing any ESP assembly discussed herein, inserting the ESP assembly into a wellbore that is in fluid communication with an underground hydrocarbon reservoir, and flowing fluid from the underground hydrocarbon reservoir through the fluid openings of the tubing string and radially outward, such that the fluid occupies a greater volume of space, thereby lowering the fluid velocity of the fluid.
[0016] In another embodiment, the invention can include a method for enhanced well control for high fluid velocity wells can include the steps of positioning casing into a bore of a hydrocarbon well, positioning production tubing at least partially within the casing, connecting a lower packer to the casing and the production tubing, connecting an upper packer to the casing and the production tubing, positioning a safety valve on an inner wall of the production tubing proximate the lower packer, communicating with the safety valve, and allowing produced fluids to flow from the reservoir through the opening of the safety valve to the production tubing and the first interstitial space, such that the fluid velocity of the produced fluid is less than the fluid velocity of the produced fluid if the first interstitial space was not in fluid communication with the production tubing.
[0017] In another embodiment, the method can also include the step of operating the ESP so that the produced fluids enter the ESP, flow through the ESP, and discharge from the ESP back into the production tubing above the isolation member and then travel on to the surface. In another embodiment, the second interstitial space is not in fluid communication with the ESP. In another embodiment, the hydrocarbon well is located offshore.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, claims, and accompanying drawings. It is to be noted, however, that the drawings illustrate only several embodiments of the invention and are therefore not to be considered limiting of the invention's scope as it can admit to other equally effective embodiments.
[0019] FIG. 1 is a front elevational view of an apparatus in accordance with an apparatus known in the prior art.
[0020] FIG. 2 is a front elevational view of an apparatus in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
[0021] While the invention will be described in connection with several embodiments, it will be understood that it is not intended to limit the invention to those embodiments. On the contrary, it is intended to cover all the alternatives, modifications and equivalents as may be included within the spirit and scope of the invention defined by the appended claims. Like numbers refer to like elements throughout.
[0022] Embodiments of the present invention can improve ESP performance in most any reservoir; however, the embodiments are most advantageous in wells that typically experience higher than normal friction losses or erosion damage to an ESP. Pressure losses at or above 50 psi are generally regarded as high friction losses. As will be understood by those skilled in the art, embodiments of the present invention, for example, also can allow produced fluids to more readily flow when pumped by use of an ESP. While the embodiments shown in the figures generally show vertical bores, those of ordinary skill in the art will understand that embodiments of the present invention can also apply to horizontal bores. Therefore, embodiments of the present invention are useful for pumping produced fluids from either a horizontal bore or vertical bore of a hydrocarbon well to the surface.
[0023] High fluid velocity can result in premature failure of down hole components such as an ESP due to erosion damage. Accordingly, embodiments of the present invention can enhance well control, for example, by improving production rates and reducing the rate of premature failure of an ESP.
[0024] Now turning to FIG. 2 . Embodiments of the present invention include positioning casing 20 within wellbore 10 . The bottom of the well can be an open-hole, cased-hole completion, or any other bottom hole completion, as will be understood by those skilled in the art, to be suitable for embodiments of the present invention. For example, an open-hole, top set, or barefoot completion can be made by drilling down producing region 30 and subsequently casing wellbore 10 . According to this embodiment, wellbore 10 is drilled through producing region 30 leaving the bottom of wellbore 10 open. Casing 20 in a cased-hole completion, according to another embodiment of the present invention, is run through the producing region 30 , and cemented in place. As illustrated in FIG. 2 , according to this embodiment, perforations 22 are made in casing 20 to allow produced fluids to fluidly travel from producing region 30 of the underground reservoir to within casing 20 and eventually onward to the surface.
[0025] After casing 20 is positioned within wellbore 10 , cement is pushed between the outer walls of casing 20 and the inner walls of wellbore 10 to set casing 20 thereto. Casing 20 , for example, can prevent the contamination of fresh water zones. Casing 20 can be made out of steel pipe to support wellbore 10 , and in accordance the American Petroleum Institute specifications and standards as understood by those skilled in the art.
[0026] To further support wellbore 10 , and to provide a pathway for produced fluids dispersed from wellbore 10 to the surface, embodiments of the present invention include production tubing 40 . Production tubing 40 has an outside diameter that is less than the inside diameter of casing 20 . Lower packer 50 is positioned between outer walls of production tubing 40 and inner walls of casing 20 and is also positioned proximate the lower end of production tubing 40 . Lower packer 50 is adapted to support the positioning of production tubing 40 within casing 20 , as well as also to prevent produced fluids from entering first interstitial space 70 without first passing through safety valve 80 when safety valve 80 is in an open biased position. When safety valve 80 is in a closed biased position, lower packer 50 , in conjunction with safety valve 80 , prevents produced fluids from entering first interstitial space 70 .
[0027] As illustrated in FIG. 2 , embodiments of the present invention include ESP 90 being operable to pump produced fluids from wellbore 10 and thereby fluidly travel to the surface. In the embodiment shown in FIG. 2 , ESP 90 is positioned entirely within production tubing 40 , with a portion of ESP 90 extending below isolation member 120 and a portion extending above isolation member 120 . The portion of ESP 90 disposed below isolation member 120 , e.g., further down hole. can include, for example, motor 92 , seal sections 94 , pump intake 96 , and at least a region of medial pump body portion 98 . The outer diameter of ESP 90 has a smaller diameter than the inner diameter of production tubing 40 .
[0028] During operation, according to certain embodiments of the present invention, motor 92 receives power through power cable 100 . In one embodiment, ESP 90 can include one or more centrifugal pumps (not shown) within medial pump body portion 98 . The one or more centrifugal pumps suction produced fluids from inner volume 105 within production tubing 40 . The produced fluids are suctioned from inner volume 105 through a plurality of intake slots 97 , and pumped by the one or more centrifugal pumps to increase the pressure and flow of the produced fluids that entered pump intake 96 . The produced fluids are then sent to pump discharge 110 and discharged through a plurality of discharge slots 111 to a proximal region within the inner walls of the production tubing 40 and onward to the surface. The outer areas of pump discharge 110 and pump intake 96 are separated by isolation member 120 . During operation, isolation member 120 provides a barrier to allow for a pressure differential to form across isolation member 120 due to the produced fluids being pumped from pump intake 96 to pump discharge 110 .
[0029] In one embodiment, ESP 90 includes motor 92 to drive one or more centrifugal pumps within medial pump body portion 98 . Motor 92 , for example, can be the most down hole major component of ESP 90 . During operation, motor 92 runs in the range of speed of about 2,500 to 3,500 rev/min. In some embodiments, motors that are operable to run at about 10,000 RPM could be used. Those of ordinary skill in the art will recognize that the speed is related to the exact equipment used. As will be understood by those skilled in the art, during operation, the flow of produced fluids that pass the outer surfaces of the motor also can act as a coolant to reduce heat associated with operation of ESP 90 to thereby assist in preventing ESP 90 from overheating.
[0030] Embodiments of ESP 90 further include one or more seal sections 94 to prevent produced fluids from entering within inside surfaces of motor 92 . In addition to preventing produced fluids from entering the inside surfaces of motor 92 , the one or more seal sections 94 equalizes external bottom hole pressures and internal pressures of the motor 92 . Moreover, as will be understood by those skilled in the art, the one or more seal sections 94 allows lubricant associated with motor 92 to thermally expand and contract.
[0031] ESP 90 can also include pump intake 96 whereby produced fluids enter ESP 90 . Pump intake 96 includes a plurality of intake slots 97 that are preferably evenly spaced in a location where the produced fluids are suctioned therethrough. The plurality of intake slots 97 can be a variety of uniform shapes including, but not limited to, spherical, ellipsoidal, or rectangular as understood by those skilled in the art. Pump intake 96 preferably is connected between a proximal end portion of the one or more seal sections 94 and a distal end portion of medial pump body portion 98 as illustrated in FIG. 2 .
[0032] Medial pump body portion 98 can include one or more centrifugal pumps to pump the produced fluids that enter ESP 90 . The horsepower of the one or more centrifugal pumps ranges from about 75 to 300 during operation. The one or more centrifugal pumps increase the flow rate of the produced fluids entering ESP 90 to artificially lift the produced fluids to the surface. In a preferred embodiment of ESP 90 , the one or more centrifugal pumps have a large number of stages, each stage having an impeller and a diffuser. Medial pump body portion 98 extends between pump intake 96 and pump discharge 110 so that produced fluids flow therebetween from pump intake 96 to pump discharge 110 .
[0033] Embodiments of the present invention can also include isolation member 120 disposed between pump discharge 110 and medial pump body portion 98 . According to embodiments of the present invention, isolation member 120 connects to the inner walls of production tubing 40 to support the positioning of ESP 90 .
[0034] ESP 90 can include pump discharge 110 to discharge the produced fluids for onward transfer within production tubing 40 to the surface. Pump discharge 110 , for example in one embodiment, includes a plurality of discharge slots 111 that can be evenly spaced in a location where the produced fluids are discharged to a proximal region within the inner walls of production tubing 40 . The plurality of discharge slots 111 , as will be understood by those skilled in the art, can be a variety of uniform shapes including, but not limited to, spherical, ellipsoidal, or rectangular. As illustrated by the arrows in FIG. 2 , for example, pump discharge 110 is positioned within production tubing 40 so that produced fluids discharge through discharge slots 111 and fluidly travel through production tubing 40 and onward to the surface.
[0035] Embodiments of the present invention can include, for example, safety valve 80 being operable to prevent produced fluids from flowing into inner volume 105 of production tubing 40 when safety valve 80 is in the closed position. Safety valve 80 selectively, or in the case of an emergency, assists to prevent produced fluids from dispersing to the surface. Safety valve 80 , according to an embodiment of the present invention, is connected to the inner walls of production tubing 40 and is distally disposed from ESP 90 within production tubing 40 . In one embodiment, safety valve 80 can be a deep set surface controlled subsurface safety valve (SCSSV). Industry well control policy requires all wells that are in close proximity to people or facilities to be equipped with an SCSSV. Conventionally, the SCSSV is shallow set (e.g. about 200-300 It below the wellhead). However, in embodiments of the present invention, safety valve 80 is deep set (e.g. located below ESP 90 ).
[0036] Embodiments of the present invention also include upper packer 60 and first interstitial space 70 . First interstitial space 70 being the annular volume created between casing 20 and production tubing 40 , and lower packer 50 and upper packer 60 . In one embodiment, a portion of production tubing 40 below isolation member 120 and above safety valve 80 contains fluid openings 140 , such that first interstitial space 70 is in fluid communication with inner volume 105 of production tubing 40 . The produced fluid can now travel all the way to casing 20 , affectively increasing the available volume, which in turn reduces the fluid velocity of the produced fluids.
[0037] Upper packer 60 is adapted to prevent produced fluids from flowing in the annular area between the inner walls of casing 20 and the outer walls of production tubing 40 above upper packer 60 , hereby defined as second interstitial space 130 .
[0038] During operation, produced fluids are produced from producing region 30 and flow through perforations 22 to the inner walls of casing 20 distal from safety valve 80 . According to an embodiment of the present invention, power and communication are transmitted to safety valve 80 through safety valve control line 82 connected to a proximal end of safety valve 80 . In one embodiment, safety valve control line 82 receives power from the surface. In another embodiment (not shown), safety valve control line 82 can receive power directly from the ESP. When safety valve 80 is in the “open” position, produced fluids flow safety valve 80 to inner volume 105 of production tubing 40 before entering first interstitial space 70 . When safety valve 80 is in the “closed” position, produced fluids are prevented from traveling to inner volume 105 of production tubing 40 or first interstitial space 70 . Safety valve 80 , as will be understood by those skilled in the art, preferably is in a fall-back mode so that any interruption or malfunction should result in safety valve 80 being in the closed position.
[0039] In another embodiment, safety valve control line 82 can be removed and replaced with a wireless communication device that is operable to communicate with safety valve 80 wirelessly. Moreover, as will be understood by those skilled in the art, embodiments of the present invention can include communicating by hydraulic or pneumatic methods as well.
[0040] While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims. The present invention may suitably comprise, consist or consist essentially of the elements disclosed and may be practiced in the absence of an element not disclosed. | A method and apparatus for reducing erosion and friction losses in a wellbore using a power cabled deployed electric submersible pump (ESP). The apparatus can include an ESP disposed within production tubing, wherein a portion of the production tubing surrounding the ESP contains fluid openings that are operable to allow produced fluids to flow outward, thereby increasing the available volume for the produced fluids. The increased volume results in lower fluid velocities of the produced fluid, which advantageously reduces erosion and friction loss. | 4 |
BACKGROUND OF THE INVENTION
The invention relates to radiotherapy, and more particularly relates to image-guided radiotherapy (“IGRT”). In its most immediate sense, the invention relates to a quality-control jig for use with IGRT apparatus.
In IGRT apparatus, two instruments are mounted upon a rotatable gantry. One of these is a linear accelerator (a “linac”). The linac produces a beam of high-energy radiation (the “treatment beam”) used to destroy tumor tissue inside the patient's body. The other is an imager (which is usually but not necessarily a cone-beam computed-tomography imager). This produces a lower-energy beam of radiation (the “imaging beam”) used to create a three-dimensional image of the patient's body region in which the patient's tumor is located. The linac's treatment beam and the imager's imaging beam are at right angles to each other.
Before a patient is imaged and subjected to radiation therapy, it is necessary to make sure that the IGRT apparatus is properly calibrated. This is because IGRT apparatus operates neither with theoretical perfection nor with absolute repeatability.
For these reasons, radiation technicians routinely carry out quality-control procedures on IGRT apparatus before patients are imaged and subjected to radiation therapy. This enables the technicians to monitor the actual performance of the IGRT apparatus and to make sure that the apparatus is properly calibrated. However, such procedures are time-consuming and complicated.
It would be advantageous to provide a jig that would make it easier to carry out quality-control procedures on IGRT apparatus, and to make it possible to carry out those procedures more quickly.
Objects of the present invention are to provide a jig that facilitates and speeds the performance of quality-control procedures on IGRT apparatus.
The invention proceeds from the realization that a ball bearing that is used to carry out a common quality-control procedure can be incorporated as a detachable part of a jig that can be used to check other apparatus parameters by shining light on the jig.
In accordance with the invention, a jig has an elongated stylus with a proximal end and a distal end. The proximal end of the stylus is secured to a three-axis positioner.
A ball bearing is provided, as is a ball bearing cap that is secured to the ball bearing and adapted to fit over the distal end of the stylus to detachably mount the ball bearing thereto. A pointer having a distal tip is provided, as is a pointer cap that is secured to the pointer and adapted to fit over the distal end of the stylus to detachably mount the pointer thereto. The ball bearing, the ball bearing cap, the pointer, and the pointer cap are all dimensioned such when the pointer cap is mounted to the distal end of the stylus, the distal tip of the pointer has the same location as does the center of the ball bearing when the ball bearing cap is mounted to the distal end of the stylus.
A flat plate is provided, as are means for fixing the plate to the stylus in such a manner that the pointer will cast a shadow on the plate when a light is directed onto the pointer from a direction normal to the plate.
This jig makes it easy to carry out many commonly-performed quality-control quickly and efficiently. Once the positioner has been used to place the ball bearing at the calculated radiation isocenter of the IGRT apparatus, measurements of other apparatus parameters can be carried out relative to the known position of the radiation isocenter by directing light onto the jig.
Advantageously, the fixing means is adapted to fix the plate to the stylus at a 0° orientation, a 90° orientation, a 180° orientation, and a 270° orientation. This allows the jig to be conveniently reconfigured for use at four gantry positions. Likewise advantageously, an axially-elongated hollow phantom is provided. The phantom is detachably securable to the positioner in a manner that the stylus extends along the axis of the phantom and has surface markings indicating locations that are axially aligned with the center of the ball bearing and that are also rotationally aligned with gantry orientations of 0°, 90°, and 270°. This makes it possible to align the lasers used to position the patient. Additionally, four infrared-reflecting markers are mounted on the anterior surface of the phantom. The locations of these markers are known precisely, making it possible to calibrate and quality-control optical tracking equipment such as is conventionally used with IGRT apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood with reference to the following illustrative and non-limiting drawings, in which:
FIG. 1 shows an image-guided radiation therapy apparatus;
FIG. 2 shows a preferred embodiment of the invention, configured to determine the radiation isocenter of an image-guided radiation therapy apparatus with which it is used;
FIG. 3 shows a portion of the preferred embodiment of the invention, configured to determine the mechanical isocenter of an image-guided radiation therapy apparatus with which it is used;
FIG. 4 shows a portion of the preferred embodiment of the invention, configured to check the calibration of an optical distance indicator in the linac of an image-guided radiation therapy apparatus with which it is used;
FIG. 5 is a perspective view of the preferred embodiment of the invention with a phantom mounted on it; and
FIG. 6 is a side view of the preferred embodiment of the invention with the phantom mounted on it.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The Figures herein are not necessarily to scale; various components may be enlarged or reduced for clarity of illustration. The same element is always indicated by the same reference numeral in all the Figures.
FIG. 1 shows a conventional image-guided radiation therapy (“IGRT”) apparatus generally indicated by reference numeral 100 . A toroidal gantry 2 is supported to rotate in a vertical plane. A linac 4 is attached to the gantry 2 , as is an imager 6 . (In this example, the imager 6 is a cone-beam computed tomography imager, but this is not required. Another imaging device, such as an X-ray apparatus, can be used instead.)
The IGRT apparatus 100 has a patient table 8 ; in use, a patient (not shown) is supported on the table 8 . Initially, the table 8 and the imager 6 are adjusted so that the imager 6 is aimed at the body region where a tumor (likewise not shown) is located. In an initial imaging phase, the gantry 2 is rotated while the imager 6 is operated to acquire image data from the patient. Once image data of the patient have been acquired through 360° of rotation of the gantry 2 , a three-dimensional image is reconstructed and registered. In this image, the location of the tumor within the body is accurately identified. Then, in a subsequent treatment phase, the gantry 2 is rotated through 360 degrees while the linac 4 is operated in accordance with the registered image information. Radiation from the linac 4 necrotizes the tumor.
Before carrying these steps out on a patient, it is necessary to carry out quality-control procedures to make sure that the IGRT apparatus 100 is properly calibrated. This is because the IGRT apparatus 100 is not mechanically perfect and does not operate with absolute repeatability. For example, the parts of the gantry 2 , the linac 4 , and the imager 6 are not absolutely rigid and all mechanical parts are subject to wear. As a result, the various parts of the IGRT apparatus 100 flex during rotation of the gantry 2 . This flexure makes points in the patient's image appear to move with rotation of the gantry 2 . To minimize flexure-caused distortion of the image reconstructed from data acquired by the imager 6 , the flexure is conventionally measured at various orientations of the gantry 2 and taken into account during image reconstruction.
To do this, in one universally-practiced quality control procedure, a ball bearing is moved to the geometric center of the radiation field of the linac 4 . The ball bearing is then imaged by the linac 4 at four orientations of the linac 4 (i.e. at gantry orientations 0°, 90°, 180°, and 270°). This localizes the ball bearing within the radiation field of the linac 4 , and the ball bearing can then be moved to the computed radiation isocenter of the IGRT apparatus 100 . After this has been done, the position of the ball bearing is measured in the coordinate system of the imager 6 throughout the range of orientations of the gantry 2 , thereby creating a so-called “Flex Map” that is used when an image is reconstructed from data acquired using the imager 6 .
This is not the only quality-control procedure applicable to calibration of IGRT apparatus; others are used as well. These will be explained below in connection with the following description of a preferred embodiment of the invention.
Referring now to FIG. 2 , a ball bearing 10 is mounted to a ball bearing cap 12 . The ball bearing cap 12 is sized to fit over the distal end of a stylus 14 , and the proximal end of the stylus 14 is secured to a three-axis positioner 16 . The positioner 16 is mounted on a base 18 .
Initially, the ball bearing cap 12 is fit over the distal end of the stylus 14 , the base 18 is placed upon the table 8 , and the ball bearing 10 is imaged by the linac 4 at the 0°, 90°, 180°, and 270° orientations of the gantry 2 . The radiation isocenter of the IGRT apparatus 100 is then computed, and the ball bearing 10 is then moved to that computed position by adjustment of the positioner 16 along directions parallel to the table 8 .
Once the ball bearing 10 has been moved to the computed radiation isocenter of the IGRT apparatus 100 , it is possible to check whether the height of the table 8 is proper. This can be done by measuring the distance between the ball bearing 10 and the table 8 and comparing that measured distance with the distance that is expected to be present.
The preferred embodiment of the invention makes it possible to check the relationship between the radiation isocenter of the IGRT 100 and the mechanical isocenter of the IGRT apparatus 100 . To do this, the ball bearing cap 12 is detached from the distal end of the stylus 14 and replaced with an assembly made up of a pointer 20 and a pointer cap 22 that is secured to the pointer 20 ( FIG. 3 ). The pointer cap 22 , like the ball bearing cap 12 , fits over the distal end of the stylus 14 . And, importantly, the dimensions of the ball bearing 10 , the ball bearing cap 12 , the pointer 20 , and the pointer cap 22 are chosen so that when the pointer cap is mounted to the distal end of the stylus 14 , the distal tip of the pointer 20 is located where the center of the ball bearing 10 is located when the ball bearing cap 12 is mounted to the distal end of the stylus 14 .
Advantageously although not necessarily, two different ball bearings 10 are provided, each being mounted on a cap 12 so as to be mountable on the stylus 14 . The ball bearings 10 and their associated caps 12 are dimensionally identical, but the two ball bearings 10 are of different densities; one has a higher density than the other. The higher density ball bearing 10 is used as stated above to compute the radiation isocenter of the IGRT apparatus 100 . In a subsequent step, the higher density ball bearing 10 and its attached cap 12 can be removed from the stylus 14 and replaced by the lower density ball bearing 10 and its attached cap 12 . Then, an image of the lower density ball bearing 10 can be acquired using the imager 6 (which is typically rotated through 360° in order to acquire the image). The displacement between the radiation isocenter and the isocenter of the imager 6 is then measured to determine whether this displacement is within specifications (it should typically be less than 2 mm). Since the radiation isocenter is sometimes referred to as the “MV isocenter” and the isocenter of the imager 6 is sometimes referred to as the “KV isocenter”, this quality control measure is referred to as a “KV and MV isocenter coincidence check”.
Each of the linac 4 and the imager 6 has a light (not specifically shown) at its radially inward face. And, a flat plate 24 is mounted to the stylus 14 . As can be seen in FIG. 3 , the flat plate 24 is so located that the pointer 20 casts a shadow on a ruled side 26 of the plate 24 when light is directed upon the pointer 20 . (The ruled side 26 bears a Cartesian coordinate system calibrated in millimeters so that the precise position of the shadow cast by the pointer 20 can be noted. The ruled side 26 can be permanently ruled or a ruled piece of paper can be detachably secured to it.)
Thus, when a light from either the linac 4 or the imager 6 is directed upon the pointer 20 , the pointer 20 casts a shadow onto the ruled side 26 of the plate 24 and the position of that shadow indicates the actual position of the linac 4 or imager 6 (as the case may be). This provides a way to track the mechanical isocenter of the IGRT apparatus 100 ; at various positions of the gantry 2 , the position of the tip of the shadow on the ruled side 26 of the flat plate 24 is noted. Advantageously, the plate 24 is so mounted to the stylus 14 that the plate can be rotated to, and fixed in, positions corresponding to the 0°, 90°, 180°, and 270° orientations of the gantry 2 . Thus, if the gantry 2 is set to the 0° orientation (i.e. with the linac 4 facing directly downwardly), the plate 24 will be rotated so that the ruled side 26 faces up; if the gantry 2 is set to the 270° orientation (i.e. with the linac 4 facing left) the plate 24 will be rotated so that the ruled side 26 faces right. A review of the variation in the position of the shadow tip at these gantry orientations makes it possible to determine whether the mechanical performance of the gantry 2 is within applicable specifications.
The linac 4 will typically have an optical distance indicator (“ODI”, not shown) that measures distance from the linac 4 to the patient to be treated. The operation of the linac 4 can be checked by rotating the plate 24 so that its non-ruled side 28 faces the linac 4 , aiming the linac 4 at the non-ruled side 28 so that the ODI directs light thereon, and checking to see if the distance measured by the ODI is within the tolerance required.
Conventionally, a room in which an IGRT apparatus is installed has a laser system that requires alignment. This is schematically illustrated in FIG. 1 , which shows laser beams 50 , 52 , and 54 that are projected toward the radiation isocenter of the IGRT apparatus 100 from lasers (not shown) that are mounted in the room in which the IGRT apparatus 100 is located. In order to make sure this laser system is properly aligned, an axially-elongated cylindrical acrylic phantom 30 ( FIGS. 5 and 6 ) is threaded onto the positioner 16 in such a manner that the stylus 14 extends along the axis of the phantom 30 .
The phantom 30 has surface markings indicating locations that are axially aligned with the center of the ball bearing 10 and that are also rotationally aligned with gantry orientations of 0°, 90°, and 270°. The circular line 32 is axially aligned with the center of the ball bearing 10 . Each of surface lines 34 , 36 , and 40 is parallel to the stylus 14 . The line 34 is on the top of the phantom 30 , at a position corresponding to a 0° orientation of the gantry 2 , the line 36 is on the side of the phantom 30 , at a position corresponding to a 90° orientation of the gantry 2 , and the line 40 is on the other side of the phantom 30 , at a position corresponding to a 270° orientation of the gantry 2 . Thus, the surface of the phantom 30 has three points of intersection (one being at the intersection of lines 32 and 34 , another being at the intersection of lines 32 and 36 , and the third being at the intersection of lines 32 and 40 ).
Once the ball bearing 10 has been moved to the computed radiation isocenter, the phantom 30 can be mounted to the positioner 16 (as by being threaded onto it). The room lasers can then be calibrated or checked by turning them on and seeing how closely the beams 50 , 52 , and 54 are projected to these three points of intersection.
Four infrared-reflecting spherical markers 42 are mounted on the anterior top surface of the phantom 30 . Each marker 42 is 1.2 cm in diameter. The four markers 42 form a 5 cm by 5 cm square centered on the center of the ball bearing 10 . The coordinates of the four markers 42 are precisely known, which enables the calibration and quality control of optical tracking equipment such as is conventionally used with IGRT apparatus.
Although a preferred embodiment has been described above, the scope of the invention is determined only by the following claims: | A jig for calibrating an image-guided radiotherapy apparatus is disclosed. The jig includes a ball bearing and a three-axis positioner. Once the ball bearing has been moved to the calculated radiation isocenter of the apparatus, other calibration procedures can be performed by directing light onto the jig. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the power control of a fax/modem, and more particularly to an automatic power control apparatus of a PC mounted fax/modem.
2. Discussion of the Related Art
A conventional PC mounted fax/modem apparatus as shown in FIG. 1 includes a ring signal sensing section 100 for searching out a signal received from a telephone line and for changing a logic value in a flag register to a logic value of one from a logic value of zero when a telephone ring signal is produced. This indicates that a fax has been received or that data has been received over a modem. An MCU 101 controls a hook switch section 102 as the logic value of one is stored in the flag register of ring signal sensing section 100. Simultaneously, the MCU 101 decodes the data received via the telephone line to provide corresponding fax or modem data. Hook switch section 102 connects or cuts off the hook switch in accordance with a control signal from MCU section 101 for connecting or cutting off the telephone line. A PC power source section 103 is supplied with AC power via a power converter for converting it into DC power. The PC power source section 103 supplies power for driving the various blocks of FIG. 1.
The operation of the automatic power control apparatus of the conventional PC mounted fax/modem will be described below.
With the power switch of the PC turned on, ring signal sensing section 100 receives the external ring signal via the telephone line. Ring signal sensing section 100 monitors the rising edge of a pulse generated when the telephone bell is to be rung, i.e., when the ring signal is received. Upon receiving a ring signal, ring signal sensing section 100 instantly writes a logic value of one into the 1-bit flag register internally mounted therein. The flag register in ring signal sensing section 100 stores a logic value of zero when the PC is operated as a transmitting fax/modem. When the PC is operated in the fax/modem mode, the telephone bell cannot be rung. The logic value changes from zero to one at the moment the telephone call is externally made.
The MCU 101 for controlling respective blocks searches out the flag register of ring signal sensing section 100 to read out the stored value. The MCU 101 supplies the read-out value as the control signal to hook switch section 102 to connect the hook switch if the value is one to permit the externally transmitted data to be received. The MCU 101 determines whether the externally received data is fax data or is general PC communication data, and accordingly identifies it as fax data or PC data. The MCU 101 determines the completion of the receipt of data by determining that no data is received for one frame period and will then open a contact point of hook switch section 102. This generates a control signal to cut off the telephone line. In other words, the hook switch section 102 turns the telephone line on and off in accordance with the control signal from the MCU 101.
However, since the conventional power control apparatus of a PC mounted fax/modem cannot perform the fax/modem function when the power of the PC is off, the PC must be maintained on in order to execute the fax/modem function, which in turn wastes too much power.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a automatic power control apparatus for a PC mounted fax/modem that substantially obviates the problems due to limitations and disadvantages of the related art.
An object of the present invention is an automatic power control apparatus for a PC mounted fax/modem for automatically supplying power upon the receipt of fax or modem data.
Another object of the present invention is an automatic power control apparatus for a PC mounted fax/modem to automatically turn off the power of the PC upon the end of receipt of fax or modem data.
Yet another object of the present invention is an automatic power control apparatus for a PC mounted fax/modem which monitors a ring signal to automatically turn the power of the PC on and off.
To achieve these and other objects and advantages and in accordance with the purpose of the present invention, as embodied and broadly described, the automatic power control apparatus of a PC mounted fax/modem includes a ring signal section having an input adapted to be connected to a telephone line, a PC power source for controllably supplying power to the PC to enable operation thereof, and a power supply control section connected to the input of the ring signal section for counting the number of ring signals received and upon receipt of a predetermined number of ring signals for controlling the PC power source to supply power to the PC to enable the receipt and processing of fax or modem data by the PC.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention. In the drawings:
FIG. 1 is a block diagram showing a power control apparatus of a conventional PC mounted fax/modem;
FIG. 2 is a block diagram showing an automatic power control apparatus of a PC mounted fax/modem according to the present invention;
FIG. 3 is a detailed circuit diagram showing the ring counter section and power switching section of FIG. 2; and
FIG. 4 is a graph of operational waveforms of the shift register shown in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to a preferred embodiment of the present invention.
FIG. 2 shows an automatic power control apparatus for a PC mounted fax/modem according to the present invention, in which a fax/modem operative section (or fax/modem operator) 1 checks for an input signal via a telephone line. This is for detecting the input of a ring signal indicating that a fax function or a modem function should be performed. A power control section 2 of the fax/modem is connected to an input terminal of the fax/modem operative section 1 and an output terminal of the fax/modem operative section 1.
The power control section 2 detects the ring signal received via the telephone line in accordance with a reference signal and automatically controls a PC power source section 204.
The power control section (or power controller) 2 of the fax/modem includes a ring counter section 200, a backup power source section 201, a power switch section 202, and a function switch section 203. The ring counter section 200 monitors the telephone line and is responsive to a telephone bell signal received over the telephone line. Upon the receipt of such a signal the ring counter section outputs a high level. A backup power source section 201 supplies power for driving the ring counter section 200. A power switch section 202 turns the power on/off in accordance with a control signal from ring counter section 200. A function switch section 203 selects a status depending on whether or not ring counter section 200 is connected to power switch section 202.
As shown in FIG. 3, the ring counter section 200 includes a differential amplifier 207 for receiving the ring signal input via the telephone line and for eliminating noise. The amplifier 207 supplies a predetermined square wave according to a reference signal V REF . An inverter 208 inverts the square wave signal from the differential amplifier 207 and provides it to a latch 209. The latch 209 latches the input signal in accordance with a high level signal from the function switch section 203.
Using the signal latched in latch 209 as a sync clock, a shift register 210 provides a logic value of one after four ring signals are received. A MOS transistor 205 controls the output signal from the shift register 210, and also controls the operation of a relay 211 of the power switch section 202.
Latch 209 includes, for example, an R/S latch circuit formed from a pair of NOR gates 213 and 218. An output terminal thereof is connected to common clock terminals CK of the stages of the shift register 210.
As shown in FIG. 3, shift register 210 has four stages of flip-flops 214, 215, 216, and 217 with respective clock terminals CK being commonly connected. Except for flip-flop 217, an output terminal Q of each of the preceding flip-flops is connected to an input terminal D of a succeeding flip-flop. Input terminal D of flip-flop 214 receives a constant high level. The Q output terminal of flip-flop 217 is commonly connected to an input terminal of NOR gate 218 of latch 209, a drain electrode of MOS transistor 205, and one terminal of function switch 203.
The operation of the automatic power control apparatus of the PC mounted fax/modem according to the present invention constructed as above will be described in detail.
The fax data and general PC communication data is received via the telephone line to the PC. The operation under the power-on state of the PC is the same as a conventional PC and will not be further described. If the power to the PC is off and function switch 203 is on (closed), the present invention will operate as described below.
A ring signal shaped as a square wave, including a noise component, will be received via the telephone line.
The differential amplifier 207 of ring counter section 200 receives the ring signal and eliminates the noise component. By use of a reference voltage within the differential amplifier 207, ring counter section 200 prevents a malfunction due to a noise component on the telephone line. Inverter 208, which receives the signal without the noise from differential amplifier 207, inverts the square wave signal to provide a signal for performing an accurate operation of the latch 209.
Flip-flops 214, 215, 216, and 217 of shift register 210 receive the signal from latch 209. Each flip-flop maintains a reset state until the clock signal is applied to the clock terminals CK. Upon the supply of the clock pulse to the commonly connected clock terminals, each flip-flop performs the shifting operation at the falling edge of each clock pulse CK as shown in FIG. 4. Thus, output Q 1 is converted from the low level to high level at the moment of the falling edge of the first clock, and output Q 2 is converted from the low level to high level at the moment of the falling edge of the second clock. Therefore, when four pulses generated from latch 209 are supplied to the clock terminal, output terminal Q 4 of flip-flop 217 of shift register 210 provides a logic value of one.
Upon the fourth ring pulse signal input to differential amplifier 207, output terminal Q 4 of flip-flop 217 of shift register 210 provides a logic value of one. Accordingly, power switch section 202 receives the high value via function switch 203 when the switch is closed. Power switch section 202 closes relay 211 to supply power from the AC supply to the PC power source section 204. Thus, power is supplied to fax/modem operative section 1 of FIG. 2. This permits the PC to perform the typical operation of the fax/modem.
After completion of the reception of data by the fax/modem in the above manner, the power of the PC will be turned off automatically. If data is not received for one frame period, the MCU 101 checks the reception state of the data and will recognize that no more data is being received. The MCU 101 supplies a high value to the gate electrode of MOS transistor 205 and hook switch section 102.
By doing so, hook switch section 102, supplied with the control signal from MCU 101, turns off the hook switch to cut off the signal line. The MOS transistor 205 is turned on to open the relay 211 in the power switching section 202 and-cut off the supply of power from the AC source to the PC power source section 204.
According to the present invention as described above, even if the power of the PC is off when a user of the PC leaves his office, the power will be automatically turned on upon receiving fax/modem data. After the data has been received power is automatically turned off. As a result, the fax data can be received while preventing unnecessary power dissipation.
It will be apparent to those skilled in the art that various modifications and variations can be made in the automatic power control apparatus of a PC mounted fax/modem 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 power control apparatus of a PC mounted fax/modem comprises a fax/modem operator detecting a ring signal and performing a fax operation or modem operation; and a power controller automatically controlling a supply of a power to a PC power source section in response to a detection of the ring signal. | 6 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] Not applicable. The present application is an original and first-filed United States Utility Patent Application.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
THE NAMES OR PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0004] Not applicable.
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The present invention generally relates to containers used to plant gardens and more particularly, to a plywood structure suitable for planting a garden.
[0007] 2. Background Discussion
[0008] Home gardens have many benefits. Gardens can provide a significant portion of a person's caloric intake as well as providing specific nutrients that may be difficult or expensive to obtain otherwise. A home gardener can ensure that their food does not contain harmful herbicides or pesticides, and food may be grown organically. Food picked and eaten fresh from a garden provides more nutrition than food purchased from a grocery store and often tastes better than store-bought food. Gardens can improve the appearance and value of a home. Gardening can provide stress relief and enjoyment. Finally, home gardens may be used to teach children about farming and about the life cycles of plants and animals.
[0009] In general gardens may be placed directly in the ground. However, at times it may be necessary to use a container for gardening, for example if adequate ground to grow a garden is unavailable or if existing ground has been contaminated by household or industrial waste. A garden container provides a gardening space that may be used either indoors or outdoors. With planning for proper drainage, a garden container can also be used on a patio, porch or even a rooftop. Gardening inside of a container has advantages compared to growing a garden directly in the ground. Garden containers may be filled with growing media best suited for what will be planted in the garden container. Garden containers offer a gardener more control over the chemical environment in the garden. Garden containers are useful to those who enjoy gardening but suffer from back pain or injury. Because a garden container can raise the gardening surface by as much as two feet, garden containers can significantly reduce the amount of bending of the back necessary for gardening. Finally, containers used for gardening can be more easily reinforced against pests such as burrowing animals than can gardens grown directly in the ground.
[0010] Prior art garden containers, typically made from plastic or thick hardwood planks, have many disadvantages. Plastic may be prone to cracking or breakage over time. Durable plastics fashioned to the size of a typical outdoor garden container would be expensive and too heavy to move or carry. Prior art plastic garden containers tend to be small and only used under controlled conditions, for example indoor gardening.
[0011] Milled hardwood planks typically used in garden containers are already in high demand by the economy. Hardwoods in particular have not been harvested sustainably in the past. Most of the world's old growth forests have already been harvested. Increasing demand for wooden garden containers may result in still more unsustainable harvesting of our forests.
[0012] Garden containers made from hardwood planks are prone to rot due to the mold and bacteria that live on the wood. A combination of rot at the corners where boards comprising the sides of the garden container are fastened together and the pressure exerted by dirt and water along the sides of the container eventually cause prior art garden containers to fail. Thus, many prior art garden containers use heavy corner posts, metal braces, metal spikes, or other devices to reinforce the corners of the container. Reinforcing the corners of the garden container in this manner adds even more weight and expense to the garden container. Rotting wood in an aging garden container made from hardwood planks introduces unwanted bacteria into the soil used to fill the container. When bacteria from rotting wood competes with beneficial bacteria for nutrients in the soil, the health of plants in the garden container may be negatively affected. Hardwood planks used to fashion prior art garden containers also provide a reservoir for excess water, which makes adjusting the pH or nutrient levels in the container more difficult. Excess water contained in the hardwood planks also contributes to the problem of rot as described above.
[0013] Paint can be an especially good way to prevent wood from rotting, which may be especially important for garden containers made from thin boards. However, prior art garden containers typically are not painted as toxic chemicals may enter the soil contained in the garden container. Although food-grade paint has been used commonly in industries where food is processed including farming, applications where paint does not make direct contact with food are not known.
[0014] Prior art garden containers may be expensive compared to other items necessary for gardening, for example dirt, seeds, and organic fertilizer.
[0015] Prior art garden containers typically come in fixed shapes or modules and typically do not include curved sides.
[0016] Prior art wooden garden containers made from hardwood planks typically are too heavy for an average person to pick up or carry.
[0017] Prior art garden containers are typically prone to another type of damage due to stress at corners, hereinafter called “aliasing,” that occurs with normal shipping and handling of the empty garden container. Aliasing occurs when opposing sides of a wooden garden container slide in opposite directions with respect to the parallel lines making up their bottom edges. The heavy weight of the hardwood planks used in prior art garden containers contributed to rather than helped to solve the aliasing problem.
[0018] Plywood is generally not used for garden containers even though it is the strongest and most sustainably produced wood available. Plywood is stronger than other wood because it is fashioned such that it has a grain running in two orthogonal directions. Plywood may be produced more sustainably than hardwood planks because plywood is fashioned from very young trees while hardwood planks are fashioned from mature trees.
[0019] The pliable nature of plywood makes plywood prone to bending (or bowing) and therefore not suitable for garden containers according to prior art. The pressure exerted by the dirt and water placed in the garden container, or bowing pressure, would cause plywood garden containers to fail shortly after being put into use according to prior art. Adding a wooden frame to support the plywood or using thick plywood would reintroduce all of the problems associated with garden containers made from hardwood planks discussed above including sustainability, expense, weight, bacterial growth, and hard to reach water.
[0020] Thus, there exists today a need for a garden container that helps to ameliorate the above-mentioned problems and difficulties as well as ameliorate those additional problems and difficulties as may be recited in the “OBJECTS AND SUMMARY OF THE INVENTION” or discussed elsewhere in the specification or which may otherwise exist or occur and that are not specifically mentioned herein.
[0021] As various embodiments of the instant invention help provide a more elegant solution to the various problems and difficulties as mentioned herein, or which may otherwise exist or occur and are not specifically mentioned herein, and by a showing that a similar benefit is not available by mere reliance upon the teachings of relevant prior art, the instant invention attests to its novelty. Therefore, by helping to provide a more elegant solution to various needs, some of which may be long-standing in nature, the instant invention further attests that the elements thereof, in combination as claimed, cannot be obvious in light of the teachings of the prior art to a person of ordinary skill and creativity.
[0022] Clearly, such an apparatus would be useful and desirable.
[0023] Garden containers are well known. For example, the following patent documents describe various types of these devices, some of which may have some degree of relevance to the invention. Other patent documents listed below may not have any significant relevance to the invention. The inclusion of these patent documents is not an admission that their teachings anticipate any aspect of the invention. Rather, their inclusion is intended to present a broad and diversified understanding regarding the current state of the art appertaining to either the field of the invention or possibly to other related or even distal fields of invention.
DESCRIPTION OF PRIOR ART
[0024] U.S. Pat. No. 7,533,491 to Singer, et al., which issued on May 19, 2009:
[0025] U.S. Pat. No. 7,490,435 to Singer, which issued on Feb. 17, 2009; U.S. Pat. No. 7,424,787 to Singer, which issued on Sep. 16, 2008; U.S. Pat. No. 6,434,882 to Becker, which issued on Aug. 20, 2002; and U.S. Pat. No. 4,897,955 to Winsor, which issued on Feb. 6, 1990.
[0026] While the structural arrangements of the above described devices may, at first appearance, have similarities with the present invention, they differ in material respects. These differences, which will be described in more detail hereinafter, are essential for the effective use of the invention and which admit of the advantages that are not available with the prior devices.
[0027] The foregoing patents reflect the current state of the art of which the present inventor is aware. Reference to, and discussion of, these patents is intended to aid in discharging Applicant's acknowledged duty of candor in disclosing information that may be relevant to the examination of claims to the present invention. However, it is respectfully submitted that none of the above-indicated patents disclose, teach, suggest, show, or otherwise render obvious, either singly or when considered in combination, the invention described and claimed herein.
BRIEF SUMMARY OF THE INVENTION
[0028] It is a first and principal object of the present invention to provide a container to be used for gardening that is made of thin, untreated plywood, and thus referred to herein as a “plywood garden container.”
[0029] Another object of the invention is to provide a plywood garden container that is made of thin boards made of raw wood.
[0030] Another important object of the invention is to provide a plywood garden container that includes a chicken wire mesh anchored proximate the bottom, on all sides, and at a multiplicity of anchor points.
[0031] Yet another object of the invention is to provide a plywood garden container that includes hardware cloth anchored on all sides and at a multiplicity of anchor points proximate the bottom of the plywood garden container.
[0032] A further object of the invention is to provide a plywood garden container that prevents bowing of straight sides.
[0033] A still further object of the invention is to provide a plywood garden container that preserves bowing of curved sides.
[0034] Another important object of the invention is to provide a plywood garden container that resists aliasing.
[0035] Still yet another object of the invention is to provide a plywood garden container with 90 degree angles between sides and with corners fashioned from lightweight corner posts.
[0036] Still yet another object of the invention is to provide a plywood garden container of any desired shape with corners fashioned from hinges.
[0037] A further object of the invention is to provide a plywood garden container that helps prohibit entry of gophers and other burrowing animals.
[0038] Still yet another important object of the invention is to provide an improvement to a wooden garden container specifically the instant plywood garden container by sealing the wood used in fashioning the container with a food-grade paint.
[0039] A first continuing object of the invention is to provide a plywood garden container made from ecologically friendly materials.
[0040] A second continuing object of the invention is to provide a plywood garden container that helps control the amount of bacteria that is present within the garden bed.
[0041] A third continuing object of the invention is to provide a plywood garden container that helps control the chemical environment within the garden bed.
[0042] A fourth continuing object of the invention is to provide a plywood garden container that is lightweight.
[0043] A fifth continuing object of the invention is to provide a plywood garden container that is inexpensive to manufacture.
[0044] A sixth continuing object of the invention is to provide a plywood garden container that includes a rectangular shape, a hexagon, or a curved shape in appearance.
[0045] A seventh continuing object of the invention is to provide a plywood garden container that includes any desired shape in appearance.
[0046] Briefly, a garden container that is constructed in accordance with the principles of the present invention includes one or more three-eighths inch thick plywood sides that form an outer structure for the plywood garden container. Each plywood side of a plywood garden container is preferably made from untreated plywood. Alternatively each side of a plywood garden container may be made from thin, e.g. one half inch, pieces of raw lumber. The sides of a plywood garden container may be straight or curved in appearance, as desired.
[0047] A food-grade paint is used to seal sides and wooden corner posts (if desired) to be used in the fabrication of the plywood garden container. Painting with food-grade paint provides a safe and novel way to extend the useful life and improve the aesthetics of a plywood garden container. Painting a plywood garden container also protects wood from rotting and gives gardeners more control over the growing environment when the container is eventually used for gardening.
[0048] A rectangular embodiment with four straight plywood sides and lightweight corner posts is first described. The dimensions of a preferred square or rectangular plywood garden container are approximately 1.5-feet tall, 4-feet wide, and 4-feet long, or, alternately, 1.5-feet tall, 4-feet wide, and 8-feet long although the size may vary, as desired. A preferred thickness for the plywood to comprise the sides of the plywood garden container is ⅜ inches but may be ¼ inch, ½ inch, or other thickness as desired. The four plywood sides are positioned upright to create a rectangular shape. Four upright posts are disposed at each corner within the interior space of the plywood garden container. The upright posts preferably include a 2-inch by 2-inch cross-sectional stock. The plywood sides are screwed onto the upright posts to form an enclosed rectangular shape for the plywood garden container.
[0049] A sheet of wire mesh (preferably conventional chicken wire) is fashioned to the size of an underside, i.e. the bottom, of the plywood garden container. For example, in the case of a preferred square 4-feet wide by 4-feet long plywood garden container, the wire mesh would be fashioned to 4-feet wide and 4-feet long. The wire mesh is pulled taught and anchored to the inside wall of the plywood garden container proximate to the bottom of the container at a multiplicity of anchor points. Anchors may be fashioned from staples, including U-shaped nails. Alternatively, anchors may be fashioned from eye screws. Anchor points are positioned preferably one per inch or at most one per two inches horizontally along each interior surface of the four sides of a plywood garden container and about two inches from the bottom of the container. Hardware cloth may be used instead of chicken wire to secure the sides of a plywood garden container. Once anchored by a multiplicity of anchor points, the wire mesh provides a novel structural capacity that distributes pressure away from the corners and to all parts of a plywood garden container. Said structural capacity provides the surprising benefit of preserving the shape of plywood sides of a plywood garden container even when plywood sides have been bowed or curved. The wire mesh also provides the added benefit of protection from burrowing animals such as gophers. Furthermore, the wire mesh provides the added benefit of preventing aliasing of a plywood garden container during shipping and handling.
[0050] Lightweight corner posts may be used for any embodiment with 90 degree angles including a rectangular shape as described above, L-shapes, U-shapes, and many other desired shapes. Alternatively one or more hinges may be disposed at a corner regardless of the desired angle formed by adjoining sides of a plywood garden container. A hexagon-shaped embodiment including six straight sides and twelve hinges for securing corners is next described. Sides may be any desired size, for example 1.5 feet high, 2.5 feet long, and ⅜ inch thick. Sides are positioned upright to form a pentagon shape for a plywood garden container. One or more hinges, i.e. two in this example, are disposed at each corner to secure adjacent sides in an upright position. Wire mesh is fashioned to the same shape as the bottom of a plywood garden container and anchored to the interior surfaces of the sides proximate the bottom of the container as described above. Other possible shapes for a plywood container garden comprised of straight sides include triangles, stars, or many other desired shapes.
[0051] The instant invention not only prevents bowing of straight sides of a plywood garden container but also stabilizes curved (or bowed) sides when desired. Outwardly curved sides (i.e., convex relative to the area outside the container; hereinafter “convex sides”) may be used, for example, to produce oval-shaped plywood garden containers (not shown). In the case of one or more inwardly curved sides (hereinafter “concave sides”) an additional area of wire mesh is disposed on the ground outside of the plywood garden container between the corners adjoining the one or more concave sides. When anchored at a multiplicity of anchor points the wire mesh provides the surprising structural capacity to preserve even a concave side in its original shape as a side of a plywood garden container. A detailed description of a curved plywood garden container with one convex side and one concave side is given below.
[0052] A top of the plywood container garden is open to provide access to the interior of the plywood garden container. The bottom is constructed only of the wire mesh, which along with the benefits mentioned above allows fluid to drain out of the plywood garden container. The primary benefit of the wire mesh was the distribution of bowing pressure to all parts of the garden container such that bowing was prevented on straight sides, bowing was preserved on convex and even on concave sides, and the need for strong or reinforced corners was eliminated. A safe and novel use of food-grade paint may extend the life of a plywood garden container to rival or surpass prior art garden containers.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0053] The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
[0054] FIG. 1A is an upper perspective view of a first preferred embodiment of the plywood garden container of the present invention, in this instance comprising a generally square configuration;
[0055] FIG. 1B is a top plan view thereof;
[0056] FIG. 1C is a partial side view in elevation showing the anchoring schedule on a bottom portion of the interior of a plywood side panel, this view showing the wire mesh implemented in the form of conventional hexagonal chicken wire;
[0057] FIG. 2A is an upper perspective view of a second preferred embodiment of the inventive plywood garden container, illustrating how the container can be configured in various complex polyhedral shapes, including that of a hexagon;
[0058] FIG. 2B is a top plan view thereof;
[0059] FIG. 2C is a partial side view in elevation showing the anchoring schedule on a bottom portion of the interior of a plywood side panel, this view showing the wire mesh implemented in the form of conventional square hardware cloth;
[0060] FIG. 3A is an upper front perspective view of a third preferred embodiment of the inventive plywood garden container, in this instance a parallelogram with opposing straight sides and opposing curved (convex and concave) sides;
[0061] FIG. 3B is a top plan view thereof;
[0062] FIG. 3C is a partial upper front perspective view showing the adjoining convex and flat sides of the third preferred embodiment;
[0063] FIG. 3D is a partial upper rear perspective view showing the adjoining concave and flat sides of the third preferred embodiment, as well as the wire mesh anchoring scheduled called for in holding the concave shape of the concave side; and
[0064] FIG. 3E is a cross-sectional side view in elevation showing the configuration of the wire mesh as anchored on the interior sides of the garden container and as stretched along the lower edge of the concave side of the container.
DETAILED DESCRIPTION OF THE INVENTION
[0065] Referring to FIGS. 1-3E , wherein like numbers refer to like elements in the various views, there is shown an improved garden container, namely, a plywood garden container, generally denominated in FIGS. 1A-3 as 100 , 200 , and 300 , respectively.
[0066] Referring first to FIG. 1A , there is shown a plywood garden container, generally denominated 100 .
[0067] The plywood garden container 100 provides a suitable environment for gardening. The plywood garden container 100 is placed directly onto a ground surface, and the interior defined by the container sides is filled with a suitable quantity of soil or another desired planting medium. Seeds or plants are then planted in the growing medium. The plywood container garden 100 provides an improved environment for gardening for many reasons described in detail below.
[0068] The plywood container garden 100 , as shown in FIGS. 1A and 1B includes first, second, third, and fourth plywood sides 102 , 104 , 106 , and 108 , respectively. The four plywood sides form a parallelogram, preferably square, for the plywood container garden 100 . Numerous alternative shapes are possible, as described in greater detail hereinafter.
[0069] The plywood used to form the first through fourth plywood sides 102 - 108 is preferably made from thin, untreated plywood. The use of untreated wood is preferred because chemicals used to treat the wood may contaminate soil with toxins. For best balancing the interests of cost, of handling, and of durability, the plywood sides are preferably ⅜-inch thick. Alternatively, plywood may be ¼ inch thick, ½ inch thick or other thickness as desired. Further to the economic, environmental, and social interests motivating the present invention, the plywood used in the present invention is preferably fabricated using trees grown in sustainable forestry programs.
[0070] Compared to milled lumber, plywood provides greater dimensional stability, greater strength, greater distribution of strength, resistance to splitting, and resistance to expansion and contraction. Because plywood is made from inexpensive materials, i.e. from a variety of young trees, costs of plywood are generally competitive with or lower than the costs of milled hardwood (i.e., redwood, oak, birch, and locust) planks. When convex or concave sides are part of a desired shape, plywood may be easily fashioned into that desired shape whereas milled lumber hardwood planks are notoriously difficult to bow.
[0071] A common problem in the prior art wooden garden containers is that the wood used to form the container sides is prone to rotting even after a short time in use. As plywood is typically made with several layers of wood veneers glued together, the plywood sides 102 - 108 are relatively durable even when maintained in contact with soil, including wet soil. Nevertheless, all wood used for garden containers rots eventually. The bacteria naturally present within rotting wood can contaminate the soil of the prior art wooden garden containers. Bacteria from the rotting wood compete with beneficial bacteria present in the soil and disrupt the desired ecosystem within the garden thus inhibiting plant growth and causing plant loss.
[0072] Besides rotting, prior art hardwood planks are subject to bowing pressure after the container is filled with soil and water. This feature alone contraindicated the use of plywood for container gardening in the minds of consumers and gardeners. The planks and heavy posts used to create prior art wooden garden containers are usually thick enough to provide support against bowing. However dirt and other contents still push against the interior sides of the side boards, which creates extreme pressure at the corners of prior art wooden garden containers. A combination of rot especially around the corners and pressure from the interior of the container causes prior art wooden garden containers to fail in the long term. Thus, the prior art hardwood planks are often reinforced with cross-bracing, metal spikes, numerous vertical posts, and other structures intended to reinforce corner supports and prevent bowing. All of these solutions, unfortunately, simply increase manufacturing and sales cost of the prior art wooden garden containers.
[0073] Due to the novel application of the wire mesh 120 used in the inventive plywood container 100 , the sides of said container are comprised only of wood, preferably of plywood or alternatively of other wood, typically one-half inch or less in thickness ( FIGS. 1A-1B ). Therefore the inventive plywood garden container 100 is less expensive to produce compared to prior art garden containers. Furthermore, plywood may be produced in an ecologically sustainable way almost anywhere in the world so the inventive plywood container will benefit the environment.
[0074] The plywood sides 102 - 108 are secured together at their respective corners by four vertical generally upright posts 110 , 112 , 114 , and 116 disposed on the interior of the container to form a generally square-shaped structure in this first preferred embodiment. The joined sides and corner posts thus define the interior of the container. Each plywood side is secured to each of two adjoining upright posts using a plurality of screws or other fasteners 118 . The upright posts 110 - 116 are preferably formed of 2-inch by 2-inch (or alternatively 1-inch by 1-inch) cross-sectional stock, and for a typical container, approximately 16-inches in height. The height of the upright posts 110 - 116 will obviously vary according to the height of the plywood sides 102 - 108 . A preferred wood for the upright posts 110 - 116 is pine but any 2-inch by 2-inch cross-sectional stock may be used.
[0075] As shown in FIGS. 1A-1B the first plywood side 102 is secured to the first and fourth upright posts 110 and 116 using screws 118 . The second plywood side 104 is secured to the first and second upright posts 110 and 112 . The third plywood side 106 is secured to the second and third upright posts 112 and 114 . The fourth plywood side 108 is secured to the third and fourth upright posts 114 and 116 .
[0076] For most residential gardens, the preferred dimensions of the first embodiment of the plywood container garden are 16-inches tall, 4-feet wide, and 4-feet long. A rectangular variation might be 16-inches tall by 4-feet wide by 8-feet long. Alternatively, fruit trees and some vegetables may require taller containers so the plywood garden container may be 2-feet tall, 3-feet wide and 6-feet long. Quite clearly, however, the size and shape variations are myriad (see FIGS. 2A-3D ).
[0077] A sheet of wire mesh 120 , preferably chicken wire, approximately 4-feet by 4-feet in size is stretched and anchored taught along an underside of the plywood garden container. If desired, hardware cloth may be used instead of chicken wire, though the latter is preferred for ease in manufacturing the inventive plywood garden container. In addition chicken wire mesh better meets the structural objectives of certain embodiments especially for example for a plywood garden container with one or more concave sides as described in detail below ( FIG. 3 ). The wire mesh 120 is anchored along the interior of all of the plywood sides 102 - 108 as close to the bottom edge of the side as structurally practicable for the plywood material used in fabricating the garden container ( FIGS. 1A and 1C ). Anchors may be industrial staples or U-shaped nails of a length that approximates the thickness of the sides a plywood garden container. Alternatively, anchors may be fashioned from eye screws. The wire mesh is anchored taught along each of its edges using a tight schedule of anchors 122 so as to ensure connections along substantially the entirety of each side and thus also to ensure broadly distributed and even tension across the entire wire mesh.
[0078] The wire mesh 120 provides several important and unexpected benefits. Most importantly, the wire mesh provides structural integrity to the inventive plywood container garden. In particular, the wire mesh 120 prevents unwanted outward bowing of the straight plywood sides. Conversely, if one or more convex or concave sides are desired, the wire mesh helps maintain the desired curvature as described below in relation to FIGS. 3A-3D . The wire mesh 120 also helps prevent gophers or other burrowing animals from entering the interior of the plywood container garden when the plywood container garden is placed directly on the ground. Another benefit is that the wire mesh 120 facilitates the rapid drainage of water from the container, thus reducing the time that water is in contact with the side panels. Another important benefit is that the wire mesh prevents aliasing of the sides 102 - 108 during shipping.
[0079] In addition to the foregoing benefits of the wire mesh, the use of a food grade paint to paint the wooden parts used in fashioning the inventive plywood garden container added several significant benefits. A first benefit of the food-grade paint used to paint the wooden parts of the inventive plywood garden container was the prevention of rot in the wooden parts of said container, after the planting of a garden in said container. A second related benefit of the food-grade paint was to help control the bacterial fauna of the soil after soil was placed in the interior of the inventive plywood garden container. A third benefit of the food-grade paint was to prevent plywood sides from soaking up water allowing for better control of the chemical environment on the interior of the inventive plywood garden container. A fourth benefit of the food-grade paint was to improve the aesthetics of the inventive plywood garden container. Finally and most importantly, all of these benefits were added safely simply because the paint was food grade.
[0080] Referring next to FIGS. 2A-2B , there is shown a second preferred embodiment 200 of the inventive plywood container garden. In this embodiment, the plywood container garden is configured into a hexagon shape as viewed from above or below. The second preferred embodiment of the plywood garden container includes an enclosed container 200 formed with 6 plywood sides 202 of identical length from which to configure a hexagon. This embodiment is identical in all material respects with that of the first preferred embodiment, save for the extra two sides, the shape of the wire mesh 204 , the pattern of the wire mesh, and the fact that the corners are secured using internal hinges 206 rather than posts.
[0081] The second modified plywood container garden 200 includes a wire mesh 204 fashioned to the same shape as said container itself and disposed along an underside, thereof. The wire mesh 204 is stretched taught and anchored along each of its edges, with staples or U-shaped nails 210 preferably placed in a schedule of one staple per square opening. The line of anchors 208 thus circumscribes the interior closely proximate the bottom of a plywood garden container 200 .
[0082] As will be appreciated, in this second preferred embodiment 200 as with the first preferred embodiment, by using hinges 206 at the corners, the container may be shaped before placement of the wire mesh 204 by adjusting each set of hinges 206 to the proper angle, thus making the container a hexagon 200 . When configured as desired, the wire mesh 204 can be anchored to the sides and the shape fixed.
[0083] Referring next to FIGS. 3A-3C , in a third preferred embodiment of the plywood container garden of the present invention 300 , a parallelogram with two straight sides 302 , 304 , and two opposing curved sides, one convex 306 , and one concave 308 , is provided. This embodiment is identical in all material respects with that of the first preferred embodiment, save for the two curved sides 306 , 308 , the shape of the wire mesh 310 and the fact that the corners are secured using internal hinges 312 rather than posts. In this third preferred embodiment, as with the second preferred embodiment, the container 300 may be shaped before placement of the wire mesh 310 by adjusting each set of hinges 312 appropriately.
[0084] As apparent in FIGS. 3A-3C the shape of the wire mesh 310 used for the inventive plywood garden container 300 will vary slightly from the shape of said container when said container is comprised of one or more concave sides. In order to help preserve the shape of the concave side 308 , an area of wire mesh 314 , comprising the area between two corners of said concave side and the edge of the concave side, is disposed along an outside bottom of the container and in a line between the two corners of the concave side. When configured as desired, the wire mesh can be secured with anchors 316 to the interior sides proximate the bottom of the inventive plywood garden container. This placement includes a line of anchors along the interior of concave side 308 , such that the wire mesh 310 is stretched along the bottom edge 309 of side 308 (see FIGS. 3D and 3E ), so as to provide still further structural support to maintain the concave shape of side 308 . As with the other embodiments, placement of the wire mesh in this manner fixes the shape of the container. Although only one set of anchors is necessary, the wire mesh 310 inside the third embodiment, the anchors and mesh along the interior side of concave side 308 , and the wire mesh 314 extending outside the concave side act independently but additively for structural support. In addition to the normal outward bowing pressure that occurs when a garden has been planted in the inventive garden container, there is a natural tendency for a bowed board to straighten or flatten. The interior anchors on side 308 and the wire mesh 314 on the outside of a concave side of the inventive plywood garden container helps to prevent this latter problem, as well as adding more resistance to the normal outward bowing pressure.
[0085] Curved and straight sides can be combined in any number of ways. It will be appreciated that the inventive plywood garden container can be configured to almost any desired shape. Additionally, the use of bender board, wiggle board, or the equivalent is contemplated for plywood garden containers having significantly curved sides.
[0086] The benefits as mentioned herein for the plywood garden container are provided with any of the embodiments. The invention has been shown, described, and illustrated in substantial detail with reference to the presently preferred embodiment. It will be understood by those skilled in this art that other and further changes and modifications may be made without departing from the spirit and scope of the invention which is defined by the claims appended hereto.
[0087] The above disclosure is sufficient to enable one of ordinary skill in the art to practice the invention, and provides the best mode of practicing the invention presently contemplated by the inventor. While there is provided herein a full and complete disclosure of the preferred embodiments of this invention, it is not desired to limit the invention to the exact construction, dimensional relationships, and operation shown and described. Various modifications, alternative constructions, changes and equivalents will readily occur to those skilled in the art and may be employed, as suitable, without departing from the true spirit and scope of the invention. Such changes might involve alternative materials, components, structural arrangements, sizes, shapes, forms, functions, operational features or the like.
[0088] Therefore, the above description and illustrations should not be construed as limiting the scope of the invention, which is defined by the appended claims. | The instant invention provides a plywood garden container that is inexpensive to manufacture, that may be produced sustainably, that is lightweight, that is durable, that is not prone to bowing of straight sides, that preserves the shape of curved sides, that is not prone to aliasing during handling, and that may be of any desired shape. A plywood garden container includes plywood boards (sides) to form an outer structure. Lightweight posts or hinges are disposed at each corner of the structure to hold sides upright and to enclose a plywood garden container. Wooden parts of a plywood garden container are painted with a food-grade paint before assembly in order to seal the wood. A sheet of wire mesh is pulled taught across an underside of the structure and secured with anchors. A plywood garden container includes an open top. After a garden is planted in a plywood garden container, the wire mesh distributes pressure away from the corners and to all parts of the container. A novel use for food-grade paint extends the useful life of the instant invention. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to a method of detecting failure to tighten screws against works and a device therefor, suitable for preventing occurrence of failure to tighten the screws in working step for tightening the screws against the works.
In an assembly line for electrical equipments, for example, various parts are mounted on an electrical equipment body as work by means of screws in a plurality of working steps. Generally, a worker in charge for each step tightens the previously allotted number of screws against each electrical equipment body sequentially conveyed along the assembly line with a tool such as an electric screwdriver or pneumatic screwdriver.
Whether or not the screws are correctly tightened against each work depends upon the degree of skillfulness and carefulness of the worker. Accordingly, it is inevitable that the failure to tighten the screws occurs at a certain rate. Particularly, various types of one electrical equipment have recently been produced in a small number in order that a diversity of consumers' needs can be met. In such circumstances, the number of screws to be used differs from one type of the electrical equipment to another and positions where the screws are tightened are changed with design changes even in one type. Accordingly, contents of work in the screw tightening step are also changed at relatively short intervals. Consequently, the workers cannot sometimes cope with the changes in the work contents, which has caused frequent occurrence of failure to tighten the screws. Conventionally, the products are checked in a final inspection at the assembly line. However, the products are visually inspected, which inevitably causes oversight.
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to provide a method of detecting failure to tighten screws and a device therefor, wherein upon occurrence of failure to tighten screws against the works in a work step of tightening the screws against the works with a tool, the failure can be immediately informed.
In order to achieve the object, the invention provides a method of detecting failure to tighten screws against works, comprising a first step of detecting every screw tightening operation against a work with a screw tightening tool after start of a screw tightening step, a second step of counting the number of times of the screw tightening operations detected in the first step, a third step of detecting the completion of the screw tightening step, and a fourth step of comparing a counted value at the time of the completion of the screw tightening step with a predetermined value, thereby informing of a result of comparison.
The invention also provides a device for detecting failure to tighten screws against works, comprising means for confirming a period for which a work step for tightening a plurality of screws against a work with a screw tightening tool is executed, counting means for counting the number of times of screw tightening operations in the confirmed period, and means for comparing the result of the counting by the counting means with a predetermined value, thereby informing of a result of comparison.
The invention may also be practiced by a device for detecting failure to tighten screws against works, comprising first detection means for detecting every screw tightening operation against a work with a screw tightening tool after start of a screw tightening step, thereby generating status signals, counting means for sequentially receiving the status signals generated by the first detection means to thereby count the number of the status signals, second detection means for detecting completion of the screw tightening step, thereby generating a completion signal, comparison means for comparing a counted value obtained by the counting means at the time of generation of the completion signal by the second detection means with a predetermined value, and means for informing of the result of comparison by the comparison means.
In the case where N (natural number) screws are tightened against the work, "N" is selected as a set value corresponding to the number of screws. In the screw tightening step, the counting means automatically counts the number of operations of the tool for tightening the screws. When the counting result at the time of completion of the screw tightening step differs from the set value "N," an alarming operation is performed. More specifically, the counting result does not reach the set value "N" owing to occurrence of failure to tighten any screws in the work step in which N screws need to be tightened. Consequently, the alarming operation is automatically performed.
The screw tightening tool may preferably include an electric tool and the first detection means may preferably comprise a current detector generating the status signal when the value of a load current supplied to the electric tool for tightening the screws exceeds a predetermined value.
Furthermore, the screw tightening tool may include a pneumatic tool having an operation member allowing and disallowing compressed air to flow thereto and the first detection means may comply a switch generating the status signal in response to an operation of the operation member of the pneumatic tool.
The second detection means may preferably be disposed on the assembly line along which works against which the screws are tightened are conveyed and generate the completion signal when the work passes a predetermined position on the line.
Preferably, the second detection means may also comprise a support on which the work against which the screws are tightened is placed and a switching element mounted on the support for responding to the placement of the work on the support.
Preferably, the second detection means may further comprise a holding member for holding a tool for tightening the screws at a standby position and a switching element mounted on the holding member for responding to the detachment of the tool from the holding member.
Other objects of the present invention will become obvious upon an understanding of the illustrative embodiments about to be described or will be indicated in the appended claims, and various advantages not referred to herein will occur to one skilled in the art upon employment of the invention in practice.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is an electrical circuit diagram employed in a first embodiment of the invention;
FIG. 2 a perspective view of a detecting device in accordance with the first embodiment;
FIGS. 3(a) to 3(l) are time charts for explaining the operation of the detecting device;
FIG. 4 is a view similar to FIG. 1 showing a second embodiment of the invention;
FIG. 5 is a longitudinal section of the major part of the detecting device in accordance with the second embodiment;
FIG. 6 is a perspective view of the major part of a third embodiment of the invention;
FIG. 7 is a perspective view of the major part of a fourth embodiment of the invention; and
FIG. 8 is a perspective view of the detecting device in accordance with a sixth embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A first embodiment of the present invention will now be described with reference to FIGS. 1 to 3(a)-3(l) of the accompanying drawings. Referring to FIG. 2, an assembly line 1 for electrical equipments such as microwave ovens is provided with a belt conveyor 2 driven at a predetermined speed. Works such as electrical equipment bodies 3 are sequentially conveyed by belt conveyor 2. For the purpose of confirming a period of a screw tightening work by detecting the completion of a screw tightening step, a displacement detecting device is provided at one of sides of belt conveyor 2 for detecting the displacement of electrical equipment body 3. The displacement detecting device comprises first and second reflection type photoelectric switches 4 and 5 disposed with a predetermined distance therebetween in the direction in which electrical equipment bodies 3 are sequentially conveyed on belt conveyor 2. The distance between photoelectric switches 4 and 5 is determined to be shorter than the dimension of electrical equipment body 3 in the direction in which it is conveyed on belt conveyor 2. Each of photoelectric switches 4 and 5 is of the built-in contact type. Photoelectric switch 4 disposed at the upper side has a normally closed sensor contact 4a (see FIG. 1) which is opened when electrical equipment body 3 being conveyed on the belt conveyor 2 is detected. Photoelectric switch 5 has a normally open sensor contact 5a (see FIG. 1) which is closed when electrical equipment body 3 is detected. Cables 4b and 5b for drawing outputs from contacts 4a and 5a are connected to photoelectric switches 4 and 5 at one ends and to plugs 4c and 5c at the other ends, respectively.
A detecting device body 6 is provided in the vicinity of belt conveyor 2 of assembly line 1. Detecting device body 6 is provided, at one side thereof, with jacks 4d and 5d to which plugs 4c and 5c are coupled. A door 6a is provided for closing the front opening of detecting device body 6. A twin plug socket 7, reset button 8 and counter unit 9 as counting means are mounted on the outer side of door 6a and an alarming buzzer 10 is mounted on the inner side thereof.
A power supply plug 11a of an electric screwdriver 11 as a tool for tightening screws is inserted into one of the plug sockets of twin plug socket 7. Electric screwdriver 11 comprises a body portion 11b which is held by a worker so that the worker performs the screw tightening job with screwdriver 11. A switch knob 11c of a power supply switch (not shown) is mounted on the body portion 11b. Knob 11c is operated so that power supply switch is closed, thereby driving an electric motor (not shown) provided within body portion 11b. Since twin plug socket 7 is employed, two electric screw drivers having different tightening torques may be used together. Two reset switches 8a and 8b (see FIG. 1) are mounted on the inner side of door 6a of detecting device body 6. Reset switches 8a and 8b are combined with reset button 8 such that both switches are opened when reset button 8 is depressed.
Counter unit 9 comprises a presettable counter 12 and a power supply section (both shown in FIG. 1). Presettable counter 12 comprises setting knobs 12a and 12b for setting a two digit preset value Ns and a display 12c each digit of which is formed from seven segments each consisting of one light-emitting diode. Display 12c is externally operated to selectively display the digital preset value Ns or a digitized value Nr counted by counter 12. Detecting device body 6 is supplied with electrical power from a AC power source through a power supply plug 14.
Various control equipments such as a relay, current relay and timer are provided within alarming device body 6. The arrangement of a control circuit including these control equipments, counter unit 9 and so on will be described with reference to FIG. 1. A DC power (100 V, for example) is supplied through a pair of power supply lines 15 and 16 and plug 14. Plug socket 7 is connected to a current relay 17 as a current detector between power supply lines 15 and 16. Consequently, when plug 11a of electric screwdriver 11 is connected to plug socket 7, electric screwdriver 11 may be energized. Upon energization of electric screwdriver 11, a load current is caused to flow through current relay 17. Current relay 17 is provided for detecting a starting current as the load current flowing into the built-in motor of screwdriver 11. In the case where the motor of screwdriver 11 draws approximately 0.75 amps. at start-up, for example, current relay 17 is operated to close normally open relay switch 17a when a current of 0.5 amps. or more is drawn.
Counter unit 9 is connected between power supply lines 15 and 16. Counter 12 of the counter unit is adapted to count up one step every time a voltage signal is stepped down after the voltage signal is supplied to a clock terminal CK. Counter 12 is adapted to initialize the counted value when the voltage signal is supplied to a reset terminal R. Counter 12 has a normally open counter switch 12d and a normally closed counter switch 12e. When the counted value Nr reaches the preset value Ns, switch 12d is closed and switch 12e opened.
A first relay 18 is connected in series to a relay switch 17a of current relay 17 and a normally closed timer contact 19a of a timer 19 between power supply lines 15 and 16. First relay 18 has three normally open relay switches 18a, 18b and 18c. Relay switch 18a is connected in parallel with relay switch 17a of current relay 17. Relay switch 18b is connected between power supply line 15 and the clock terminal CK of counter 12. Timer 19 is connected in parallel with first relay 18. Timer 19 is adapted to open timer contact 19a thereof when energization thereof is continued for a predetermined period T (1.5 seconds, for example). Period T is set so as to be a little longer than a period necessary for tightening a screw with the screwdriver 11.
A second relay 20 is connected in series to sensor contacts 4a and 5a between power supply lines 15 and 16. Second relay 20 has three normally open relay switches 20a, 20b and 20c. Relay switch 12a is connected between power supply line 15 and the reset terminal R of counter 12.
A third relay 21 is connected in series to relay switch 18c of first relay 18, a normally closed relay switch 22a of a fourth relay 22 described later, and reset switch 8a between power supply lines 15 and 16. Relay 21 has three normally open relay switches 21a, 21b and 21c. Relay switch 21a is connected in parallel with relay switch 18c of first relay 18.
Fourth relay 22 has a normally closed relay switch 22b as well as relay switch 22a. Fourth relay switch 22 is connected in series to counter switch 12d of counter 12, relay switches 20b, 21b and 22b between power supply lines 15 and 16.
An alarm buzzer 10 is connected in series to counter switch 12e of counter 12, relay switches 20c and 21c and reset switch 8b between power supply lines 15 and 16, which series circuit constitutes an alarm circuit 23.
Operation of the above-described arrangement will now be described with reference to FIG. 4 as well as FIGS. 1 and 2. In the case where four screws are to be tightened against each work with electric screwdriver 11 in the screw tightening step, the preset value Ns of counter 12 is set at "4." Display 12c may be switched so as to display the preset value Ns for confirmation thereof and need be switched again so as to display the counted value Nr after confirmation.
When first reflection-type photoelectric switch 4 detects electrical equipment body 3 conveyed on the belt conveyor 2, sensor contact 4a of the photoelectric switch is opened, thereby detecting start of the screw tightening step. Subsequently, when electric screwdriver 11 is driven so that a first screw is tightened against a predetermined position of electrical equipment 3 (at time t1 in FIG. 3), a large starting current of approximately 0.7 amps. flows into built-in motor of screwdriver 11, thereby determining that the screw tightening operation has been performed. Upon detection of the starting current, current relay 17 causes relay switch 17a to be closed. Consequently, first relay 18 is energized with the result that relay switches 18a, 18b and 18c are closed (at time t2). In response to closure of relay switch 18a, first relay 18 is maintained in the self-holding state and timer 19 is continuously energized in response to the self-holding state of relay 18. Timer contact 19a is opened after timer 19 is energized for the predetermined period T, thereby releasing relay 18 from the self-holding state (at time t3). Consequently, since relay contact 18b is opened and then closed, that is, since the voltage applied to clock terminal CK of counter 12 is stepped down, counter 12 counts up one step at time t3 when relay switch 18b is opened. As described above, third relay 21 is energized to thereby close relay switches 21a, 21b and 21c at time t2 when relay switch 18c is closed. Third relay 21 is maintained in the self-holding state owing to closure of relay switch 21a.
When the screw is tightened against electrical equipment body 3 by electric screwdriver 11, the load current flowing into the motor of screwdriver 11 varies as shown in FIG. 3(c). More specifically, upon start of drive of screwdriver 11, the relatively large starting current of approximately 0.7 amps. temporally flows into the motor of screwdriver 11. Thereafter, when the screw tightening is completed, a lock current of approximately 0.5 amps. is drawn. Accordingly, relay switch 17a of current relay 17 the operative current of which is set at 0.5 amps. could be closed when the lock current is drawn. As a result, counter 12 counts up at the occurrence of the lock current and there is the possibility that the counted value Nr does not correspond to the number of screws tightened against the work. However, first relay 18 is maintained in the self-holding state such that counter 12 counts up by one step, until the period T set in timer 19 elapses, the period T being set so as to be a little longer than the period necessary for tightening one screw with the screwdriver. Consequently, the counted value Nr corresponds to the number of screws tightened with screwdriver 11.
Relay 18 is thus operated by timer 19 every time the screw tightening operation is executed. Counter 12 counts up by one step every time relay 18 is operated. When the counted value Nr of counter 12 reaches the preset value Ns or "4" or when the necessary number of screws are tightened, counter switch 12d is closed and counter switch 12e is opened (at time t4). On the other hand, electrical equipment body 3 is further conveyed on belt conveyor 2 and detected by second photoelectric switch 5. Sensor contact 5a of photoelectric switch 5 is closed to thereby detect the completion of the screw tightening step. Since the distance between photoelectric switches 4 and 5 is set so as to be shorter than the dimension of electrical equipment body 3 in the direction in which it is conveyed on belt conveyor 2, sensor contact 4a of first photoelectric switch 4 is still opened. When electrical equipment 3 is further conveyed on belt conveyor 2, sensor contact 4a of first photoelectric switch 4 is closed at time t5 corresponding to the time of completion of the screw tightening step. Then, both of sensor contacts 4a and 5a are closed and second relay 20 is energized, thereby closing relay switches 20a and 20b. Counter 12 is initialized when relay switch 20a is closed. Relay switch 21b of third relay 21 which is still in the self-holding state is in the on-state and counter switch 12d is closed. Consequently, fourth relay 22 is energized when relay switch 20b is closed. Then, since relay switches 22a and 22b are opened, third relay 21 is released from the self-holding state and second relay 22 is deenergized, thereby restoring the initial state. Since counter switch 12e is opened, alarm buzzer 10 is not energized even when relay switch 20c is closed, that is, alarm buzzer 10 is not driven when necessary four screws are tightened against electrical equipment 3, with the result that electrical equipment 3 is successively conveyed on belt conveyor 2.
On the contrary, when all the screws are not tightened against electrical equipment 3 by the worker's mistake, counter switch 12d remains open and counter switch 12e remains closed. Accordingly, even when relay switch 20b is closed in response to energization of second relay 20 at the time of completion of the screw tightening step or when sensor contact 4a is re-closed, fourth relay 22 is not energized with the result that third relay 21 is maintained in the self-holding state. Consequently, when relay switch 20c of second relay 20 is closed, alarm buzzer 10 is energized through counter switch 12e, relay switches 20c and 21c and reset switch 8b, thereby informing of the occurrence of failure in the screw tightening. Upon alarming operation of buzzer 10, the worker can tighten one or more screws which have not tightened. Upon the alarming operation, reset button 8 is depressed to open reset switches 8a and 8b, whereby third relay 21 is released from the self-holding state and alarm buzzer 10 is deenergized, thereby restoring the initial state.
According to the above-described embodiment, when all the screws are not tightened in the work step of tightening necessary number of screws against the electrical equipment 3, alarm buzzer 10 is immediately driven in the work step to thereby inform the worker of the occurrence of a failure. Consequently, such occurrence of the failure to tighten the screws against the electrical equipment 3 may safely be coped with. Furthermore, since the automatic execution of the alarming operation necessitates only the setting of the necessary number of screws as the preset value Ns in counter 12, the screw tightening efficiency is not reduced.
FIGS. 4 and 5 illustrate a second embodiment of the invention. Although the screws are tightened against the electrical equipments 3 conveyed on belt conveyor 2 in the foregoing embodiment, the invention may be applied to a screw tightening step in which jigs are employed. Referring to FIG. 5, an electrical equipment panel 24 as a work is placed on a holding jig 25. A plurality of boss portions 24a are formed in panel 24. A necessary number of screws 27 is engaged with boss portions 24a so that, for example, a printed wiring board 26 is secured. A normally closed limit switch 28 serving as means for generating a screw tightening completion signal is mounted on jig 25 for the purpose of confirming the period necessary for the screw tightening step. Limit switch 28 is opened when panel 24 is placed on jig 25.
Limit switch 28 is connected between power supply lines 4 and 5 through second relay 20 within alarming device body 6, as shown in FIG. 4. Provision of limit switch 28 eliminates first and second photoelectric switches 4 and 5 from alarming device body 6 in the foregoing embodiment. Connection of limit switch 28 is made by means of jack 4d of detecting device body 6 and jack 5d is short-circuited by, for example, a plug adapter (not shown).
The predetermined number of screws 27 is set at counter 12 as the preset value Ns. In the condition that panel 24 is placed on jig 25, limit switch 28 is opened and accordingly, second relay 20 is deenergized. During deenergization of second relay 20, counter 12 counts up by one step every time one screw is tightened with electric screwdriver 11. When the necessary number of screws are tightened, counter switch 12d is closed and counter switch 12e is opened. Thereafter, when panel 24 is removed from jig 25 and limit switch 28 is closed, fourth relay 22 is energized through counter switch 12d and relay switches 20b, 21b and 22b. Consequently, alarm buzzer 10 is not driven. On the other hand, in the case that the necessary number of screws are not tightened against electrical equipment 3 by the worker's mistake or that counter contact 12d is opened and counter switch 12e is closed, fourth relay 22 is not energized even when panel 24 is removed from jig 25 and limit switch 28 is closed. Consequently, alarm buzzer 10 is energized to thereby inform the worker of the occurrence of failure to tighten screws.
Although limit switch 28 is mounted on jig 25 for detecting completion of the screw tightening step, in the second embodiment, it may be mounted on a conventional reel disposed over the worker for holding electric screwdriver 11 at a standby position as shown in FIG. 6 as a third embodiment. Limit switch 28 is closed when a wire 29a suspending electric screwdriver 11 is taken up by reel 29 such that electric screwdriver 11 is lifted. Or, as illustrated in FIG. 7 as a fourth embodiment, limit switch 28 may be mounted on a stand 30 of electric screwdriver 11 disposed in the vicinity of the worker. Limit switch 28 is closed when electric screwdriver 11 is held on stand 30.
The system shown in FIGS. 1 and 2 may be further modified as a fifth embodiment. In order to tighten the screws against one work with a plurality of electric screwdrivers in a single screw tightening step, n number of electric screwdrivers 11 are provided. Between power supply lines 4 and 5 are connected two or more screw-tightening detecting circuits each including plug socket 7 and current relay 17 connected in the same manner as shown in FIG. 1 and two or more circuits each including relay 18, timer 19 and relay switches 17a, 18a and 19a connected in the same manner as shown in FIG. 1. Two or more relay switches 18b of relays 18 of circuits are connected in parallel with one another between power supply line 15 and clock terminal CK of counter unit 19. In the fifth embodiment, failure to tighten the screws may be detected and informed when a plurality of workers are engaged in the screw tightening work against one work.
Referring to FIG. 8 illustrating a sixth embodiment, a pneumatic screwdriver 32 is provided as a screw tightening tool so as to be driven by compressed air supplied through a hose 31 communicated to a compressed air source (not shown). Pneumatic screwdriver 32 has a lever 33 for closing and opening a valve which allows and disallows compressed air to flow to pneumatic screwdriver 32 and a first switch 34 connected in series to a lead wire 35. First switch 34 is interlocked with lever 33. When lever 33 is gripped by the worker for the screw tightening, the valve is opened, thereby driving pneumatic screwdriver and turning a first switch on by way of lever 33. A holder 36 is provided over assembly line 2 for holding pneumatic screwdriver 32 with completion of the screw tightening step. Holder 36 is provided with a second switch 37 responsive to the weight of pneumatic screwdriver 32. A circuit arrangement wherein first switch 34 is employed instead of switch 17a and second switch 37 instead of switches 4a and 5a in FIG. 1 performs the same operation of detecting failure to tighten screws as the device shown in FIG. 1.
The foregoing disclosure and drawings are merely illustrative of the principles of the present invention and are not to be interpreted in a limiting sense. The only limitation is to be determined from the scope of the appended claims. | A method of detecting failure to tighten screws against works includes steps of detecting every screw tightening operation against a work after start of a screw tightening step, counting the number of times of the screw tightening operations detected in the previous step, detecting the completion of the screw tightening step, and comparing a counted value at the time of the completion of the screw tightening step with a predetermined value, thereby informing of a result of comparison. A device for carrying out this method includes a current relay responsive to a large load current during the tightening operation of an electric screwdriver in a screw tightening step, a presettable counter for counting the number of operations of the current relay for the purpose of counting the number of screw tightening operations, setting knobs operated for setting a desirable number of screws to be tightened, photoelectric switches for detecting completion of the screw tightening step for the work, and an alarming device for comparing a counter value obtained by the presettable counter and the value set by the knobs when a screw tightening work completion signal is generated by any one of the photoelectric switches. The alarming device includes a buzzer energized when counted value does not reach the preset value set at the presettable counter. | 1 |
This application is a continuation of prior U.S. patent application Ser. No. 12/571,687—filed on Oct. 1, 2009 now abandoned and naming Steven J. Knasko as an inventor—which is herein incorporated by reference.
FIELD OF THE INVENTION
This invention relates to support brackets, particularly those that are used in portable enclosures, particularly supporting a camera or gun on the framework of a hunting blind.
BACKGROUND OF THE INVENTION
Interacting with animals, especially through hunting, bird watching, or photography, is a popular activity. Interacting with animals in a natural environment is preferable. In this way, animals must be prevented from detecting when an observer, hunter, or photographer is present. If this is not done, animals may be frightened and stay away from the location of the individual. Therefore, it is important to make the individual visually undetectable.
Blinds are often utilized to conceal individuals and equipment in such an environment. Numerous types of blinds exist, and many are generally portable and collapsible structures. A common type of hunting blind is one that is a cover portion supported by a framework. The cover portion could range anywhere from a rubber-like substance to a type of fabric material. This cover portion is held in a desired position and shape due to the structure of the framework, which is then supported by the ground. In a number of such blinds have a X-shaped framework on at least one side of the blind, such as disclosed in U.S. Pat. No. 6,296,415 and 7,320,332.
It is known in the prior art to have a support for a gun or camera located near a window of a blind such as described in U.S. Pat. No. 5,964,435. However, supports like those described are large and would be difficult to transport. Also, if more than one is needed, the task of transporting them becomes even greater. In addition, the support must be attached to the tent wall and supported on the ground, making guaranteed stability impossible on insubstantial or uneven terrain. The tent wall may not be of sufficient strength to support particular accessories. When the tent wall is made of fabric, supports depending on wall support are limited by the amount of force the wall will bear. Furthermore, the size and complexity of mounting makes their interchangeability cumbersome. Due to this, only one sort of support is provided that must try to suffice for all sorts of attachments.
The present inventor has recognized the need for a blind accessory support bracket that is reasonably small and easy to transport.
The present inventor has also recognized the need for a blind accessory support bracket that is securely mounted on a blind regardless of the terrain or blind location.
The present inventor has also recognized the need for a blind accessory support bracket that maximizes that utilizes the support frame work of a blind.
The present inventor has also recognized the need for a blind accessory support bracket that is capable of being designed for a specific accessory and interchanged with other specifically designed supports.
SUMMARY OF THE INVENTION
The present invention comprises a blind accessory support bracket for use with a blind tent or protable structure having an X-shaped frame component. This blind accessory support bracket includes a blind attachment portion coupled to an accessory support portion.
The blind attachment portion is similar for all different support apparatuses. The blind attachment portion has a body that is shaped to fit snugly into the top V-shape formed by the X-shaped framework of the blind. This body may be upside down triangularly shaped or upside down trapezoidally shaped. The body lies in the same plane as the X-shaped framework, and the sides of the body resting against the framework making up the top of the X-shape. Therefore, the blind attachment portion body is prevented from sliding down by the X-shaped framework of the blind. In this way, the blind accessory support bracket of the present invention may support as much downward force as the framework of the blind can withstand.
Further, the blind attachment portion contains retaining abutments to prevent movement of the blind accessory support bracket in a direction perpendicular to the plane in which the X-shaped framework lies. A top abutment and a bottom abutment extend out from the blind attachment portion body, in a direction substantially parallel to the plane of the ground. The top abutment is attached to the blind attachment portion body on a side outside of the X-shaped structure, toward the blind outer covering. The bottom abutment is attached to the blind attachment portion body on a side inside of the X-shaped structure, toward the inside of the blind. Both the top and bottom abutments are transverse to the X-shaped framework at their respective locations.
When the blind accessory support bracket is mounted on the blind, the top and bottom abutments press against the X-shaped framework of the blind on an outside and an inside, respectively. When an amount of weight is applied to the accessory support portion, a torque is applied to the blind attachment portion, pressing and securing the abutments on the framework with increased force. The blind accessory support bracket is prevented from becoming displaced inside of the framework by the top abutment and prevented from becoming displaced outside of the framework by the bottom abutment.
The accessory support portion may be of a number of configurations, and may serve a number of functions. One embodiment shows the accessory support portion as a camera brace or a gun brace. Different accessory support portions are designed depending on the different mounting mechanisms of the cameras or guns. In addition, the accessory support portion may comprise a shelf for use with a number of accessories.
The blind accessory support bracket is preferably located on the framework of a blind on the inside of an opening of the blind. Therefore, the camera or gun brace supports a camera or gun with a clear viewing and aiming medium. In this way, the activity becomes more easy and efficient through the assistance of the blind accessory support bracket.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a blind accessory support bracket of the invention mounted on the framework of a blind, wherein the accessory support portion comprises a gun brace;
FIG. 2 is a rear view of the blind accessory support bracket of FIG. 1 ;
FIG. 3 is a front view of the blind accessory support bracket of FIG. 1 ;
FIG. 4 is a top view of the blind accessory support bracket of FIG. 1 ;
FIG. 5 is a bottom view of the blind accessory support bracket of FIG. 1 ;
FIG. 5 b is a perspective view of a blind with an internal framework shown with the use of dashed lines;
FIG. 6 is a perspective view of a second embodiment of a blind accessory support bracket of the invention mounted on the framework of a blind, wherein the accessory support portion comprises a camera brace with camera mounting fastened thereon;
FIG. 7 is a rear bottom perspective view of the blind accessory support bracket of FIG. 6 ;
FIG. 8 is a front top perspective view of the blind accessory support bracket of FIG. 6 ;.
FIG. 9 is a top perspective view of the blind accessory support bracket of FIG. 6 ;
FIG. 10 is a perspective view of a third embodiment of a blind accessory support bracket of the invention mounted on the framework of a blind, wherein the accessory support portion comprises a shelf;
FIG. 11 is a front view of the blind accessory support bracket of FIG. 10 ;
FIG. 12 is a rear view of the blind accessory support bracket of FIG. 10 ;
FIG. 13 is a bottom view of the blind accessory support bracket of FIG. 10 ;
FIG. 14 is a top view of the blind accessory support bracket of FIG. 10 ; and
FIG. 15 is a rear view of a fourth embodiment of a blind accessory support bracket.
DETAILED DESCRIPTION
While this invention is susceptible of embodiment in many different forms, there are shown in the drawings, and will be described herein in detail, specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments illustrated.
FIGS. 1-5 show one embodiment of the blind accessory support bracket 30 mounted on a frame 32 of a hunting blind, tent, or portable structure. The blind accessory support bracket 30 comprises a blind attachment portion 34 and an accessory support portion 36 .
In this embodiment, the accessory support portion 36 comprises a notch 38 formed into a blind attachment portion body 40 . Notch 38 may be sized, shaped, and configured to fit a gun barrel for support when hunting. In one embodiment, notch 38 is V-shaped in the center of the blind attachment portion body 40 .
Blind attachment portion 34 rests on a portion of an X-shaped structure 42 of the framework 32 . In one type of X-shaped framework, a first frame member 42 a converges toward a second frame member 42 b . The first and second frame members 42 a , 42 b converge to a connection point 42 c . The first and second frame members 42 a , 42 b of the type shown in FIG. 1 are the upper V portion of the X-shaped framework.
Blind attachment portion body 40 is upside down trapezoidally shaped, with a first lateral side 44 and a second lateral side 46 configured to rest against X-shaped structure 42 . The first lateral side 44 is shaped to rest on the first converging frame member 42 a and the second lateral side 46 is shaped to rest against the second converging frame member. In one embodiment, the lateral sides 44 , 46 are shaped to contact the corresponding converging frame members 42 a , 42 b along substantially the entire surface of the lateral sides 44 , 46 . The lateral sides have a front edge 44 a , 46 a and a back edge 44 b , 46 b defining a width of each lateral side.
While the embodiment shown is a trapezoidal shape, other shapes fitting with the top of an X-shaped structure are possible configuration of the accessory support bracket 30 . Blind attachment portion body 40 also has a top 48 and bottom 50 that are substantially parallel. Blind attachment portion body 40 lies in the same plane as X-shaped structure 42 . The sides 44 , 46 press down against X-shaped structure 42 and resist the tendency of the blind accessory support bracket 30 to fall downward. Blind attachment portion body 40 may be injection molded out of plastic or made of another material such as wood or metal.
Blind attachment portion 34 also comprises a top abutment 52 and a bottom abutment 54 . Abutments 52 , 54 extend out from blind attachment portion body 40 in a direction substantially parallel to top 48 and bottom 50 . It is also possible for the abutments to extend from the body 40 at angles other than parallel to the top 48 or the bottom 50 . Abutment 52 extends in front of the X-shaped structure 42 and the abutment 55 extends behind the X-shaped structure. Abutments 52 , 54 may be injection molded out of plastic or made of another material such as wood or metal. The abutments may also be integrally molded with the body 40 to form one unified component.
Top abutment 52 is positioned on a forward side of the X-shaped structure 42 in relation to an inside location 64 . The inside location 64 is where the user is on the inside of the blind, tent, or support structure. If the blind is not a fully enclosed structure, the inside user location 64 is behind the a wall having the X-shaped structure with a support 30 . Top abutment 52 prevents the motion of the blind accessory support bracket 30 in a direction out of the plane of the X-shaped structure, and toward the inside location 64 .
The top abutment 52 has two inside facing portions 52 a , 52 b at opposite lateral ends of the abutment 52 . The first inside face 52 a of the abutment 52 and the adjacent portion of the sidewall 44 form a L-shaped channel portion 52 c for receiving the frame member 42 a . Likewise a second inside face 52 b and the adjuacent portion of the sidewall 46 form an L-shaped channel portion 52 d for receiving the frame member 42 b.
Bottom abutment 54 is located on a near side of X-shaped structure 42 , with respect to the inside location 64 . Bottom abutment 54 prevents the motion of the blind accessory support bracket 30 in a direction out of the plane of the X-shaped structure 42 , and away from the inside location 64 . With these provisions, the blind accessory support bracket 30 is provided with resistance to motion in the forward, rearward, and downward directions and provides significant stability.
The bottom abutment 54 has two inside facing portions 54 a , 54 b at opposite lateral ends of the abutment 54 . The first inside face 54 a and the adjacent portion of the sidewall 44 form a L-shaped channel portion 54 c for receiving the frame member 42 a . Likewise a second inside face 54 b and the adjacent portion of the sidewall 46 form an L-shaped channel portion 54 d for receiving the frame member 42 b.
While the embodiment shown provides channel portions 52 c , 52 d , 54 c , 54 d , in an alternatively embodiment the channel portions comprise channels extending along both the front and back sides of a frame member 42 a or 42 b and extending along the length of the side wall and when positioned on a frame 42 .
FIG. 5 b shows the outside of a blind to be used in connection with the present invention. Blind covering 62 lies on the framework 32 . Blind covering 62 encloses the inside location 64 . Framework 32 is located inside blind covering 62 , but is shown here with the use of dashed lines. An opening 66 is shown just above X-shaped structure 42 . The opening 66 is shown as a triangle shape but may take other forms, including square or rectangle. The blind accessory support bracket 30 is preferably mounted on X-shaped structure so that the accessories being supported thereby are readily alignable with the opening 66 .
FIGS. 6-9 show second embodiment of a blind accessory support bracket 130 mounted on the framework 32 of a hunting blind. The blind accessory support bracket 130 comprises a blind attachment portion 134 and an accessory support portion 136 .
Blind attachment portion 134 rests on an X-shaped structure 42 of framework 32 . Blind attachment portion body 140 is upside down trapezoidally shaped, with sides 144 , 146 configured to rest against X-shaped structure 42 . The body 140 is similar in structure to the body 40 . Blind attachment portion body 140 also has a top 148 and bottom 150 that are substantially parallel. Blind attachment portion body 140 lies in the same plane as X-shaped structure 42 . The sides 144 , 146 press down against X-shaped structure 42 and resist the tendency of the blind accessory support bracket 130 to fall downward. Blind attachment portion body 140 may be injection molded out of plastic or made of another material such as wood or metal.
Blind attachment portion 134 also comprises a top abutment 152 and a bottom abutment 154 . Abutments 152 , 154 extend out from blind attachment portion body 140 in a direction substantially parallel to top 148 and bottom 150 . Abutments 152 , 154 are transverse to the X-shaped structure 42 . Abutments 152 , 154 may be injection molded out of plastic or made of another material such as wood or metal.
Top abutment 152 is positioned on a forward side of the X-shaped structure 42 , with respect to the inside location 64 . Top abutment 152 prevents the motion of the blind accessory support bracket 130 in a direction out of the plane of the X-shaped structure, and toward the inside location 64 .
Bottom abutment 154 is located on a near side of X-shaped structure 42 , with respect to a blind location 64 . Bottom abutment 154 prevents the motion of the blind accessory support bracket 130 in a direction out of the plane of the X-shaped structure 42 , and away from the location 64 . With these provisions, the blind accessory support bracket 130 is provided with resistance to motion in the forward, rearward, and downward directions and provides significant stability
In this second embodiment, however, the accessory support portion 136 comprises a camera brace 156 . Camera brace 156 is mounted on a near side of blind attachment portion 134 , with respect to the inside location 64 . FIG. 6 shows a camera stand 158 clamped onto camera brace 156 . In one embodiment the camera brace 156 is a squared annular shape. Accessory support portion 136 comprising a camera brace 156 may be injection molded with the rest of blind accessory support bracket 130 , or made of another material such as wood or metal. The Accessory support may be integrally molded or formed with the body 140 to comprise a unitary part.
A third embodiment is shown in FIGS. 10-14 . In this embodiment, a blind accessory support bracket 230 is mounted on the framework 32 of a hunting blind. The blind accessory support bracket 230 comprises a blind attachment portion 234 and an accessory support portion 236 .
Blind attachment portion 234 rests on an X-shaped structure 42 of framework 32 . Blind attachment portion body 240 is upside down trapezoidally shaped, with sides 244 , 246 configured to rest against X-shaped structure 42 . The body 140 is similar in structure to the body 40 . Blind attachment portion body 240 also has a top 248 and bottom 250 that are substantially parallel. Blind attachment portion body 240 lies in the same plane as X-shaped structure 42 . The sides 244 , 246 press down against X-shaped structure 42 and resist the tendency of the blind accessory support bracket 230 to fall downward. Blind attachment portion body 240 may be injection molded out of plastic or made of another material such as wood or metal.
Blind attachment portion 234 also comprises a top abutment 252 and a bottom abutment 254 . Abutments 252 , 254 extend out from blind attachment portion body 240 in a direction substantially parallel to top 248 and bottom 250 . Abutments 252 , 254 are transverse to the X-shaped structure 42 . Abutments 252 , 254 may be injection molded out of plastic or made of another material such as wood or metal.
Top abutment 252 on a forward side of the X-shaped structure 42 , with respect to the inside location 64 . Top abutment 252 prevents the motion of the blind accessory support bracket 230 in a direction out of the plane of the X-shaped structure, and toward the inside location 64 .
Bottom abutment 254 is located on a near side of X-shaped structure 42 , with respect to the inside location 64 . Bottom abutment 254 prevents the motion of the blind accessory support bracket 230 in a direction out of the plane of the X-shaped structure 42 , and away from the inside location 64 . With these provisions, the blind accessory support bracket 230 is provided with resistance to motion in the forward, rearward, and downward directions and provides significant stability.
In this third embodiment, the accessory support portion comprises a shelf 260 . Shelf 260 is attached on a near side of blind attachment portion 234 , with respect to a inside location 64 . Accessory support portion 236 comprising a shelf 260 may be injection molded with the rest of blind accessory support bracket 230 , or made of another material such as wood or metal.
In a fourth embodiment, as shown in FIG. 15 , the blind accessory support bracket 330 comprises a blind attachment portion body 340 . The support bracket is configured to engage one or more accessory support portions, such as accessory support portions 136 , 236 . The accessory support portions 136 , 236 are interchangeably and detachably connectable with the blind attachment portion body 340 .
The blind attachment portion body 340 has an engagement device for securing the attachment support portions to the body 340 . The engagement device may comprise any number of means of securing one component to another component. The engagement device may comprise channels 311 , 313 for lockably receiving end portions 156 a , 156 b of the camera brace 156 . The engagement device may have a horizontal channel 317 , 315 for lockably receiving a front end engagement portion 260 a of the shelf 260 . The engagement device may comprise dovetailed channels for slidably receiving dovetail members of the accessory support portion. The engagement device may also comprise other devices and methods of releasably attaching one component to another component, such as a lock and release mechanism. While the blind accessory support bracket 330 is shown in FIG. 15 with an accessory support portion 336 , the accessory support portion 336 is optional in an embodiment configured to interchangeably and detachably connect various accessory support portions.
From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred. | A blind accessory support bracket is disclosed. The bracket is configured to fit into the X-shaped framework of a hunting blind, tent, or portable structure. Abutments are located on either side of the bracket, containing the framework therebetween, and securing the bracket in place. The bracket may provide a variety of different supports, including a gun brace, a camera mount, or a shelf. When the bracket is located on framework near an opening of the blind, it may assist in aiming or shooting of a camera or gun at a target outside the blind. | 6 |
CLAIM OF PRIORITY
[0001] This application claims the benefit of priority under 35 U.S.C. §119(e) of U.S. Provisional Application Ser. No. 60/966036 filed on Aug. 24, 2007.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of large aperture imaging optics, and more specifically relates to photographic, cinematographic and reconnaissance optical systems that are extremely well corrected at a relative aperture of about f/1.5 or faster over a full field of view of approximately 5 degrees or more throughout a large spectral range. The present invention also relates to the field of cinematographic optical systems that are well corrected for breathing over a wide magnification range.
BACKGROUND ART
[0003] A long sought-after goal of photographic optical design is to provide a large aperture objective having an f/number of about f/1.5 or smaller that is well corrected for all aberrations over a large flat field and over a large spectral range. In addition, a goal for objectives used in cinematography is that they be corrected for “breathing.” Breathing is defined as a change in chief ray angle in object space as the lens is focused, and it causes objects to move radially in the image frame as they go in and out of focus.
[0004] The Petzval design form is capable of being well corrected at a large aperture over a small field of view, and has been used for many decades in applications such as cinema projection lenses, heads-up displays, and microscope objectives. Although the Petzval form is too limited for use as a general-purpose photographic or cinematographic lens, it provides important insights about large aperture lens design. In particular, a Petzval lens achieves excellent correction at large apertures by minimizing the power of the negative lens elements located far from the image plane. Petzval objectives often employ a negative field flattener located fairly close to the image plane. As a result, the positive lens elements can be made from low-index fluor crown glass or calcium fluoride crystal if desired in order to reduce or eliminate the secondary spectrum. Examples of large aperture Petzval lenses include U.S. Pat. No. 2,649,021; U.S. Pat. No. 3,255,664; and U.S. Pat. No. 4,329,024.
[0005] The double-Gauss design form is very widely used for high-speed objectives that must cover a relatively wide field of view. However, double-Gauss designs rely on the use of positive elements made of high index crown glass in order to flatten the field, and as a result it is difficult or impossible to correct the secondary spectrum. Double-Gauss designs also have a strong tendency to suffer from oblique spherical aberration that severely limits off-axis performance at wide apertures. Vignetting is normally used to control the aberrated tangential rays, so high-speed double-Gauss designs have a characteristic strong illumination fall off coupled with a large amount of residual sagittal oblique spherical aberration. The oblique spherical aberration can be corrected to a large extent by relaxing the requirement for a large working distance and/or by introducing one or more aspheric surfaces into the design. Examples of high-speed double-Gauss designs include U.S. Pat. No. 2,012,822; U.S. Pat. No. 3,504,961; and U.S. Pat. No. 4,394,095.
[0006] Triplet derivatives, including the Sonnar and Emostar design forms, have also been widely used in the past for high-speed objectives with small to moderate fields of view. These designs tend to have many of the strengths and shortcomings of the double-Gauss type designs, but are generally more suited to narrower fields of view. Examples include U.S. Pat. No. 1,975,678; U.S. Pat. No. 2,310,502; and U.S. Pat. No. 3,994,576. An interesting sub grouping of triplet derivatives designed mainly for television cameras is moderately well corrected for extremely large apertures of about f/0.7 and incorporate a meniscus doublet lens group with a very strong concave surface near the image plane. This meniscus group serves to flatten the field. These designs also have characteristics similar to Petzval lenses, particularly the minimization of negative power in large elements located far from the image plane. Examples of this type include U.S. Pat. No. 2,978,957; U.S. Pat. No. 3,300,267; U.S. Pat. No. 3,445,154; U.S. Pat. No. 3,454,326; and U.S. Pat. No. 3,586,420.
[0007] The reverse telephoto design form is useful for achieving both a large aperture and a wide field of view. However, the image quality for high-speed wide-angle examples is generally mediocre, and these lenses need to be stopped down substantially to achieve good results. An exception is found in microfilm objectives, such as U.S. Pat. No. 3,817,602 and U.S. Pat. No. 4,310,223; and microscope objectives such as U.S. Pat. No. 5,920,432. However in these cases a high image quality is achieved at the expense of image size. Examples of high-speed wide-angle reverse telephoto designs include U.S. Pat. No. 3,992,085; U.S. Pat. No. 4,025,169; U.S. Pat. No. 4,095,873; U.S. Pat. No. 4,136,931; and U.S. Pat. No. 5,315,441.
[0008] Despite the above efforts, virtually all high-speed photographic lenses designed to date are compromised by the need to balance large aberrations against each other. Most often these designs are notably soft in the outer sub-group of the image field, and must be stopped far down to achieve good performance. Accordingly, there is a need for high-speed optical systems that are both extremely well corrected and reasonably compact when scaled to an image diagonal of about 28 mm. In addition, for cinematographic applications, there is a need for such optical systems to be well corrected for breathing.
SUMMARY OF THE INVENTION
[0009] The present invention is directed to optical systems that are extremely well corrected at an f/# of about f/1.5 or less over a moderate to wide field of view. More specifically, the present invention is directed to cinematographic and photographic objectives that are extremely well corrected at an aperture of about f/1.3 to f/1.4, and are optionally well corrected for breathing.
[0010] The recent rise of electronic image capture in the fields of still photography and cinematography have opened up new challenges and opportunities for the optical systems used in these applications. In cinematography, for example, new high-quality digital cameras often dispense with an optical viewfinder in order to reduce noise and cost. As a result, the optics can take advantage of a shorter working distance to improve speed, optical correction, or both. However, the optical design may need to take into account any plane parallel filters in the optical path near the image plane. These include IR/UV blocking filters, anti-aliasing filters, and sensor cover glasses. The exit pupil of the optical design must also match the characteristics of the sensor as closely as possible.
[0011] In the present invention, an extraordinary degree of optical correction is achieved at a very large aperture by allowing the working distance to become relatively short, and also by employing a unique optical construction. The main part of this optical construction is a primary lens group (“primary group”), or PG, that in turn comprises a front negative-powered sub-group P 1 , followed by a positive-powered sub-group P 2 , followed by a negative-powered sub-group P 3 , and optionally followed by a final sub-group P 4 that can be either negatively or positively powered. In the discussion below, the focal length of primary group PG is called FG. Also in the discussion below, the focal lengths of sub-groups P 1 , P 2 , P 3 , and P 4 are called F 1 , F 2 , F 3 , and F 4 , respectively.
[0012] Sub-group P 1 has only a weak negative power, and its function is to help flatten the field as well as to reduce the chief ray angle as it enters the remaining sub-group of PG. Sub-group P 1 can also be usefully split into two parts that move separately during focusing to aid in aberration and breathing correction. Elements in sub-group P 1 that are near the aperture stop are also good locations for an aspheric surface to correct spherical aberration.
[0013] Sub-group P 2 has a strong positive power, and its focal length F 2 is somewhat less than FG. Sub-group P 2 is the main collective group of lenses within primary group PG. Since field curvature is corrected elsewhere within the lens it is not necessary to use high index glass for the positive elements in sub-group P 2 , so low index glass with anomalous dispersion can be used. This is analogous to the use of low-index anomalous-dispersion glass in the positive-powered elements of a Petzval type lens, where field curvature is typically corrected by the use of a field flattener located near the image plane. The ability to use low-index anomalous-dispersion glasses is critical for achieving the excellent color correction necessary for any fast lens that must be extremely well corrected. By judicious use of these anomalous-dispersion glasses it is possible to achieve good correction over a very broad waveband. Surfaces within sub-group P 2 that are near the aperture stop can provide a good location for an asphere to correct spherical aberration.
[0014] Sub-group P 3 is a moderately high-powered negative group whose primary function is to flatten the field and to correct astigmatism. The rearmost surface of sub-group P 3 , referred to below as SC, has a very short radius of curvature and is concave toward the image plane. Much of the field flattening correction takes place at surface SC. Rearmost surface SC is readily identified as being the first air-glass interface within primary group PG that is concave toward the image and that has a radius of curvature less than FG and in which the marginal ray height is substantially less than the maximum value of the marginal ray height in the system. The radius of curvature of rearmost surface SC is called R SC . The distance along the optical axis from surface SC to the image plane is called Z SC .
[0015] Rearmost surface SC is also located axially in such a way that the marginal ray height as it intersects this surface is small relative to its largest value. This condition may be expressed as 1.3<y MAX /y SC <4.0, where y MAX is the maximum height of the marginal ray as it passes through the lens and y SC is the height of the marginal ray as it intersects the surface SC. The large negative power of surface SC combined with the fact that the marginal ray height is relatively small at SC is what enables this particular surface to have such an important contribution to field curvature correction.
[0016] Sub-group P 4 is the remaining group of elements located on the image side of sub-group P 3 . This sub-group has relatively low power, which can be either positive or negative. The function of sub-group P 4 is primarily to help control the exit pupil location, to correct distortion, and to make final adjustments to astigmatism. Sub-group P 4 is optional and may be eliminated if requirements for off-axis image quality are not so stringent.
[0017] Example embodiments with an image diagonal of about 28 mm and a focal length of about 40 mm or larger may be solely comprised of primary lens group PG. Example embodiments with an image diagonal of about 28 mm and a focal length shorter than about 40 mm are best comprised of primary lens group PG plus a grouping of lens elements in front of PG. These elements in front of PG essentially act as a wide-angle afocal attachment to shorten the focal length and widen the field of view while allowing primary group PG to retain its basic structure. Of course, the added elements in front of PG need not function precisely as an afocal attachment, and can have a net negative or net positive power. Consequently, the object magnification for primary group PG, calculated as the slope of the marginal ray entering the primary group divided by the slope of the marginal ray exiting this group, can be negative, zero, or positive. The object magnification of primary group PG is called OBMG PG
[0018] Lenses for cinematography must be well corrected for a wide range of object distances, and in addition should be well corrected for breathing. Breathing is a phenomenon in which off-axis image points move radially within the image format as they go in and out of focus. A lens that is focused by simply moving the entire optical structure as a unit along the optical axis will suffer from breathing because the image format will subtend a larger angle for a distant object than it will for a close object. A lens corrected for breathing will have a chief ray angle that is constant for all focus settings. Breathing is defined by the expression:
[0000] B =(100%) (chief ray angle−chief ray angle at infinity)/(chief ray angle at infinity),
[0000] where the chief ray angle is measured in object space.
[0019] It is also desirable for cinematographic and general photographic objectives to have a variable soft focus feature so that a wide variety of special effects can be achieved. This is especially true of cinematographic objectives with a focal length of about 50 mm and longer, which are frequently used for close-up headshots and the like. The best method of introducing a soft focus is to vary the amount of spherical aberration in a controlled manner by an axial adjustment of one or more lens elements. Ideally a lens with a variable soft focus adjustment will also have a means for adjusting paraxial focus at the same time spherical aberration is changed. This will allow for the best balance of defocus and spherical aberration to achieve the desired soft focus effect.
[0020] In addition to cinematographic and general photographic applications, the present invention is well-suited to demanding reconnaissance, surveillance, and inspection applications. These applications generally require a narrower magnification range than cinematography or general photography. For example, lenses used for aerial reconnaissance are typically always used with a very distant object, and need not be optimized for close focusing. Surveillance lenses are also typically used with distant object distances, though perhaps a bit closer than the object distances encounted in aerial photography. Inspection lenses are typically used for close object distances, but only a narrow range of magnifications.
[0021] A lens designed according to the present invention for cinematographic or general photographic applications may be applied to applications requiring only a narrow range of magnifications simply because the broad magnification range of the design encompasses the magnification range required for the application at hand. However, it is generally be better to optimize an optical system to work best under the actual conditions in which it is used. So, for example, an aerial reconnaissance lens should be optimized to perform best at infinite or nearly infinite conjugates, and this performance need not be compromised to improve performance for closer object distances.
[0022] Surveillance and reconnaissance lenses are also often required to work well over an extended waveband that includes the near-infrared portion of the spectrum. This allows for improved imagery through haze and atmospheric scattering, and it also permits the use of specialized sensors for low-light applications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 a is a layout drawing of an f/1.33 lens system showing magnification settings of 0.0× and −0.137× according to Example 1 of the present invention.
[0024] FIG. 1 b are plots of MTF vs. Image Height at spatial frequencies of 10 cycles/mm, 20 cycles/mm and 40 cycles/mm for magnification settings of 0.0×, −0.032×, −0.064× and −0.137× over a waveband of 435 nm to 656 nm according to Example 1 of the present invention.
[0025] FIG. 1 c are plots of Distortion and Astigmatism (S and T) vs. Image Height for magnification settings of 0.0×, −0.032×, −0.064× and −0.137× according to Example 1 of the present invention.
[0026] FIG. 1 d is a plot of Relative Illumination vs. Image Height for apertures of f/1.33 and f/2.8 and a magnification of 0.0× according to Example 1 of the present invention.
[0027] FIG. 2 a is a layout drawing of an f/1.4 lens system showing magnification settings of 0.0× and −0.124× according to Example 2 of the present invention.
[0028] FIG. 2 b are plots of MTF vs. Image Height at spatial frequencies of 10 cycles/mm, 20 cycles/mm and 40 cycles/mm for magnification settings of 0.0×, −0.032×, −0.064× and 0.124× over a waveband of 435 nm to 656 nm according to Example 2 of the present invention.
[0029] FIG. 2 c are plots of Distortion and Astigmatism (S and T) vs. Image Height for magnification settings of 0.0×, −0.032×, −0.064× and −0.124× according to Example 2 of the present invention.
[0030] FIG. 2 d is a plot of Relative Illumination vs. Image Height for apertures of f/1.4 and f/2.8 and a magnification of 0.0× according to Example 2 of the present invention.
[0031] FIG. 3 a is a layout drawing of an f/1.4 lens system according to Example 3 of the present invention.
[0032] FIG. 3 b are plots of MTF vs. Image Height at spatial frequencies of 10 cycles/mm, 20 cycles/mm and 40 cycles/mm for a magnification setting of 0.0× over a waveband of 435 nm to 656 nm according to Example 3 of the present invention.
[0033] FIG. 3 c are plots of Distortion and Astigmatism (S and T) vs. Image Height for a magnification setting of 0.0× according to Example 3 of the present invention.
[0034] FIG. 3 d is a plot of Relative Illumination vs. Image Height for apertures of f/1.4 and f/2.8 and a magnification of 0.0× according to Example 3 of the present invention.
[0035] FIG. 4 a is a layout drawing of an f/1.33 lens system showing magnification settings of 0.0× and −0.094× according to Example 4 of the present invention.
[0036] FIG. 4 b are plots of MTF vs. Image Height at spatial frequencies of 10 cycles/mm, 20 cycles/mm and 40 cycles/mm for magnification settings of 0.0×, −0.030×, −0.060× and −0.094× over a waveband of 435 nm to 656 nm according to Example 4 of the present invention.
[0037] FIG. 4 c are plots of Distortion and Astigmatism (S and T) vs. Image Height for magnification settings of 0.0×, −0.030×, −0.060× and −0.094× according to Example 4 of the present invention.
[0038] FIG. 4 d is a plot of Relative Illumination vs. Image Height for apertures of f/1.33 and f/2.8 and a magnification of 0.0× according to Example 4 of the present invention.
[0039] FIG. 5 a is a layout drawing of an f/1.4 lens system showing magnification settings of 0.0× and −0.033× according to Example 5 of the present invention.
[0040] FIG. 5 b are plots of MTF vs. Image Height at spatial frequencies of 10 cycles/mm, 20 cycles/mm and 40 cycles/mm for magnification settings of 0.0× and −0.033× over a waveband of 435 nm to 656 nm according to Example 5 of the present invention.
[0041] FIG. 5 c are plots of Distortion and Astigmatism (S and T) vs. Image Height for magnification settings of 0.0× and −0.033× according to Example 5 of the present invention.
[0042] FIG. 5 d is a plot of Relative Illumination vs. Image Height for apertures of f/1.4 and f/2.8 and a magnification of 0.0× according to Example 5 of the present invention.
[0043] FIG. 6 a is a layout drawing of an f/1.4 lens system showing magnification settings of 0.0× and −0.05× according to Example 6 of the present invention.
[0044] FIG. 6 b are plots of MTF vs. Image Height at spatial frequencies of 10 cycles/mm, 20 cycles/mm and 40 cycles/mm for magnification settings of 0.0× and −0.05× over a waveband of 435 nm to 656 nm according to Example 6 of the present invention.
[0045] FIG. 6 c are plots of Distortion and Astigmatism (S and T) vs. Image Height for magnification settings of 0.0×, and −0.05× according to Example 6 of the present invention.
[0046] FIG. 6 d is a plot of Relative Illumination vs. Image Height for apertures of f/1.4 and f/2.8 and a magnification of 0.0× according to Example 6 of the present invention.
[0047] FIG. 7 a is a layout drawing of an f/1.4 lens system showing magnification settings of 0.0× and −0.065× according to Example 7 of the present invention.
[0048] FIG. 7 b are plots of MTF vs. Image Height at spatial frequencies of 10 cycles/mm, 20 cycles/mm and 40 cycles/mm for magnification settings of 0.0× and −0.065× over a waveband of 435 nm to 656 nm according to Example 7 of the present invention.
[0049] FIG. 7 c are plots of Distortion and Astigmatism (S and T) vs. Image Height for magnification settings of 0.0× and −0.065× according to Example 7 of the present invention.
[0050] FIG. 7 d is a plot of Relative Illumination vs. Image Height for apertures of f/1.4 and f/2.8 and a magnification of 0.0× according to Example 7 of the present invention.
[0051] FIG. 8 a is a layout drawing of an f/1.33 lens system showing magnification settings of 0.0× and −0.137× according to Example 8 of the present invention.
[0052] FIG. 8 b are plots of MTF vs. Image Height at spatial frequencies of 10 cycles/mm, 20 cycles/mm and 40 cycles/mm for magnification settings of 0.0×, −0.032×, −0.064× and −0.137× over a waveband of 435 nm to 656 nm according to Example 8 of the present invention.
[0053] FIG. 8 c is a plot of MTF vs. Image Height at a spatial frequency of 20 cycles/mm for temperatures of 0 C, 20 C and 40 C according to Example 8 of the present invention.
[0054] FIG. 8 d are plots of Distortion and Astigmatism (S and T) vs. Image Height for magnification settings of 0.0×, −0.032×, −0.064× and −0.13 7× according to Example 8 of the present invention.
[0055] FIG. 8 e is a plot of Relative Illumination vs. Image Height for apertures of f/1.33 and f/2.8 and a magnification of 0.0× according to Example 8 of the present invention.
[0056] FIG. 9 a is a layout drawing of an f/1.4 lens system showing magnification settings of 0.0× and −0.064× according to Example 9 of the present invention.
[0057] FIG. 9 b are plots of MTF vs. Image Height at spatial frequencies of 10 cycles/mm, 20 cycles/mm and 40 cycles/mm for magnification settings of 0.0× and −0.064× over a waveband of 435 nm to 656 nm according to Example 9 of the present invention.
[0058] FIG. 9 c are plots of Distortion and Astigmatism (S and T) vs. Image Height for magnification settings of 0.0× and −0.064× according to Example 9 of the present invention.
[0059] FIG. 9 d is a plot of Relative Illumination vs. Image Height for apertures of f/1.4 and f/2.8 and a magnification of 0.0× according to Example 9 of the present invention.
[0060] FIG. 10 a is a layout drawing of an f/1.4 lens system showing magnification settings of 0.0× and −0.056× according to Example 10 of the present invention.
[0061] FIG. 10 b are plots of MTF vs. Image Height at spatial frequencies of 10 cycles/mm, 20 cycles/mm and 40 cycles/mm for magnification settings of 0.0× and −0.056× over a waveband of 435 nm to 656 nm according to Example 10 of the present invention.
[0062] FIG. 10 c are plots of Distortion and Astigmatism (S and T) vs. Image Height for magnification settings of 0.0× and −0.056× according to Example 10 of the present invention.
[0063] FIG. 10 d is a plot of Relative Illumination vs. Image Height for apertures of f/1.4 and f/2.8 and a magnification of 0.0× according to Example 10 of the present invention.
[0064] FIG. 11 a is a layout drawing of an f/1.4 lens system showing magnification settings of 0.0× and −0.037× according to Example 11 of the present invention.
[0065] FIG. 11 b are plots of MTF vs. Image Height at spatial frequencies of 10 cycles/mm, 20 cycles/mm and 40 cycles/mm for magnification settings of 0.0× and −0.037× over a waveband of 435 nm to 656 nm according to Example 11 of the present invention.
[0066] FIG. 11 c are plots of Distortion and Astigmatism (S and T) vs. Image Height for magnification settings of 0.0× and −0.037× according to Example 11 of the present invention.
[0067] FIG. 11 d is a plot of Relative Illumination vs. Image Height for apertures of f/1.4 and f/2.8 and a magnification of 0.0× according to Example 11 of the present invention.
[0068] FIG. 12 a is a layout drawing of an f/1.4 lens system according to Example 12 of the present invention.
[0069] FIG. 12 b are plots of MTF vs. Image Height at spatial frequencies of 50 cycles/mm, 100 cycles/mm and 200 cycles/mm for an object at infinity over a waveband of 435 nm to 1000 nm according to Example 12 of the present invention.
[0070] FIG. 12 c are plots of Distortion and Astigmatism (S and T) vs. Image Height for an object at infinity according to Example 12 of the present invention.
[0071] FIG. 12 d is a plot of Relative Illumination vs. Image Height for an aperture of f/1.4 and an object at infinity according to Example 12 of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0072] The present invention relates to the field of large aperture imaging optics. More specifically, the present invention relates to optical systems that are extremely well corrected throughout a large waveband for an aperture of about f/1.5 or faster.
[0073] In the Summary of the Invention section above, in the descriptions below and in the claims, the phrases “well-corrected” and “extremely well-corrected” in relation to the optical system of the present invention is understood in the art to mean that the collective effect of aberrations in the optical system are reduced to the point where the optical system is able to satisfactorily perform its particular imaging function. For example, in a photographic objective optical system according to the present invention, the Modulation Transfer Function (MTF) is an excellent and widely accepted means by which to judge the state of optical correction.
[0074] In particular, a photographic or cinematographic objective with a focal length greater than about 35 mm intended for a format diagonal of about 28 mm is considered to be well-corrected if the MTF values at 20 cycles/mm is approximately 80% or greater on-axis and is approximately 60% or greater at image heights less than or equal to 14 mm off-axis.
[0075] For wide-angle objectives the criteria for “well-corrected” are relaxed slightly in the outer part of the image field. Thus, a photographic or cinematographic objective with a focal length less than about 35 mm intended for a format diagonal of about 28 mm is considered to be well-corrected if the MTF values at 20 cycles/mm is 80% or greater on-axis and is approximately 50% or greater at image heights less than or equal to 14 mm off-axis.
[0076] An objective covering a format diagonal of about 28 mm can be considered to be “extremely well-corrected” if it fulfills the above conditions for off-axis field points and the MTF value at 40 cycles/mm is approximately 80% or greater on-axis.
[0077] Twelve examples of the present invention are discussed below. In order to better define and compare these examples with each other and with the prior art a set of eight parameters is calculated for each example and tabulated in Table 12. These parameters are discussed above in general terms in the Summary of the Invention section above, and in more specific terms below.
[0078] All twelve of the examples set forth below are scaled to an image diagonal of about 28 mm. However, there is nothing in the present invention that precludes scaling to smaller or larger image sizes.
EXAMPLE 1
[0079] Example 1, which is a 65 mm focal length objective for 35 mm format cinematography, is illustrated in FIG. 1 a, which shows cross-sectional layouts at magnifications of 0 and −0.137×. All of the element and group designations mentioned below are shown in FIG. 1 a. The relative aperture is f/1.33, the image diagonal is 28 mm, and the diagonal field of view (FOV) is 24.3 degrees.
[0080] MTF vs. Image Height at 10, 20 and 40 cycles/mm for four different object distances is illustrated in FIG. 1 b . These curves indicate that Example 1 is extremely well corrected at f/1.33, with MTF values at 40 cycles/mm greater than 80% near the optical axis in the middle part of the focusing range and very near 80% at the extreme ends of the focusing range. This extraordinary performance falls off very gradually to the corner of the field, and the S and T curves stay close together. FIG. 1 c shows distortion and astigmatism (Coddington curves) for the same four object distances used in FIG. 1 b. Distortion is virtually zero at all magnifications, and astigmatism is also very well controlled. FIG. 1 d is a plot of relative illumination vs. image height at f/1.33 and f/2.8, and it indicates that the Example 1 design has extremely low illumination falloff for such a high-speed lens.
[0081] The primary group PG comprises the entire lens except for a plane parallel filter element 114 . As discussed above, primary group PG comprises a negative powered front sub-group P 1 , followed by a positive powered sub-group P 2 , followed by a negative powered sub-group P 3 , followed by a sub-group P 4 that can be either positively or negatively powered.
[0082] In Example 1, sub-group P 1 comprises two negative lens groups: a negative doublet 116 and a negative singlet 103 . The convex object-facing surface of element 103 is aspherical, and singlet 103 is made of S-BSL7 to ensure that manufacturing this aspherical surface will not be problematic. The doublet 116 uses high-index anomalous dispersion materials N-KZFS4 and S-NPH1 to advantage, and as a result aids in reducing secondary and tertiary chromatic aberrations. The surface of sub-group P 1 closest to the object is a concave surface.
[0083] Sub-group P 2 comprises two positive lens groups: a positive singlet 105 and a positive doublet 117 . The positive elements in sub-group P 2 are elements 105 and 107 . Both are made of low-index anomalous dispersion material S-FPL51. The single negative element 106 is made of a matching anomalous dispersion material N-KZFS4. Since most of the positive optical power for Example 1 resides in sub-group P 2 , the system as a whole is very well corrected for chromatic aberrations, and is in fact apochromatic over a waveband extending from the deep violet end of the visible spectrum to about 1000 nm in the near infrared.
[0084] Sub-group P 3 comprises a single negative powered doublet 118 . Anomalous dispersion materials S-FPL51y and N-KZFS4 are used for the individual lens elements 108 and 109 , respectively, which aids in the correction of secondary spectrum. The outer shape of doublet 118 is meniscus toward the image plane. The concave surface SC is strongly curved and therefore helps a great deal in correcting field curvature and astigmatism.
[0085] Sub-group P 4 is a fairly weak positive group comprising a positive doublet 119 , a negative singlet 112 , and a positive singlet 113 . Sub-group P 4 serves mainly to correct distortion and astigmatism, and to make fine adjustments to the exit pupil location.
[0086] Element 114 is a plane parallel plate that serves to model the effect of the anti-aliasing filter, the IR/UV filter, and the sensor cover plate that are commonly found in digital cameras. Element 114 is not intended as a precise model for any particular brand or model of camera, but rather is intended as a viable means for avoiding any filter-induced aberrations. In Example 1, element 114 has been made fairly thick, and in all likelihood would be too thick to accurately model a camera filter pack. However, in this case the thickness of element 114 could be reduced so that when a real filter pack is introduced the aberration balance is not disturbed. This is particularly important in digital photography and cinematography with extremely well corrected high-speed lenses because the filter pack thickness is likely to vary from camera to camera, and it will be a great advantage to be able to customize the lens for an individual camera simply by changing a filter in the rear.
[0087] Focusing from a distant to a close object is accomplished by moving sub-group P 1 and group 120 independently away from the image plane as illustrated by FIG. 1 a. Element 113 is stationary with respect to the image plane. This complex focusing motion ensures that performance remains very high throughout the focusing range, and simultaneously ensures that breathing is almost zero. Breathing reaches a maximum value of only −0.09% at closest focus, which is almost undetectable. In Example 1, sub-group P 1 moves a relatively great distance during focusing because it is a relatively weak group. Although this results in a good aberration balance and loose tolerances it does also result in greater bulk as the lens is focused up close.
[0088] Soft focus correction is readily accomplished in Example 1 by a number of different methods, of which three are particularly useful. These three methods, which will be called Type 1 , Type 2 , and Type 3 , respectively, all involve axial motions of the third and fourth lens elements 103 and 105 . The advantage of these three methods is that the two elements involved are located near the aperture stop, so the induced aberration is almost all spherical aberration, and it is added almost uniformly throughout the image field.
[0089] In Type 1 , soft-focus element 103 is displaced axially. When the displacement is positive, meaning that element 103 moves toward the image plane, the spherical aberration correction is changed from its nominal well-corrected state to an over-corrected state. Over-corrected spherical aberration is effective in giving defocused foreground highlights a soft edge. When the displacement is negative, meaning that element 103 moves away from the image plane, the spherical aberration is changed from nominal to an under-corrected state. Under-corrected spherical aberration is effective in giving background highlights a soft edge. The top set of curves in FIG. 1 e shows the effect of moving element 103 by plus or minus 1 mm. An important feature of Type 1 soft-focus is that the change optical correction involves almost a pure change in spherical aberration with very little induced defocus.
[0090] In Type 2 soft-focus, element 105 is displaced axially. The induced spherical aberration is similar in magnitude but opposite in direction compared to Type 1 . In other words, when the displacement of element 105 is positive the spherical aberration is changed from nominal to an under-corrected state rather than to an over-corrected state. Another important difference between Type 1 and Type 2 soft-focus is that a substantial amount of defocus is also induced with Type 2 . The middle set of curves in FIG. 1 e shows the effect of moving element 105 by plus or minus 1 mm.
[0091] Type 3 soft-focus is a combination of Type 1 and Type 2 in which both element 103 and 105 are displaced axially. By taking advantage of the different defocus and spherical aberration inducing qualities of Type 1 and Type 2 , Type 3 is able to achieve a wide range of spherical aberration states together with a specific amount of defocus. In general, a modest amount of defocus is beneficial when adding spherical aberration to a lens system to achieve a soft focus effect. The bottom set of curves in FIG. 1 e shows the effect of moving element 103 by minus 0.5 mm and element 105 by plus 0.5 mm.
EXAMPLE 2
[0092] Example 2, which is a 65 mm focal length objective for 35 mm format cinematography, is illustrated in FIG. 2 a , which shows cross-sectional layouts at magnifications of 0 and −0.124×. All of the element and group designations mentioned below are shown in FIG. 1 a. The relative aperture is f/1.4, the image diagonal is 28 mm, and the diagonal field of view (FOV) is 24.3 degrees.
[0093] MTF vs. Image Height at 10, 20 and 40 cycles/mm for four different object distances is illustrated in FIG. 2 b . These curves indicate that Example 2 is extremely well corrected at f/1.4, with MTF values at 40 cycles/mm greater than 80% near the optical axis in the middle part of the focusing range and very near 80% at closest focus. This extraordinary performance falls off very gradually to the corner of the field, and the S and T curves stay close together. FIG. 2 c shows distortion and astigmatism (Coddington curves) for the same four object distances used in FIG. 2 b . Distortion is less than 1% at all magnifications, and astigmatism is also very well controlled. FIG. 2 d is a plot of relative illumination vs. image height at f/1.4 and f/2.8, and it indicates that the Example 2 design has extremely low illumination falloff for such a high-speed lens.
[0094] The primary group PG comprises the entire lens except for a plane parallel filter element 216 . As discussed above primary group PG comprises a negative powered front sub-group P 1 , followed by a positive powered sub-group P 2 , followed by a negative powered sub-group P 3 , followed by a sub-group P 4 that can be either positively or negatively powered.
[0095] In Example 2, sub-group P 1 comprises a single negative group: a negative doublet 218 . Doublet 218 uses high-index anomalous dispersion materials N-KZFS4 and S-NPH1 to advantage, and as a result aids in reducing secondary and tertiary chromatic aberrations. The surface of sub-group P 1 closest to the object is a concave surface.
[0096] Sub-group P 2 comprises three positive groups: a positive doublet 219 , a positive singlet 206 and a positive doublet 220 . The positive elements 204 , 206 and 208 are made of anomalous dispersion materials S-FPL53, S-FPL53 and S-PHM52, respectively. The single negative element 207 is made of a matching anomalous dispersion material N-KZFS4. Since most of the positive optical power for Example 2 resides in sub-group P 2 , the system as a whole is very well corrected for chromatic aberrations, and is in fact apochromatic over a waveband extending from the deep violet end of the visible spectrum to about 1000 nm in the near infrared. The convex object side surface of doublet 219 is aspherical in order to control spherical aberration.
[0097] Sub-group P 3 comprises a single negative powered doublet 221 . Anomalous dispersion materials S-PHM52 and N-KZFS4 are used for the individual lens elements 209 and 211 , respectively, which aids in the correction of secondary spectrum. The outer shape of doublet 221 is meniscus toward the image plane. The concave surface SC is strongly curved and therefore helps a great deal in correcting field curvature and astigmatism.
[0098] Sub-group P 4 is a positive group comprising two positive doublets 222 and 223 . Sub-group P 4 serves mainly to correct distortion and astigmatism, and to make fine adjustments to the exit pupil location.
[0099] Element 216 is a plane parallel plate that serves to model the effect of the anti-aliasing filter, the IR/UV filter, and the sensor cover plate that are commonly found in digital cameras. As with the corresponding element 114 in Example 1, element 216 is not intended as a precise model for any particular brand or model of camera, but rather is intended as a viable means for avoiding any filter-induced aberrations.
[0100] Moving groups P 1 , 224 and 223 independently away from the image plane as illustrated by FIG. 2 a accomplishes focusing from a distant to a close object. This complex focusing motion ensures that performance remains very high throughout the focusing range, and simultaneously ensures that breathing is almost zero. Breathing reaches a maximum value of only −0.01% in the middle portion of the focusing range. Compared with Example 1, sub-group P 1 moves a relatively small distance during focusing because it is a relatively weak group. This has advantages for packaging and handling.
EXAMPLE 3
[0101] Example 3, which is a 65 mm focal length objective for 35 mm format cinematography, is illustrated in FIG. 3 a , which shows cross-sectional layout. All of the element and group designations mentioned below are shown in FIG. 3 a . The relative aperture is f/1.4, the image diagonal is 28 mm, and the diagonal field of view (FOV) is 24.3 degrees.
[0102] MTF vs. Image Height at 10, 20 and 40 cycles/mm is illustrated in FIG. 3 b . These curves indicate that Example 3 is extremely well corrected at f/1.4, with MTF values at 40 cycles/mm well above 80% over the majority of the image circle. This extraordinary performance falls off very gradually to the corner of the field, and the S and T curves stay extremely close together. FIG. 3 c shows distortion and astigmatism (Coddington curves). Both Distortion and astigmatism are virtually zero, and there is just a trace of field curvature. FIG. 3 d is a plot of relative illumination vs. image height at f/1.4 and f/2.8, and it indicates that the Example 3 design has extremely low illumination falloff.
[0103] The primary group PG comprises the entire lens. As discussed above, PG comprises a negative powered front sub-group P 1 , followed by a positive powered sub-group P 2 , followed by a negative powered sub-group P 3 , followed by a sub-group P 4 that can be either positively or negatively powered.
[0104] In Example 3, sub-group P 1 comprises a single negative element 301 . The nearly plano image-facing surface of element 301 is aspherical, and 301 is made of S-BSL7 to ensure that manufacturing this aspherical surface will not be problematic. The surface of sub-group P 1 closest to the object is a concave surface.
[0105] Sub-group P 2 comprises two positive groups: a positive singlet 303 and a positive triplet 312 . The positive elements in groups 303 , 304 , and 306 , are made of anomalous dispersion S-FPL53, S-FPL53, and S-PHM52. The single negative element 305 is made of a matching anomalous dispersion material N-KZFS4. Since most of the positive optical power for Example 1 resides in sub-group P 2 , the system as a whole is very well corrected for chromatic aberrations, and is in fact apochromatic over a waveband extending from the deep violet end of the visible spectrum to about 1000 nm in the near infrared.
[0106] Sub-group P 3 comprises a positive powered singlet 307 and a negative powered singlet 308 to form an air spaced doublet. The combined power of elements 307 and 308 is negative. Ordinarily it would be advantageous to cement elements 307 and 308 together to loosen tolerances and improve transmission. However, the main purpose of Example 3 is to demonstrate that sub-group P 3 can comprise an air-spaced doublet instead of the cemented doublet used in other examples. Of course, it would also be possible to formulate sub-group P 3 as a cemented or air spaced triplet or quadruplet or even singlet without departing from the spirit of the present invention. Anomalous dispersion materials S-PHM52 and N-KZFS4 are used for the individual lens elements 307 and 308 , respectively, which aids in the correction of secondary spectrum. The outer shape of air-spaced doublet P 3 is meniscus toward the image plane. The concave surface SC is strongly curved and therefore helps a great deal in correcting field curvature and astigmatism.
[0107] Sub-group P 4 is a fairly weak positive group comprising a positive doublet 313 . Sub-group P 4 serves mainly to correct distortion and astigmatism, and to make fine adjustments to the exit pupil location.
EXAMPLE 4
[0108] Example 4 is similar in form to Example 2, but is scaled and optimized for a longer 125 mm focal length. Chromatic aberration correction is also improved, and is now superachromatic in the visible to near infrared range. Example 4 is illustrated in FIG. 4 a , which shows cross-sectional layouts at magnifications of 0 and −0.094×. All of the element and group designations mentioned below are shown in FIG. 4 a . The relative aperture is f/1.33, the image diagonal is 28 mm, and the diagonal field of view (FOV) is 12.8 degrees.
[0109] MTF vs. Image Height at 10, 20 and 40 cycles/mm for four different object distances is illustrated in FIG. 4 b . These curves indicate that Example 4 is extremely well corrected at f/1.33, with MTF values at 40 cycles/mm greater than 80% near the optical axis except at the closest object distance. At the optimum object distance of about 3 to 4 meters the on-axis MTF at 40 cycles/mm exceeds 90% on-axis. This extraordinary performance falls off very gradually to the corner of the field, and the S and T curves stay reasonably close together. FIG. 4 c shows distortion and astigmatism (Coddington curves) for the same four object distances used in FIG. 4 b . Distortion is virtually zero at all magnifications, and astigmatism is also very well controlled. FIG. 4 d is a plot of relative illumination vs. image height at f/1.33 and f/2.8, and it indicates that the Example 4 design has extremely low illumination falloff even at the widest aperture of f/1.33.
[0110] The primary group PG comprises the entire lens. As discussed above primary group PG comprises a negative powered front sub-group P 1 , followed by a positive powered sub-group P 2 , followed by a negative powered sub-group P 3 , followed by a sub-group P 4 that can be either positively or negatively powered.
[0111] In Example 4, sub-group P 1 comprises a single negative doublet 415 . This doublet uses high-index anomalous dispersion materials N-KZFS4 and S-NPH1 to advantage, and as a result aids in reducing secondary and tertiary chromatic aberrations. The surface of sub-group P 1 closest to the object is a concave surface.
[0112] Sub-group P 2 comprises three positive groups: a positive doublet 416 , a positive singlet 405 and a positive doublet 417 . The positive elements 404 , 405 and 407 are made of S-FPL53, CaF2, and S-FPL53, respectively. The single negative element 406 is made of a matching anomalous dispersion material N-KZFS4. Since most of the positive optical power for Example 4 resides in sub-group P 2 , the system as a whole is very well corrected for chromatic aberrations, and is in fact superachromatic over a waveband extending from the near ultraviolet to the near infrared.
[0113] Sub-group P 3 comprises a single negative powered doublet 418 . Anomalous dispersion materials S-PHM52 and N-KZFS4 are used for the individual lens elements 409 and 410 , respectively, which aids in the correction of secondary spectrum. The outer shape of doublet 418 is meniscus toward the image plane. The concave surface SC is strongly curved and therefore helps a great deal in correcting field curvature and astigmatism.
[0114] Sub-group P 4 is a fairly weak positive group comprising positive doublets 419 and 420 . Sub-group P 4 serves mainly to correct distortion and astigmatism, and to make fine adjustments to the exit pupil location.
[0115] Moving groups P 1 , 421 , and 420 independently away from the image plane as illustrated by FIG. 4 a accomplishes focusing from a distant to a close object. This complex focusing motion ensures that performance remains very high throughout the focusing range, and simultaneously ensures that breathing is almost zero. Breathing reaches a maximum value of only −0.78% at closest focus, which is very low for a longer focal length lens.
EXAMPLE 5
[0116] Example 5, which is a 14.5 mm focal length ultra wide-angle objective for 35 mm format cinematography, is illustrated in FIG. 5 a , which shows cross-sectional layouts at magnifications of 0 and −0.033×. All of the element and group designations mentioned below are shown in FIG. 5 a . The relative aperture is f/1.4, the image diagonal is 28 mm, and the diagonal field of view (FOV) is 89.12 degrees. Since this objective has a small amount of barrel distortion, it provides a somewhat larger field of view than its paraxial focal length of 14.5 mm would suggest. In this case the effective corrected focal length is equal to the image height of 14 mm divided by the tangent of the half angle of view (HFOV):
[0000] FC=IH /tan( HFOV )=14/tan(44.56)=14.2 mm
[0117] MTF vs. Image Height at 10, 20 and 40 cycles/mm for four different object distances is illustrated in FIG. 5 b . These curves indicate that Example 5 is well corrected at f/1.4, especially for such an extremely wide-angle objective. Performance falls off gradually to the corner of the field, and the S and T curves stay close together. FIG. 5 c shows distortion and astigmatism (Coddington curves) for the same two object distances used in FIG. 5 b . Distortion is very low for an ultra-wide angle lens, and astigmatism is also very well controlled. The shape of the distortion curve indicates that under corrected (barrel) third order distortion is partially balanced by overcorrected fifth order distortion. This provides excellent straight-line rendition that is significantly better than a pure under corrected distortion of the same magnitude would provide. FIG. 5 d is a plot of relative illumination vs. image height at f/1.4 and f/2.8, and it indicates that the Example 5 design has low illumination falloff for a fast wide-angle lens.
[0118] The primary group PG comprises only the rear sub-group of Example 5. The front sub-group of the lens, comprising groups 528 and 529 , functions approximately as a wide-angle afocal attachment that outputs nearly collimated light into primary group PG. Group 528 has negative power and includes an asphere on the outermost object-side surface. Group 529 has positive power to roughly collimate the light output from group 528 . However, groups 528 and 529 together are not precisely afocal, and as a result the object magnification of primary group PG is −0.049×. As discussed above, primary PG comprises a negative powered front sub-group P 1 , followed by a positive powered sub-group P 2 , followed by a negative powered sub-group P 3 , followed by a sub-group P 4 that can be either positively or negatively powered.
[0119] In Example 5, sub-group P 1 comprises a single negative element 507 . The concave image-facing surface of element 507 is aspherical, and 507 is made of S-NSL3 to ensure that manufacturing this aspherical surface will not be problematic. The surface of sub-group P 1 closest to the object is a convex surface.
[0120] Sub-group P 2 comprises three positive groups: a positive doublet 523 , a positive triplet 524 , and a positive doublet 525 . The positive elements 510 , 511 , and 513 are all made of low-index anomalous dispersion material S-FPL53, and positive element 515 is made of anomalous dispersion material S-PHM52. The negative elements 509 , 512 , and 514 are all made of a matching anomalous dispersion material N-KZFS4. Since most of the positive optical power for Example 5 resides in sub-group P 2 , the system as a whole is very well corrected for chromatic aberrations, and is in fact apochromatic over a waveband extending from the deep violet end of the visible spectrum to the near infrared.
[0121] Sub-group P 3 comprises a single negative powered doublet 526 . Anomalous dispersion materials S-PHM52 and N-KZFS4 are used for the individual lens elements 516 and 517 , respectively, which aids in the correction of secondary spectrum. The outer shape of doublet 526 is meniscus toward the image plane. The concave surface SC is strongly curved and therefore helps a great deal in correcting field curvature and astigmatism.
[0122] Sub-group P 4 is a fairly weak positive group comprising a weak negative powered doublet 527 and a very weak positive powered meniscus singlet 520 . Sub-group P 4 serves mainly to correct distortion and astigmatism, and to make fine adjustments to the exit pupil location. The object-side surface of doublet 527 is aspherical in order to control higher order astigmatism.
[0123] Focusing from a distant to a close object is accomplished by moving groups 528 and 529 independently away from the image plane as illustrated by FIG. 5 a . Primary group PG remains stationary with respect to the image plane, which substantially simplifies the mechanical design. This focusing motion ensures that performance remains very high throughout the focusing range, and simultaneously ensures that breathing is almost zero. Breathing reaches a maximum value of only −0.14% at closest focus, which is almost undetectable.
[0124] Because Example 5 has an extremely wide field of view any filter used in the conventional location on the object side of the front element would necessarily be very large. As an alternative, the filter can be placed inside the optical system closer to the aperture stop so that its size is reduced. Example 5 includes just such a filter: element 506 , which is located just in front of primary group PG. This location is particularly advantageous in this case because it is a nearly collimated air space. This means that the tolerances on the thickness of the filter can be very loose if desired. The filter can be placed on a turret along with a wide range of other filters.
EXAMPLE 6
[0125] Example 6, which is a 24 mm focal length wide-angle objective for 35 mm format cinematography, is illustrated in FIG. 6 a , which shows cross-sectional layouts at magnifications of 0 and −0.05×. All of the element and group designations mentioned below are shown in FIG. 6 a . The relative aperture is f/1.4, the image diagonal is 28 mm, and the diagonal field of view (FOV) is 60.5 degrees.
[0126] MTF vs. Image Height at 10, 20 and 40 cycles/mm for four different object distances is illustrated in FIG. 1 b . These curves indicate that Example 6 is well corrected at f/1.4, with MTF values at 40 cycles/mm approaching 80% near the optical axis for longer object distances. This excellent performance falls off gradually to the corner of the field, and the S and T curves stay close together. FIG. 6 c shows distortion and astigmatism (Coddington curves) for the same two object distances used in FIG. 6 b . Distortion is very low at all magnifications, and astigmatism is also very well controlled. FIG. 6 d is a plot of relative illumination vs. image height at f/1.4 and f/2.8, and it indicates that the Example 6 design has very low illumination falloff.
[0127] The primary group PG comprises only the rear portion of Example 6. The front portion of the lens, comprising elements 601 , 602 , 603 , and 604 , functions approximately as a wide-angle afocal attachment that outputs nearly collimated light into primary group PG. Elements 601 and 602 both have negative power, and element 601 includes as asphere on its object side surface to correct distortion. Elements 603 and 604 both have positive power, and combine to roughly collimate the light output from group elements 601 and 602 . However, the collimation is not perfect, and as a result the object magnification of PG is +0.088×. As discussed above, primary group PG comprises a negative powered front sub-group P 1 , followed by a positive powered sub-group P 2 , followed by a negative powered sub-group P 3 , followed by a sub-group P 4 that can be either positively or negatively powered.
[0128] In Example 6, sub-group P 1 comprises a single negative element 605 with a concave object-facing surface.
[0129] Sub-group P 2 comprises three positive groups: a positive doublet 622 , a positive triplet 623 , and a positive doublet 624 . The positive elements 608 , 609 , 611 and 613 are made of anomalous dispersion materials S-FPL53, S-FPL53, S-FPL51, and S-PHM52, respectively. The negative elements 610 and 612 are both made of a matching anomalous dispersion material N-KZFS4. Since most of the positive optical power for Example 6 resides in sub-group P 2 , the system as a whole is very well corrected for chromatic aberrations, and is in fact apochromatic over a waveband extending from the deep violet end of the visible spectrum to the near infrared.
[0130] Sub-group P 3 comprises a single negative powered doublet 625 . Anomalous dispersion materials S-PHM52 and N-KZFS4 are used for the individual lens elements 614 and 615 , respectively, which aids in the correction of secondary spectrum. The outer shape of doublet 625 is meniscus toward the image plane. The concave surface SC is strongly curved and therefore helps a great deal in correcting field curvature and astigmatism.
[0131] Sub-group P 4 is a fairly weak positive group comprising a positive triplet 626 and a negative doublet 627 . Sub-group P 4 serves mainly to correct distortion and astigmatism, and to make fine adjustments to the exit pupil location.
[0132] Focusing from a distant to a close object is accomplished by moving groups 628 and 629 independently toward and away from the image plane as illustrated by FIG. 6 a . Element 601 is stationary with respect to the image plane, which means that the vertex length of the system as a whole remains constant during focusing. This focusing motion ensures that performance remains very high throughout the focusing range, and simultaneously ensures that breathing is well corrected. Breathing reaches a maximum value of 2.01% at closest focus.
EXAMPLE 7
[0133] Example 7, which is a 35 mm focal length objective for 35 mm format cinematography, is illustrated in FIG. 7 a , which shows cross-sectional layouts at magnifications of 0 and −0.065×. All of the element and group designations mentioned below are shown in FIG. 7 a . The relative aperture is f/1.4, the image diagonal is 28 mm, and the diagonal field of view (FOV) is 44.5 degrees.
[0134] MTF vs. Image Height at 10, 20 and 40 cycles/mm for four different object distances is illustrated in FIG. 7 b . These curves indicate that Example 7 is extremely well corrected at f/1.4, with MTF values at 40 cycles/mm greater than 80% near the optical axis for all object distances. This extraordinary performance falls off very gradually to the corner of the field. FIG. 7 c shows distortion and astigmatism (Coddington curves) for the same two object distances used in FIG. 1 b . Both distortion and astigmatism are well controlled. FIG. 7 d is a plot of relative illumination vs. image height at f/1.4 and f/2.8, and it indicates that the Example 7 design has low illumination falloff.
[0135] The primary group PG comprises only the rear sub-group of Example 7. The front sub-group of the lens, comprising elements 701 and 702 , functions roughly as a wide-angle afocal attachment for primary group PG. Elements 701 and 702 have negative and positive power, respectively, and element 701 includes as asphere on its convex object side surface to correct distortion. The object magnification of PG is −0.364× when the lens is focused on a distant object. As discussed above, primary group PG comprises a negative powered front sub-group P 1 , followed by a positive powered sub-group P 2 , followed by a negative powered sub-group P 3 , followed by a sub-group P 4 that can be either positively or negatively powered.
[0136] In Example 7, sub-group P 1 comprises a single negative element 703 with a concave object-facing surface. The convex image-facing surface of 703 is aspheric in order correct spherical aberration. Element 703 is made of S-BSL7 to enhance manufacturability.
[0137] Sub-group P 2 comprises five positive groups: two positive singlets 705 and 706 , followed by a positive doublet 717 , followed by two more positive singlets 709 and 710 . Elements 705 , 706 , 707 , and 710 are all made from low-index anomalous dispersion material S-FPL51, and element 709 is made from low-index anomalous dispersion material S-FPL53. The single negative element 708 is made of a matching anomalous dispersion material N-KZFS4. Since most of the positive optical power for Example 7 resides in sub-group P 2 , the system as a whole is very well corrected for chromatic aberrations, and is in fact apochromatic over a waveband extending from the deep violet end of the visible spectrum to the near infrared.
[0138] Sub-group P 3 comprises a single negative powered doublet 718 . Anomalous dispersion materials S-PHM52 and N-KZFS4 are used for the individual lens elements 711 and 712 , respectively, which aids in the correction of secondary spectrum. The outer shape of doublet 718 is meniscus toward the image plane. The concave surface SC is strongly curved and therefore helps a great deal in correcting field curvature and astigmatism.
[0139] Sub-group P 4 is a fairly weak positive group comprising a positive doublet 719 , a negative meniscus singlet 715 . P 4 serves mainly to correct distortion and astigmatism, and to make fine adjustments to the exit pupil location.
[0140] Focusing from a distant to a close object is accomplished by moving groups 701 , 702 and PG independently away from the image plane as illustrated by FIG. 7 a . This complex focusing motion ensures that performance remains very high throughout the focusing range, and simultaneously ensures that breathing is almost zero. Breathing reaches a maximum value of only −0.03% at closest focus, which is almost undetectable.
EXAMPLE 8
[0141] Example 8, which is a 65 mm focal length objective for 35 mm format cinematography, is illustrated in FIG. 8 a , which shows cross-sectional layouts at magnifications of 0 and −0.137×. All of the element and group designations mentioned below are shown in FIG. 8 a . The relative aperture is f/1.33, the image diagonal is 28 mm, and the diagonal field of view (FOV) is 24.3 degrees.
[0142] Example 8 is very similar to Example 1, with a key difference that it has been made athermal by the use of acrylic polymer for element 803 . One of the reasons for the very high optical performance of all of the examples in the present invention is that they are either apochromatic or superachromatic. This is brought about by extensive use of anomalous dispersion materials such as CaF2, S-FPL53, S-FPL51, and S-PHM52. Unfortunately, all of these materials have a high thermal expansion coefficient coupled with a large negative value for dn/dt. As a result, the focal plane will drift significantly with temperature. Although this focus drift can be dealt with by various active and passive mechanical means, it is most desirable to eliminate it by passive optical means.
[0143] Since most of the thermal drift mentioned above is caused by positive lens elements made of materials with a negative dn/dt, it follows that the thermal drift can be corrected by introducing one or more negative elements with an even larger negative value for dn/dt. Fortunately, such materials do exist in the form of optically transparent polymers such as acrylic. In the case of acrylic, its change of refractive index with temperature (dn/dt) is about an order of magnitude greater than that of the anomalous dispersion glasses listed above, so all that is necessary is to incorporate a relatively weak negative powered acrylic element. In Example 1 the third element has weak negative power and is made from S-BSL7, which has a roughly similar refractive index to acrylic. So, for Example 8, this third element was replaced by a similar element made from acrylic, and optimized for athermal performance over a broad temperature range. FIG. 8 c is a plot of MTF vs. Image Height at a spatial frequency of 20 cycles/mm for three different temperatures of 0 C, 20 C, and 40 C. No re-focusing is done for the different temperatures, and the mounting material is assumed to be aluminum. FIG. 8 c clearly shows that Example 8 is athermal in the sense that it maintains excellent optical performance at a large aperture over a wide temperature range without re-focusing.
[0144] MTF vs. Image Height at 10, 20 and 40 cycles/mm for four different object distances is illustrated in FIG. 8 b . These curves indicate that Example 8 is extremely well corrected at f/1.33, with MTF values at 40 cycles/mm greater than 80% near the optical axis except at closest focus. This excellent performance falls off very gradually to the corner of the field, and the S and T curves stay close together. FIG. 8 d shows distortion and astigmatism (Coddington curves) for the same four object distances used in FIG. 8 b . Distortion is virtually zero at all magnifications, and astigmatism is also very well controlled. FIG. 8 e is a plot of relative illumination vs. image height at f/1.33 and f/2.8, and it indicates that the Example 8 design has extremely low illumination falloff.
[0145] The primary group, PG comprises the entire lens except for a plane parallel filter element 814 . As discussed above, primary group PG comprises a negative powered front sub-group P 1 , followed by a positive powered sub-group P 2 , followed by a negative powered sub-group P 3 , followed by a sub-group P 4 that can be either positively or negatively powered.
[0146] In Example 8, sub-group P 1 comprises two negative groups: a negative doublet 816 and a negative singlet 803 . The convex object-facing surface of element 803 is aspherical, and 803 is made of acrylic polymer to achieve athermalization and to ensure straightforward manufacturing. Acrylic optical elements can be made either by direct diamond machining or by molding. The doublet 816 uses high-index anomalous dispersion materials N-KZFS4 and S-NPH1 to advantage, and as a result aids in reducing secondary and tertiary chromatic aberrations. The surface of P 1 closest to the object is a concave surface.
[0147] Sub-group P 2 comprises two positive groups: a positive singlet 805 and a positive doublet 817 . The positive elements in groups P 2 , 805 and 807 are both made of low-index anomalous dispersion material S-FPL51. The single negative element 806 is made of a matching anomalous dispersion material N-KZFS4. Since most of the positive optical power for Example 8 resides in sub-group P 2 , the system as a whole is very well corrected for chromatic aberrations, and is in fact apochromatic over a waveband extending from the deep violet end of the visible spectrum to about 1000 nm in the near infrared.
[0148] Sub-group P 3 comprises a single negative powered doublet 818 . Anomalous dispersion materials S-FPL51y and N-KZFS4 are used for the individual lens elements 808 and 809 , respectively, which aids in the correction of secondary spectrum. The outer shape of doublet 818 is meniscus toward the image plane. The concave surface SC is strongly curved and therefore helps a great deal in correcting field curvature and astigmatism.
[0149] Sub-group P 4 is a fairly weak positive group comprising a positive doublet 819 , a negative singlet 812 , and a positive singlet 813 . Sub-group P 4 serves mainly to correct distortion and astigmatism, and to make fine adjustments to the exit pupil location.
[0150] Element 814 is a plane parallel plate that serves to model the effect of the anti-aliasing filter, the IR/UV filter, and the sensor cover plate that are commonly found in digital cameras. As in the analogous Element 114 in Example 1, Element 814 is not intended as a precise model for any particular brand or model of camera, but rather is intended as a viable means for avoiding any filter-induced aberrations. In Example 8, element 814 has been made fairly thick, and in all likelihood would be too thick to accurately model a camera filter pack. However, in this case the thickness of element 814 could be reduced so that when a real filter pack is introduced the aberration balance is not disturbed. This is particularly important in digital photography and cinematography with extremely well corrected high-speed lenses because the filter pack thickness is likely to vary from camera to camera, and it will be a great advantage to be able to customize the lens for an individual camera simply by changing a filter in the rear.
[0151] Focusing from a distant to a close object is accomplished by independently moving groups P 1 and 820 away from the image plane, as illustrated by FIG. 8 a . Element 813 is stationary with respect to the image plane. This complex focusing motion ensures that performance remains very high throughout the focusing range, and simultaneously ensures that breathing is almost zero. Breathing reaches a maximum value of only 0.14% in the middle of the focusing range, which is almost undetectable. In Example 8, sub-group P 1 moves a relatively great distance during focusing because it is a relatively weak group. Although this results in a good aberration balance and loose tolerances it does also result in greater bulk as the lens is focused up close.
EXAMPLE 9
[0152] Example 9, which is a 35 mm focal length objective for 35 mm format cinematography, is illustrated in FIG. 9 a , which shows cross-sectional layouts at magnifications of 0 and −0.037×. All of the element and group designations mentioned below are shown in FIG. 9 a . The relative aperture is f/1.4, the image diagonal is 28 mm, and the diagonal field of view (FOV) is 43.6 degrees.
[0153] MTF vs. Image Height at 10, 20 and 40 cycles/mm for four different object distances is illustrated in FIG. 9 b . These curves indicate that Example 9 is extremely well corrected at f/1.4, with MTF at 20 cycles/mm exceeding 90% over nearly the entire field of view and MTF at 40 cycles/mm exceeding 80% over a large central portion of the field of view. Performance falls off very gradually from the center to the corner of the field, and the S and T curves stay close together. FIG. 9 c shows distortion and astigmatism (Coddington curves) for the same two object distances used in FIG. 9 b . Both distortion and astigmatism are very well corrected. FIG. 9 d is a plot of relative illumination vs. image height at f/1.4 and f/2.8, and it indicates that the Example 9 design has low illumination falloff.
[0154] The primary group PG comprises only the rear sub-group of Example 5. The front sub-group of the lens, comprising groups 901 and 916 , functions approximately as a wide-angle afocal attachment in front of primary group PG. Group 901 has negative power and includes an asphere on the outermost object-side surface. Group 916 has positive power to roughly collimate the light output from group 901 . However, groups 901 and 916 together are not precisely afocal, and as a result the object magnification of primary group PG is −0.288×. As discussed above, primary PG comprises a negative powered front sub-group P 1 , followed by a positive powered sub-group P 2 , followed by a negative powered sub-group P 3 , followed by a sub-group P 4 that can be either positively or negatively powered.
[0155] In Example 9, sub-group P 1 comprises a single negative element 904 . The convex image-facing surface of element 904 is aspherical, and 904 is made of S-BSL7 to ensure that manufacturing this aspherical surface will not be problematic. The surface of sub-group P 1 closest to the object is a concave surface.
[0156] Sub-group P 2 comprises five positive groups: two positive singlets 906 and 907 , a positive doublet 917 , and two positive singlets 910 and 911 . The positive elements 906 , 907 , 908 , 910 , and 911 are all made of low-index anomalous dispersion material S-FPL53, and the negative element 909 is made of a matching anomalous dispersion material N-KZFS4. Since most of the positive optical power for Example 5 resides in sub-group P 2 , the system as a whole is very well corrected for chromatic aberrations, and is in fact apochromatic over a waveband extending from the deep violet end of the visible spectrum to the near infrared.
[0157] Sub-group P 3 comprises a negative powered singlet 912 made of anomalous dispersion material N-KZFS4, which aids in the correction of secondary spectrum. Element 912 is meniscus toward the image plane. The concave surface SC is strongly curved and therefore helps a great deal in correcting field curvature and astigmatism.
[0158] Sub-group P 4 is a fairly weak positive group comprising a positive powered singlet 913 and a negative powered singlet 914 . Sub-group P 4 serves mainly to correct distortion and astigmatism, and to make fine adjustments to the exit pupil location.
[0159] Focusing from a distant to a close object is accomplished by moving groups 901 , 916 , and PG independently away from the image plane as illustrated by FIG. 9 a . This complex focusing motion ensures that performance remains very high throughout the focusing range, and simultaneously ensures that breathing is almost zero. Breathing reaches a maximum value of only −0.23% at closest focus, which is almost undetectable.
EXAMPLE 10
[0160] Example 10, which is a 24 mm focal length wide-angle objective for 35 mm format cinematography, is illustrated in FIG. 10 a , which shows cross-sectional layouts at magnifications of 0 and −0.056×. All of the element and group designations mentioned below are shown in FIG. 10 a. The relative aperture is f/1.4, the image diagonal is 28 mm, and the diagonal field of view (FOV) is 60.5 degrees.
[0161] MTF vs. Image Height at 10, 20 and 40 cycles/mm for four different object distances is illustrated in FIG. 10 b . These curves indicate that Example 10 is extremely well corrected at f/1.4, especially for a wide-angle objective. The MTF at 20 cycles exceeds 90% over nearly the entire field of view, and the MTF at 40 cycles/mm is approximately 80% over a large central region of the field of view. Performance falls off gradually to the corner of the field, and the S and T curves stay close together. FIG. 10 c shows distortion and astigmatism (Coddington curves) for the same two object distances used in FIG. 10 b. Distortion is very low for a wide-angle lens, and astigmatism is also very well controlled. FIG. 10 d is a plot of relative illumination vs. image height at f/1.4 and f/2.8, and it indicates that the Example 10 design has low illumination falloff.
[0162] The primary group PG comprises only the rear sub-group of Example 10. The front sub-group of the lens, comprising groups 1001 , 1002 , and 1003 , functions approximately as a wide-angle afocal attachment that outputs quasi-collimated light into primary group PG. Groups 1001 and 1002 have a combined negative power and include an asphere on the outermost object-side surface. Group 1003 has positive power to roughly collimate the light output from groups 1001 and 1002 . However, groups 1001 and 1002 together are not precisely afocal, and as a result the object magnification of primary group PG is −0.210×. As discussed above, primary PG comprises a negative powered front sub-group P 1 , followed by a positive powered sub-group P 2 , followed by a negative powered sub-group P 3 , followed by a sub-group P 4 that can be either positively or negatively powered.
[0163] In Example 10, sub-group P 1 comprises a single negative element 1004 . The convex image-facing surface of element 1004 is aspherical, and 1004 is made of S-BSL7 to ensure that manufacturing this aspherical surface will not be problematic. The surface of sub-group P 1 closest to the object is a concave surface.
[0164] Sub-group P 2 comprises five positive groups: two positive singlets 1006 and 1007 , a positive doublet 1017 , and two positive singlets 1010 and 1011 . The positive elements 1006 , 1007 , 1009 , 1010 , and 1011 are all made of low-index anomalous dispersion material CaF2, also called Calcium Fluoride, and the negative element 1008 is made of a matching material S-BAL42.
[0165] Since most of the positive optical power for Example 5 resides in sub-group P 2 , the system as a whole is very well corrected for chromatic aberrations, and is in fact apochromatic over a waveband extending from the deep violet end of the visible spectrum to the near infrared.
[0166] Sub-group P 3 comprises a single negative powered singlet 1012 made of anomalous dispersion material N-KZFS4, which aids in the correction of secondary spectrum. The concave surface SC facing the image plane is strongly curved and therefore helps a great deal in correcting field curvature and astigmatism.
[0167] Sub-group P 4 is a weak negative group comprising a positive powered singlet 1013 and a negative powered singlet 1014 . Sub-group P 4 serves mainly to correct distortion and astigmatism, and to make fine adjustments to the exit pupil location.
[0168] Focusing from a distant to a close object is accomplished by moving groups 1016 and PG independently toward and away from the image plane, respectively, as illustrated by FIG. 10 a . The front group 1001 remains stationary with respect to the image plane. This focusing motion ensures that performance remains very high throughout the focusing range, and simultaneously ensures that breathing is well-corrected. Breathing reaches a maximum value of −2.42% at closest focus.
EXAMPLE 11
[0169] Example 11, which is a 14.4 mm focal length ultra wide-angle objective for 35 mm format cinematography, is illustrated in FIG. 11 a, which shows cross-sectional layouts at magnifications of 0 and −0.037×. All of the element and group designations mentioned below are shown in FIG. 11 a. The relative aperture is f/1.4, the image diagonal is 28 mm, and the diagonal field of view (FOV) is 91.3 degrees. Since this objective has a small amount of barrel distortion, it provides a somewhat larger field of view than its paraxial focal length of 14.4 mm would suggest. In this case the effective corrected focal length is equal to the image height of 14 mm divided by the tangent of the half angle of view (HFOV):
[0000] FC=IH /tan( HFOV )=14/tan(45.63)=13.7 mm
[0170] MTF vs. Image Height at 10, 20 and 40 cycles/mm for four different object distances is illustrated in FIG. 11 b. These curves indicate that Example 11 is extremely well corrected at f/1.4, especially for such an extremely wide-angle objective. Performance falls off gradually to the corner of the field, and the S and T curves stay close together. FIG. 11 c shows distortion and astigmatism (Coddington curves) for the same two object distances used in FIG. 11 b. Distortion is reasonably well corrected for an ultra-wide angle lens, and astigmatism is also very well controlled. FIG. 11 d is a plot of relative illumination vs. image height at f/1.4 and f/2.8, and it indicates that the Example 11 design has extremely low illumination falloff for a fast wide-angle lens.
[0171] The primary group PG comprises only the rear sub-group of Example 11. The front sub-group of the lens, comprising groups 1125 , 1122 and 1126 , functions approximately as a wide-angle afocal attachment in front of the primary group PG. Group 1125 has negative power and includes an asphere on the outermost object-side surface. Groups 1122 and 1126 have a combined positive power to roughly collimate the light output from group 1125 . However, groups 1125 , 1122 and 1126 together are not precisely afocal, and as a result the object magnification of primary group PG is −0.175×. As discussed above, primary PG comprises a negative powered front sub-group P 1 , followed by a positive powered sub-group P 2 , followed by a negative powered sub-group P 3 , followed by a sub-group P 4 that can be either positively or negatively powered.
[0172] In Example 11, sub-group P 1 comprises a single negative element 1110 . The convex image-facing surface of element 1110 is aspherical, and 1110 is made of S-BSL7 to ensure that manufacturing this aspherical surface will not be problematic. The surface of sub-group P 1 closest to the object is a concave surface.
[0173] Sub-group P 2 comprises five positive groups: two positive singlets 1112 and 1113 , a positive doublet 1124 , and two positive singlets 1116 and 1117 . The positive elements 1112 , 1113 , 1114 , 1116 , and 1117 are all made of low-index anomalous dispersion material S-FPL53, and the negative element 1115 is made of a matching anomalous dispersion material N-KZFS4. Since most of the positive optical power for Example 5 resides in sub-group P 2 , the system as a whole is very well corrected for chromatic aberrations, and is in fact apochromatic over a waveband extending from the deep violet end of the visible spectrum to the near infrared.
[0174] Sub-group P 3 comprises a single negative powered singlet 1118 made of anomalous dispersion material N-KZFS4, which aids in the correction of secondary spectrum. Element 1118 is meniscus toward the image plane. The concave surface SC is strongly curved and therefore helps a great deal in correcting field curvature and astigmatism.
[0175] Sub-group P 4 is a fairly weak positive group comprising a positive powered singlet 1119 and a negative powered singlet 1120 . Sub-group P 4 serves mainly to correct distortion and astigmatism, and to make fine adjustments to the exit pupil location.
[0176] Focusing from a distant to a close object is accomplished by moving groups 1122 and 1126 independently toward the image plane as illustrated by FIG. 11 a. Primary group PG and group 1125 remain stationary with respect to the image plane during focusing, which substantially simplifies the mechanical design. This focusing motion ensures that performance remains very high throughout the focusing range, and simultaneously ensures that breathing is almost zero. Breathing reaches a maximum value of only +0.16% at closest focus, which is almost undetectable.
[0177] 1109 is a vignetting stop that restricts the lower rim rays in order to control both aberrations and illumination.
EXAMPLE 12
[0178] Example 12, which is a 200 mm focal length objective optimized for aerial reconnaissance, is illustrated in FIG. 12 a , which shows a cross-sectional layout. All of the element and group designations mentioned below are shown in FIG. 12 a . The relative aperture is f/1.4, the image diagonal is 28 mm, and the diagonal field of view (FOV) is 8.0 degrees. Example 12 is corrected over a waveband ranging from about 435 nm to 1000 nm, which is an especially useful waveband for reconnaissance and night-vision applications.
[0179] MTF vs. Image Height at 50, 100 and 200 cycles/mm for an object at infinity is illustrated in FIG. 12 b . These curves indicate that Example 12 is extraordinarily well corrected at f/1.4, with MTF values at 100 cycles/mm greater than 80% over the entire image field. Example 12 does in fact meet the Rayleigh criterion for diffraction-limited performance at f/1.4 over most of the image field. FIG. 1 c shows distortion and astigmatism (Coddington curves) for an object at infinity. Both distortion and astigmatism are nearly zero. FIG. 12 d is a plot of relative illumination vs. image height at f/1.4, and it indicates that the Example 12 design has extremely low illumination falloff for such a high-speed lens.
[0180] The primary group PG comprises the entire lens. As discussed above, primary group PG comprises a negative powered front sub-group P 1 , followed by a positive powered sub-group P 2 , followed by a negative powered sub-group P 3 , followed by sub-group P 4 that can be either positively or negatively powered.
[0181] In Example 12, sub-group P 1 comprises a negative doublet 1215 . This doublet uses high-index anomalous dispersion materials N-KZFS4 and S-NPH1 to advantage, and as a result aids in reducing secondary chromatic aberrations. The surface of sub-group P 1 closest to the object is a concave surface.
[0182] Sub-group P 2 comprises six single-element lens groups: positive singlets 1203 , 1204 , 1205 , 1208 , and 1209 ; and negative singlet 1206 . The convex object-facing surface of element 1203 is aspherical, and singlet 1203 is made of S-BSL7 to ensure that manufacturing this aspherical surface will not be problematic. The positive elements in sub-group P 2 are elements 1203 , 1204 , 1205 , 1208 , and 1209 . All of these except 1203 are made of low-index anomalous dispersion materials. The single negative element 1206 is made of a matching anomalous dispersion material N-KZFS4. Since most of the positive optical power for Example 12 resides in sub-group P 2 , the system as a whole is very well corrected for chromatic aberrations, and is in fact superachromatic (i.e., with four color crossings) over a waveband extending from 435 nm to 1000 nm.
[0183] Sub-group P 3 comprises a single negative powered doublet 1216 . Anomalous dispersion materials S-PHM52 and N-KZFS4 are used for the individual lens elements 1210 and 1211 , respectively, which aids in the correction of secondary spectrum. The outer shape of doublet 1216 is meniscus toward the image plane. The concave surface SC is strongly curved and therefore helps a great deal in correcting field curvature and astigmatism.
[0184] Sub-group P 4 is a fairly weak positive group comprising a positive doublet 1217 . Sub-group P 4 serves mainly to correct distortion and astigmatism.
[0185] Since Example 12 is intended for aerial reconnaissance applications, it has been optimized for an object located at infinity. However, small focus adjustments can be made by moving the entire lens without significantly degrading the lens performance.
[0186] Optical Prescription Data
[0187] Tables 1a, 2a, 3a, 4a, 5a, 6a, 7a, 8a, 9a, 10a, 11a and 12a below provide optical prescription data for Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 and 12, respectively. The data provided includes surface number, radius of curvature, thickness, glass type, and the diameter of the clear aperture. OBJ refers to the object surface, IMA refers to the image surface, and STO refers to the aperture stop surface. Tables 1b, 2b, 4b, 5b, 6b, 7b, 8b, 9b, 10b, and 11b provide focusing data for Examples 1, 2, 4, 5, 6, 7, 8, 9, 10, and 11, respectively. In these Tables, OBMG refers to object magnification, and OBIM refers to the total distance from the object plane to the image plane.
[0188] Aspherical surfaces are expressed by the following equation:
[0000] Z ( r )= r 2 /( R (1 +SQRT (1−(1 +k ) r 2 /R 2 )))+ C 4 r 4 +C 6 r 6 +C 8 r 8 +C 10 r 10 +C 12 r 12 +C 14 r 14 +C 16 r 16
[0189] Where Z is the displacement in the direction of the optical axis measured from the polar tangent plane, r is the radial coordinate, R is the base radius of curvature, k is the conic constant, and Ci is the i-th order aspherical deformation constant. Tables 1c, 2c, 3b, 4c, 5c, 6c, 7c, 8c, 9c, 10c, 11c and 12b provide aspheric surface data for examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 and 12, respectively.
[0190] Values for the defining conditions for each of the eight examples are given in Table 13. A listing of refractive index at various wavelengths for all of the glass types used in the Examples is provided in Table 14.
[0000]
TABLE 1a
Prescription Data for Example 1
Surf
Radius
Thickness
Glass
Diameter
OBJ
Infinity
Infinity
1
−243.9697
4
N-KZFS4
61.76092
2
206.7449
5
S-NPH1
60.82355
3
422.6313
1.949756
60.3132
4
81.99985
10
S-BSL7
56.56122
5
71.78633
28.64799
53.75262
STO
Infinity
2.934045
54.7
7
113.8222
13
S-FPL51
57.16058
8
−91.91932
1.918958
57.46784
9
105.3766
3
N-KZFS4
55.07957
10
41.14905
14.88799
S-FPL51
52.07915
11
−93.91761
0.25
51.56341
12
34.49819
13
S-FPL51Y
43.1011
13
−194.7093
2.5
N-KZFS4
38.62962
14
21.47767
2.844639
30.07902
15
30.81431
2.5
N-KZFS4
29.87583
16
16.63395
7
S-LAH53
28.05017
17
28.83075
2.756143
26.85199
18
47.79796
2.5
S-LAL14
26.84398
19
31.35968
4.043165
26.02517
20
79.29547
5
S-PHM52
28
21
377.9263
13.03858
28
22
Infinity
5
S-BSL7
32
23
Infinity
4.8
32
IMA
Infinity
28.000
[0000]
TABLE 1b
Focusing and Breathing Data for Example 1
OBMG
0.0
−0.032
−0.062
−0.137
OBIM
Infinity
2163.4
1174.8
609.6
T0
Infinity
2000.0
1000.0
409.1
T3
1.950
12.745
22.411
44.023
T19
4.043
6.046
7.816
11.948
Breathing
0.00%
+0.03%
+0.08%
−0.09%
[0000]
TABLE 1c
Aspheric Surface Data for Example 1
Surf. #
4
R
82.000
k
0.0
C4
−1.727197e−6
C6
−1.667576e−10
C8
−7.766913e−13
C10
5.730591e−16
C12
4.667245e−19
C14
−1.252642e−21
C16
6.603991e−25
[0000]
TABLE 2a
Prescription Data for Example 2
Surf
Radius
Thickness
Glass
Diameter
OBJ
Infinity
Infinity
1
−55.04161
3
N-KZFS4
50.67136
2
950.3995
5
S-NPH1
52.03579
3
−528.7796
3
52.52354
4
107.022
5
S-LAH53
53.41207
5
153.2842
8
S-FPL53
53.17786
6
−133.139
10.68225
53.25474
STO
Infinity
1.2
51.34386
8
90.4377
12
S-FPL53
52.14142
9
−70.2512
0.25
51.8957
10
325.283
2.5
N-KZFS4
48.85419
11
40.1485
10.5
S-PHM52
45.70621
12
−310.7279
0.25
44.77577
13
32.86969
11
S-PHM52
39.3514
14
−1017.895
2.5
N-KZFS4
35.09814
15
17.80344
3.320912
26.56843
16
31.75178
2.5
N-KZFS4
26.46405
17
14.51134
6
S-LAH53
23.59758
18
28.43016
15.93711
22.35022
19
−41.12113
7.458793
S-PHM52
23.69697
20
−22.20727
3
N-LASF9
25.28074
21
−33.70055
1
27.03097
22
Infinity
5
S-BSL7
27.27129
23
Infinity
4.8
27.47853
IMA
Infinity
28.000
[0000]
TABLE 2b
Focusing and Breathing Data for Example 2
OBMG
0.0
−0.032
−0.064
−0.124
OBIM
Infinity
2127.7
1131.3
636.6
T0
Infinity
2000.0
1000.0
499.0
T3
3.000
4.813
6.579
9.929
T18
15.937
12.657
9.946
5.547
T23
4.800
10.101
14.572
22.004
Breathing
0.00%
−0.01%
0.00%
0.00%
[0000]
TABLE 2c
Aspheric Surface Data for Example 2
Surf. #
4
R
107.022
k
0.0
C4
−1.239477e−6
C6
−1.464631e−10
C8
−1.068124e−13
C10
1.130896e−17
C12
0.0
C14
0.0
C16
0.0
[0000]
TABLE 3a
Prescription Data for Example 3
Surf
Radius
Thickness
Glass
Diameter
OBJ
Infinity
Infinity
1
−84.5919
5
S-BSL7
49.85981
2
−389.7759
15.79056
49.35585
STO
Infinity
1.5
50.8863
4
112.8608
13
S-FPL53
52.70803
5
−55.78134
15.72615
53.07695
6
88.85746
11
S-FPL53
44.88271
7
−58.14963
2.5
N-KZFS4
43.37819
8
705.2347
7
S-PHM52
41.68126
9
−78.161
0.5
40.71523
10
48.79291
10
S-PHM52
35.37947
11
−110.2849
1
30.88737
12
−81.14733
2.5
N-KZFS4
30.03937
13
21.88237
2.398791
26.28744
14
39.86111
2.5
N-KZFS4
26.39182
15
17.11893
10.51624
S-LAH53
26.1893
16
33.65242
24.31896
24.40891
IMA
Infinity
28.000
[0000]
TABLE 3b
Aspheric Surface Data for Example 3
Surface #
2
R
−389.776
k
0.0
C4
2.876369e−6
C6
5.936459e−10
C8
9.064682e−13
C10
−1.958467e−16
C12
0.0
C14
0.0
C16
0.0
[0000]
TABLE 4a
Prescription Data for Example 4
Surf
Radius
Thickness
Glass
Diameter
OBJ
Infinity
Infinity
1
−243.9697
5
N-KZFS4
90.9493
2
206.7449
8
S-NPH1
95.17419
3
422.6313
2
97.01629
4
81.99985
12
S-PHM52
100.6275
5
71.78633
13
S-FPL53
101.196
6
Infinity
24.8115
101.747
7
113.8222
20.83024
CaF2
100.7282
8
−91.91932
0.5
99.66903
9
105.3766
5
N-KZFS4
91.88288
10
41.14905
18.72651
S-FPL53
85.07208
11
−93.91761
2
83.05963
STO
34.49819
2
78.9513
13
−194.7093
22
S-PHM52
69.69548
14
21.47767
5
N-KZFS4
61.72373
15
30.81431
6.641824
45.27939
16
16.63395
5
N-KZFS4
45.20044
17
28.83075
10.78727
S-LAH53
40.95277
18
47.79796
21.30254
39.11442
19
31.35968
20.5
S-BSM16
37.87622
20
79.29547
6
S-TIH1
38.17191
21
377.9263
9
38.54315
IMA
Infinity
28.000
[0000]
TABLE 4b
Focusing and Breathing Data for Example 4
OBMG
0.0
−0.030
−0.060
−0.094
OBIM
Infinity
4231.0
2239.5
1500.0
T0
Infinity
4000.0
2000.0
1251.0
T3
2.000
9.462
14.745
20.782
T18
21.303
16.290
12.846
9.316
T21
9.000
17.467
24.126
31.076
Breathing
0.00%
+0.41%
−0.19%
−0.78%
[0000]
TABLE 4c
Aspheric Surface Data for Example 4
Surface #
4
21
R
185.301
−70.903
k
0.0
0.0
C4
−1.910272e−7
4.626607e−7
C6
−7.138951e−12
−2.368491e−9
C8
2.519699e−16
5.512831e−12
C10
−1.906009e−19
−5.494228e−15
C12
0.0
0.0
C14
0.0
0.0
C16
0.0
0.0
[0000]
TABLE 5a
Prescription Data for Example 5
Surf
Radius
Thickness
Glass
Diameter
OBJ
Infinity
Infinity
1
375.5463
5
S-PHM52
91.92377
2
37.73174
25.83448
65.79916
3
−86.34626
3.5
S-FPL51
65.73444
4
57.95547
2.008227
61.80289
5
72.05063
3.5
S-NPH1
61.81905
6
42.61828
12
N-KZFS4
59.68593
7
101.2987
11.86961
59.44564
8
82.44051
13
S-LAH60
63.52585
9
−182.3396
34.84959
62.7011
10
Infinity
5
S-BSL7
34.87959
11
Infinity
5
32.85024
12
237.532
5
S-NSL3
29.40529
13
50.6145
8.489515
26.37966
STO
Infinity
3.071435
26.78562
15
102.3559
3.5
S-LAH63
28.24707
16
124.9423
8
S-FPL53
28.47063
17
−66.92142
0.25
29.28444
18
94.94834
6
S-FPL53
29.33022
19
−68.09017
2.5
N-KZFS4
29.05241
20
125.6468
6
S-FPL53
28.91357
21
−53.67274
0.25
28.90076
22
46.87171
1.998782
N-KZFS4
30.21724
23
22.65798
10.04979
S-PHM52
29.8263
24
−61.68191
0.25
29.60787
25
54.7172
6.925449
S-PHM52
27.83196
26
−31.5037
1.998782
N-KZFS4
26.79483
27
22.58101
3.469186
22.81917
28
111.9798
2
N-KZFS4
22.79616
29
22.78321
4.624977
S-PHM52
23.29371
30
84.68205
2.394582
23.49102
31
−47.88134
2.649691
S-BAL42
23.52596
32
−47.94859
9
24.50782
IMA
Infinity
28.000
[0000]
TABLE 5b
Focusing and Breathing Data for Example 5
OBMG
0.0
−0.033
OBIM
Infinity
606.1
T0
Infinity
400.0
T4
2.008
3.832
T9
34.850
29.133
Breathing
0.00%
0.14%
[0000]
TABLE 5c
Aspheric Surface Data for Example 5
Surface #
1
13
28
R
375.546
50.614
111.980
k
0.0
0.0
0.0
C4
1.333707e−6
1.204138e−5
−3.462446e−5
C6
−2.060015e−10
−2.759991e−9
1.890542e−8
C8
4.106414e−14
1.027888e−10
−9.138490e−10
C10
1.924041e−18
−2.113544e−13
1.622290e−12
C12
0.0
0.0
0.0
C14
0.0
0.0
0.0
C16
0.0
0.0
0.0
[0000]
TABLE 6a
Prescription Data for Example 6
Surf
Radius
Thickness
Glass
Diameter
OBJ
Infinity
Infinity
1
92.60746
4
S-BAL42
75.04797
2
45.74328
12.78556
65.11839
3
581.3462
3.5
S-FPL51
65.0555
4
47.48849
54.99829
58.3797
5
−89.49438
5
S-FSL5
55.56219
6
−60.55685
0.5
55.98575
7
61.06037
7
S-FPL51
52.43241
8
371.3011
27.48415
51.47304
9
−44.26416
4
S-BSL7
36.28671
10
−211.557
2
35.68603
STO
Infinity
2
35.09028
12
73.75098
3.5
S-LAH53
36.12446
13
86.92011
8
S-FPL53
35.99807
14
−94.0894
0.2495871
36.29503
15
58.71839
6
S-FPL53
35.93812
16
326.8157
2.5
N-KZFS4
35.0456
17
357.0363
5.331577
S-FPL51
34.48392
18
−87.41435
0.345288
33.69834
19
58.2085
1.998782
N-KZFS4
31.28165
20
24.90714
6.282571
S-PHM52
28.73855
21
179.6464
0.4350781
27.50653
22
30.76528
4.092707
S-PHM52
25.80209
23
100.0604
1.998782
N-KZFS4
24.33576
24
17.16774
3.277854
21.73136
25
83.63094
2
N-KZFS4
21.7505
26
18.66912
10.91264
S-PHM52
22.01914
27
−14.75671
2
N-KZFS4
22.24207
28
−250.6923
4.307977
22.86026
29
−27.73417
2.502858
S-PHM52
23.04734
30
−25.15099
2
N-KZFS4
23.8395
31
−41.74433
9
25.0488
IMA
Infinity
28.000
[0000]
TABLE 6b
Focusing and Breathing Data for Example 6
OBMG
0.0
−0.050
OBIM
Infinity
609.6
T0
Infinity
409.6
T2
12.786
19.625
T8
27.484
19.594
T31
9.000
10.050
Breathing
0.00%
2.01%
[0000]
TABLE 6c
Aspheric Surface Data for Example 6
Surface #
1
12
R
92.607
73.751
k
0.0
0.0
C4
3.457947e−7
−2.202698e−6
C6
1.407617e−10
−6.299493e−10
C8
−2.136379e−14
2.204620e−12
C10
1.804411e−17
−2.816188e−15
C12
0.0
0.0
C14
0.0
0.0
C16
0.0
0.0
[0000]
TABLE 7a
Prescription Data for Example 7
Surf
Radius
Thickness
Glass
Diameter
OBJ
Infinity
Infinity
1
396.9664
4
S-BSL7
48.4
2
38.47405
15.86035
43
3
49.92867
7
S-TIM2
40
4
56.06739
23.0195
38
5
−42.09343
4
S-BSL7
33.2
6
−103.028
2.372342
36.4
STO
Infinity
2
38.34528
8
474.2342
7
S-FPL51
40.71931
9
−58.61468
0.25
42.23332
10
−198.4969
7
S-FPL51
43.66711
11
−49.81846
0.25
44.79874
12
126.6418
11
S-FPL51
45.55004
13
−52.1216
2.5
N-KZFS4
45.35187
14
−129.611
0.25
45.4687
15
721.1586
8.5
S-FPL53
44.98233
16
−61.33901
0.25
44.38943
17
44.12771
9
S-FPL51
38.94397
18
−486.2903
0.25
35.92704
19
130.5751
9
S-PHM52
33.81175
20
−35.0691
2
N-KZFS4
33.81175
21
18.9107
4.417785
23.48
22
−207.8419
2
N-KZFS4
23.48
23
30.18606
7
S-PHM52
24
24
−33.99464
1.105499
24
25
−24.05843
2.5
S-BSM4
23
26
−48.65227
15.72706
24
IMA
Infinity
28.000
[0000]
TABLE 7b
Focusing and Breathing Data for Example 7
OBMG
0.0
−0.065
OBIM
Infinity
655.1
T0
Infinity
500.0
T2
15.860
1.990
T4
23.020
41.598
T26
15.727
17.899
Breathing
0.00%
−0.03%
[0000]
TABLE 7c
Aspheric Surface Data for Example 7
Surface #
1
6
R
396.966
−103.028
k
0.0
0.0
C4
−3.585839e−7
7.833468e−6
C6
9.755781e−10
2.834875e−9
C8
−1.576946e−12
−3.428422e−12
C10
1.165119e−15
9.842607e−16
C12
0.0
0.0
C14
0.0
0.0
C16
0.0
0.0
[0000]
TABLE 8a
Prescription Data for Example 8
Surf
Radius
Thickness
Glass
Diameter
OBJ
Infinity
Infinity
1
−283.9121
4
N-KZFS4
61.6184
2
204.1113
5
S-NPH1
60.59697
3
366.4659
2
60.01507
4
87.86912
10
ACRYLIC
55.98527
5
76.18259
27.65287
53.48406
STO
Infinity
2.997092
54.48122
7
140.7083
13
S-FPL51
56.69821
8
−87.01917
2.082923
57.24739
9
105.2124
3
N-KZFS4
55.19328
10
45.35061
14.9561
S-FPL51
52.6903
11
−88.21712
0.25
52.05543
12
35.79661
13
S-FPL51Y
43.42701
13
−150.139
2.5
N-KZFS4
39.11433
14
22.08163
2.832599
30.50124
15
28.92564
2.5
N-KZFS4
30.16155
16
16.95775
7
S-LAH53
28.38056
17
25.87959
3.153191
26.86656
18
47.66877
2.5
S-LAL14
26.93462
19
34.94616
1.75774
26.2819
20
96.94503
5
S-PHM52
27.11023
21
770.8764
15.16361
27.11922
22
Infinity
5
S-BSL7
28.000
23
Infinity
4.8
27.62637
IMA
Infinity
28.000
[0000]
TABLE 8b
Focusing and Breathing Data for Example 8
OBMG
0.0
−0.032
−0.062
−0.137
OBIM
Infinity
2163.0
1174.4
609.6
T0
Infinity
2000.0
1000.0
409.5
T3
2.000
12.880
22.446
44.067
T19
1.758
3.753
5.539
9.688
Breathing
0.00%
0.14%
−0.09%
0.02%
[0000]
TABLE 8c
Aspheric Surface Data for Example 8
Surface #
5
R
87.869
k
0.0
C4
−1.961709e−6
C6
−1.791880e−10
C8
−1.068037e−12
C10
1.896598e−15
C12
−2.843718e−18
C14
2.457603e−21
C16
−8.748159e−25
[0000]
TABLE 9a
Prescription Data for Example 9
Surf
Radius
Thickness
Glass
Diameter
OBJ
Infinity
Infinity
1
333.9197
4
S-FPL53
58.22967
2
38.30447
20.67997
50.95781
3
54.68269
4
S-TIH53
50.85248
4
50.56709
6
N-KZFS4
48.6793
5
63.96197
29.92107
46.69942
6
−26.59337
4
S-BSL7
34.48456
7
−73.84637
2.413273
37.60764
STO
Infinity
2
39.51109
9
−1054.178
8.946326
S-FPL53
41.47097
10
−35.74606
0.25
42.90604
11
−614.98
7.676709
S-FPL53
45.80089
12
−47.17851
0.25
46.41689
13
87.01859
13
S-FPL53
46.00835
14
−47.23339
2.5
N-KZFS4
45.21423
15
−127.2815
0.25
44.90176
16
173.0087
8.026098
S-FPL53
43.78873
17
−78.90241
0.25
42.71688
18
34.08032
9
S-FPL53
36.5209
19
381.1721
0.25
32.94332
20
91.59234
5.338591
N-KZFS4
31.6
21
19.37844
14.57205
25.8
22
−56.03064
6
S-FPL53
25.4
23
−31.00777
1.193065
25.52397
24
−22.63342
2.5
N-KZFS4
25.52397
25
−34.92177
9.0806
27
IMA
Infinity
28.000
[0000]
TABLE 9b
Focusing and Breathing Data for Example 9
OBMG
0.0
−0.064
OBIM
Infinity
670.7
T0
Infinity
500.0
T2
20.680
4.107
T5
29.921
52.876
T25
9.081
11.345
Breathing
0.00%
−0.23%
[0000]
TABLE 9c
Aspheric Surface Data for Example 9
Surface #
1
7
R
333.920
−73.846
k
0.0
0.0
C4
3.394842e−7
8.11606e−6
C6
3.05377e−10
1.990386e−9
C8
−1.402218e−13
−4.780505e−12
C10
6.990304e−17
−3.430611e−16
C12
0.0
0.0
C14
0.0
0.0
C16
0.0
0.0
[0000]
TABLE 10a
Prescription Data for Example 10
Surf
Radius
Thickness
Glass
Diameter
OBJ
Infinity
Infinity
1
100.4234
5
S-FPL51
73.48584
2
37.38913
18.51934
60.32297
3
−147.4289
4
CaF2
59.25265
4
55.04329
25.08171
54.91074
5
216.8735
8
S-BAL42
55.90533
6
−139.4082
56.78947
55.69153
7
−40.97067
4
S-BSL7
36.80999
8
−110.0568
2.413273
39.47896
STO
Infinity
2
41.62642
10
1349.394
11
CaF2
45.6
11
−43.21708
0.25
45.6
12
−473.4083
10
CaF2
47.1
13
−53.85559
0.25
47.32
14
119.5412
2.5
S-BAL42
46
15
31.90913
15
CaF2
44
16
−272.1249
0.25
44
17
106.3444
9
CaF2
44
18
−71.05028
0.25
44
19
39.68814
13
CaF2
38.4
20
−69.05873
0.25
38.4
21
−185.5592
2
N-KZFS4
34
22
25.56384
13.18843
29
23
500.099
6
CaF2
27.6
24
−37.13322
1.193065
27.6
25
−26.3389
2.5
S-BAL42
27.10797
26
−89.46392
12.58599
27.8
IMA
Infinity
28.000
[0000]
TABLE 10b
Focusing and Breathing Data for Example 10
OBMG
0.0
−0.056
OBIM
Infinity
605.0
T0
Infinity
380.0
T2
18.519
32.141
T6
56.789
41.689
T26
12.586
14.081
Breathing
0.00%
−2.42%
[0000]
TABLE 10c
Aspheric Surface Data for Example 10
Surface #
1
8
R
100.423
−110.057
k
0.0
0.0
C4
7.760058e−7
7.048276e−6
C6
1.290256e−10
4.832011e−10
C8
−5.36044e−14
1.525344e−12
C10
3.874459e−17
−4.411433e−15
C12
0.0
0.0
C14
0.0
0.0
C16
0.0
0.0
[0000]
TABLE 11a
Prescription Data for Example 11
Surf
Radius
Thickness
Glass
Diameter
OBJ
Infinity
Infinity
1
127.4965
5
S-PHM52
108.0221
2
43.87358
31.87358
80.72893
3
−167.2721
3.5
S-FPL51
80.45617
4
60.97883
3
72.33558
5
77.11638
3.5
S-NPH1
72.34854
6
43.80593
12
N-KZFS4
68.04119
7
87.73247
25.05135
67.54355
8
163.6522
13
S-LAH60
71.87265
9
−154.9931
1.804394
71.39477
10
177.1917
4
S-FPL53
64.80238
11
41.56382
25.38503
57.16877
12
70.88989
4
S-TIH53
51.9796
13
85.19841
6
N-KZFS4
50.51155
14
97.69889
32.10155
47.98542
15
Infinity
15
31
16
−28.37547
4
S-BSL7
32.24222
17
−67.85317
2.413273
35.2074
STO
Infinity
2
37.23384
19
351.0629
8.043594
S-FPL53
39.4388
20
−40.03792
0.25
40.49308
21
−565.0694
6.591541
S-FPL53
41
22
−47.81657
0.25
41
23
90.31838
9.455159
S-FPL53
40
24
−44.1493
2.5
N-KZFS4
40
25
−173.1045
0.25
40
26
143.7942
6.476801
S-FPL53
39.8997
27
−75.13476
0.25
39.39415
28
34.15295
6.727187
S-FPL53
36
29
505.9532
0.25
34.8
30
90.79729
2.516471
N-KZFS4
33.4
31
20.62152
6.357717
28.8
32
−222.4085
6
S-FPL53
28.8
33
−30.19114
0.648371
29
34
−26.87561
2.5
N-KZFS4
29
35
−51.55495
22.29939
30
IMA
Infinity
28.000
[0000]
TABLE 11b
Focusing and Breathing Data for Example 11
OBMG
0.0
−0.037
OBIM
Infinity
609.6
T0
Infinity
334.6
T4
3.000
14.306
T7
25.051
21.027
T14
32.102
24.827
Breathing
0.00%
0.16%
[0000]
TABLE 11c
Aspheric Surface Data for Example 11
Surface #
1
10
17
R
127.496
177.192
−67.853
k
0.0
0.0
0.0
C4
6.386489e−7
6.302277e−7
8.104566e−6
C6
−5.204384e−11
9.365987e−10
2.137244e−9
C8
7.139764e−15
−3.328055e−13
−2.210840e−12
C10
1.397088e−18
2.363550e−16
−2.049639e−15
C12
0.0
0.0
0.0
C14
0.0
0.0
0.0
C16
0.0
0.0
0.0
[0000]
TABLE 12a
Prescription Data for Example 12
Surf
Radius
Thickness
Glass
Diameter
OBJ
Infinity
Infinity
1
−172.16
7
N-KZFS4
135.6177
2
Infinity
12
S-NPH1
141.6501
3
−766.15
4.8
143.8727
4
451.74
25
S-BSL7
147.7423
5
−218.85
1.9
149.1813
6
300.00
18
CaF2
147.2112
7
1676.30
0.5
145.0360
8
196.12
18
CaF2
141.8413
9
726.80
5
138.5623
10
541.42
8
N-KZFS4
135.5623
11
118.64
44.7
126.5730
STO
Infinity
4
128.6329
13
201.50
25
S-FPL53
129.8978
14
−301.88
0.5
128.8176
15
150.80
25
S-FPL53
120.3746
16
−291.55
11.6
116.7305
17
328.00
25
S-PHM52
93.4670
18
−255.20
20
N-KZFS4
79.2993
19
49.97
20.2
57.0197
20
95.00
11.6
N-KZFS4
54.7523
21
39.66
13.6
S-LAH53
49.6368
22
93.31
51.118
46.2380
IMA
Infinity
28.0000
[0000]
TABLE 12b
Aspheric Surface Data for Example 12
Surf. #
4
R
451.74
k
0.0
C4
−7.071869e−08
C6
5.824021e−13
C8
−1.045519e−17
C10
2.748538e−22
C12
0.0
C14
0.0
C16
0.0
[0000]
TABLE 13
Values for the Conditions for Each Example
F1/FG
F2/FG
F3/FG
F4/FG
y MAX /y SC
Z SC /FG
R SC /FG
OBMG PG
Ex. 1
−3.576
0.919
−1.431
2.256
1.972
0.761
0.340
0.000
Ex. 2
−1.646
0.774
−1.471
1.815
2.010
0.754
0.274
0.000
Ex. 3
−3.202
0.851
−1.088
2.241
2.228
0.611
0.337
0.000
Ex. 4
−2.109
0.812
−1.442
1.587
2.280
0.634
0.245
0.000
Ex. 5
−3.611
0.816
−2.027
−20.31
1.990
0.704
0.659
−0.049
Ex. 6
−2.121
0.676
−1.481
5.308
1.889
0.727
0.337
0.088
Ex. 7
−3.568
0.731
−0.945
8.747
2.379
0.893
0.484
−0.364
Ex. 8
−3.558
0.914
−1.408
2.290
1.938
0.765
0.340
0.000
Ex. 9
−2.000
0.671
−0.990
−8.742
2.220
0.868
0.473
−0.288
Ex. 10
−2.723
0.648
−0.767
−7.586
2.102
0.789
0.546
−0.210
Ex. 11
−2.243
0.618
−1.006
12.399
1.883
0.876
0.478
−0.175
Ex. 12
−2.029
0.677
−0.515
1.402
2.712
0.483
0.250
0.000
[0000]
TABLE 14
Refractive Indices for Glasses Used in the Examples
N F′
N e
N C′
Glass Type
Maker
λ = 480 nm
λ = 546 nm
λ = 644 nm
N-KZFS4
Schott
1.623802
1.616638
1.609873
S-NPH1
Ohara
1.835745
1.816432
1.799572
S-BSL7
Ohara
1.522357
1.518250
1.514251
S-FPL51
Ohara
1.501575
1.498454
1.495433
S-FPL51Y
Ohara
1.501604
1.498465
1.495430
S-LAH53
Ohara
1.821104
1.810774
1.801169
S-LAL14
Ohara
1.706235
1.699788
1.693583
N-LASF9
Schott
1.870583
1.856501
1.843756
ACRYLIC
Ohara
1.498324
1.493801
1.489370
S-FPL53
Ohara
1.442214
1.439854
1.437559
CaF2
Schott
1.437268
1.434929
1.432673
S-PHM52
Ohara
1.625350
1.620327
1.615507
S-BSM16
Ohara
1.628151
1.622864
1.617775
S-TIH1
Ohara
1.736122
1.723096
1.711428
S-LAH63
Ohara
1.819895
1.809220
1.799323
S-LAH60
Ohara
1.851152
1.839322
1.828416
S-NSL3
Ohara
1.524856
1.520325
1.515981
S-BAL42
Ohara
1.590519
1.585467
1.580614
S-FSL5
Ohara
1.492672
1.489147
1.485688
S-TIM2
Ohara
1.633149
1.624087
1.615811
S-BSM4
Ohara
1.620577
1.615203
1.610050
S-TIH53
Ohara
1.874313
1.855040
1.838067 | Large aperture optical systems that are extremely well corrected over a large flat field and over a large spectral range are disclosed. Breathing and aberration variation during focusing are optionally controlled by moving at least two groups of lens elements independently. Aberration correction in general is aided by allowing the working distance to become short relative to the format diagonal. Field curvature is largely corrected by a steeply curved concave surface relatively close to the image plane. This allows the main collective elements to be made of low-index anomalous dispersion materials in order to correct secondary spectrum. In wide-angle example embodiments, distortion may be controlled with an aspheric surface near the front of the lens. | 6 |
This application claims priority from European Patent Application No. 09155125.9 filed Mar. 13, 2009, the entire disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to a mould for fabricating a micromechanical part using galvanoplasty and the method of fabricating said mould.
BACKGROUND OF THE INVENTION
Galvanoplasty has been used and known for a long time. LIGA type methods (a well know abbreviation for the German term “röntgenLlthographie, Galvanoformung & Abformung”) are more recent. They consist in forming a mould by photolithography using a photosensitive resin, and then, by galvanoplasty, growing a metal deposition, such as nickel, therein. The precision of LIGA techniques is much better than that of a conventional mould, obtained, for example, by machining. This precision thus allows the fabrication of micromechanical parts, particularly for timepiece movements, which could not have been envisaged before.
However, these methods are not suitable for micromechanical parts with a high slenderness ratio, such as a coaxial escape wheel made of nickel-phosphorus containing, for example 12% phosphorus. Electrolytic depositions of this type of part delaminate during plating, because of internal stresses in the plated nickel-phosphorus, which cause it to split away at the interface with the substrate.
SUMMARY OF THE INVENTION
It is an object of the present invention to overcome all or part of the aforementioned drawbacks, by proposing an alternative mould that offers at least the same fabrication precision and allows fabrication of parts with several levels and/or a high slenderness ratio.
The invention therefore concerns a method of fabricating a mould that includes the following steps:
a) providing a substrate that has a top layer and a bottom layer made of electrically conductive, micromachinable material, and secured to each other by an electrically insulating, intermediate layer; b) etching at least one pattern in the top layer as far as the intermediate layer so as to form at least one cavity in said mould; c) coating the top part of said substrate with an electrically insulating coating; d) directionally etching said coating and said intermediate layer to limit their presence exclusively at each vertical wall formed in said top layer.
According to other advantageous features of the invention:
a second pattern is etched in step b) to form at least one recess that communicates with said at least one cavity, providing said top layer with a second level; after step d), a part is mounted to form at least one recess that communicates with said at least one cavity, providing said mould with a second level; the method includes the final step e): mounting a rod in said at least one cavity to form a hole in the future part made in said mould; step b) includes phase f): structuring at least one protective mask on the conductive top layer, phase g): performing an anisotropic etch of said top layer on the parts that are not coated by said at least one protective mask and phase h): removing the protective mask; after the preceding steps, the method includes step a′): depositing an electrically conductive material in the bottom of said at least one cavity, b′): etching a pattern in the bottom layer as far as the deposition of said conductive material, to form a least one cavity in said mould and c′): coating the whole assembly with a second, electrically insulting coating; after step c′), the method includes step d′): directionally etching said second coating to limit the presence thereof exclusively at each vertical wall formed in said bottom layer; a second pattern is etched during step b′) to form at least one recess that communicates with said at least one cavity, providing said bottom layer with a second level; a part is mounted after step d′) to form at least one recess that communicates with said at least one cavity, providing said mould with a second level; the method includes the final step e′): mounting a rod in said at least one cavity in the bottom layer to form a hole in the future part made in said mould; step b′) includes phase f): structuring at least one protective mask on the conductive top layer, g′): performing an anisotropic etch of said top layer on the parts that are not covered by said at least one protective mask and h′): removing the protective mask; several masks are fabricated on the same substrate; the conductive layers include a doped, silicon-based material.
The invention also relates to a method of fabricating a micromechanical part using galvanoplasty, characterized in that it includes the following steps:
i) fabricating a mould in accordance with the method of one of the preceding variants; j) performing an electrodeposition by connecting the electrode to the conductive bottom layer of the substrate to form said part in said mould; k) releasing the part from said mould.
Finally, the invention relates to a mould for fabricating a micromechanical part using galvanoplasty, characterized in that it includes a substrate that has a top layer and a bottom layer, which are electrically conductive and secured to each other by an electrically insulating, intermediate layer, wherein the top layer has at least one cavity, which reveals part of the bottom layer of said substrate and has electrically insulating walls, allowing an electrolytic deposition to be grown in said at least one cavity.
According to other advantageous features of the invention:
the top layer also has at least one recess that communicates with said at least one cavity and has electrically insulating walls for continuing the electrolytic deposition in said at least one recess after said at least one cavity has been filled; the bottom layer includes at least one cavity that reveals part of the electrically conductive layer of said substrate and has electrically insulating walls, allowing an electrolytic deposition to be grown in said at least one cavity in the bottom layer; the bottom layer also has at least one recess that communicates with said at least one cavity in the bottom layer and has electrically insulating walls for continuing the electrolytic deposition in said at least one recess, after said at least one cavity in the bottom layer has been filled.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages will appear more clearly from the following description, given by way of non-limiting illustration, with reference to the annexed drawings, in which:
FIGS. 1 to 7 are diagrams of the successive steps of a method of fabricating a micromechanical part in accordance with a first embodiment of the invention;
FIGS. 8 to 12 are diagrams of the successive steps of a method of fabricating a micromechanical part in accordance with a second embodiment of the invention;
FIG. 13 is a flow chart of a method of fabricating a micromechanical part in accordance with the invention;
FIGS. 14 to 19 are diagrams of the successive steps of a method of fabricating a micromechanical part in accordance with a variant of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
As FIG. 13 shows, the invention relates to a method 1 of fabricating a micromechanical part 41 , 41 ′, 41 ″ using galvanoplasty. Method 1 preferably includes a method 3 of fabricating a mould 39 , 39 ′, 39 ″ followed by galvanoplasty step 5 and step 7 of releasing part 41 , 41 ′, 41 ″ from said mould.
Mould fabrication method 3 includes a series of steps for fabricating a mould 39 , 39 ′, 39 ″ that preferably includes silicon-based materials.
A first step 10 of method 3 consists in taking a substrate 9 , 9 ′ that includes a top layer 21 , 21 ′ and a bottom layer 23 , 23 ′, which are made of electrically conductive, micromachinable material and secured to each other by an electrically conductive, intermediate layer 22 , 22 ′, as illustrated in FIGS. 1 to 8 .
Preferably, substrate 9 , 9 ′ is a S.O.I. (Silicon On Insulator). Moreover, top and bottom layers 21 , 21 ′ and 23 , 23 ′ are made of crystalline silicon, sufficiently doped to be electrically conductive and the intermediate layer is made of silicon dioxide.
According to the invention, method 3 includes two distinct embodiments after step 11 , respectively represented by a triple line and a single line in FIG. 13 .
According to a first embodiment, in step 11 , protective masks 15 , then 24 , are structured on conductive top layer 21 as illustrated in FIG. 2 . As FIG. 2 also shows, mask 15 has at least one pattern 27 which does not cover top layer 21 . Moreover, mask 24 , which preferably totally covers mask 15 , has at least one pattern 26 , which does not cover top layer 21 .
By way of example, mask 15 can be made by depositing a silicon oxide layer to form said mask to a predetermined depth. Next, mask 24 can, for example, be obtained by photolithography, using a photosensitive resin to cover mask 15 .
According to the first embodiment shown in a triple line in FIG. 13 , in a third step 2 , top layer 21 is etched to reveal intermediate layer 22 . According to the invention, etching step 2 preferably includes an anisotropic dry attack of the Deep Reactive Ion Etching type (DRIE).
First of all in step 2 , an anisotropic etch is performed in top layer 21 in pattern 26 of mask 24 . This etch is the start of the etching of at least one cavity 25 in top layer 21 over one part of the thickness thereof. Secondly, mask 24 is removed, then a second anisotropic etch is performed in pattern 27 of mask 15 that is still present on top layer 21 . The second etch continues the etching of said at least one cavity 25 , but also starts the etching of at least one recess 28 , which communicates with said at least one cavity 25 , but has a larger section.
In a fourth step 4 , mask 15 is removed. Thus, as FIG. 3 shows, at the end of fourth step 4 , the entire thickness of top layer 21 is etched with said at least one cavity 25 and a part of the thickness thereof is etched with said at least one recess 28 .
In a fifth step 6 , an electrically insulating coating 30 is deposited, covering the entire top of substrate 9 , as illustrated in FIG. 4 . Coating 30 is preferably obtained by oxidising the top of the etched top layer 21 and intermediate layer 22 .
In a sixth step 8 , a directional etch of coating 30 and intermediate layer 22 is performed. Step 8 is for limiting the presence of the insulating layers exclusively at each vertical wall formed in top layer 21 , i.e. walls 31 and 32 respectively of said at least one cavity 25 and said at least one recess 28 . According to the invention, during a directional or anisotropic etch, the vertical component of the etch phenomenon is favoured relative to the horizontal component, by modulating, for example, the chamber pressure (very low working pressure), in a RIE reactor. This etch may be, by way of example, ion milling or sputter etching.
By performing step 8 , as illustrated in FIG. 5 , it is clear that the bottom of cavity 25 reveals the electrically conductive, bottom layer 23 and that the bottom of recess 28 reveals top layer 21 , which is also conductive.
In order to improve the adhesion of the future galvanoplasty, an adhesion layer can be provided on the bottom of each cavity 25 and/or on the bottom of each recess 28 . The adhesion layer could thus consist of a metal, such as the alloy CrAu.
Preferably, during sixth step 8 , as illustrated in FIG. 5 , a rod 29 is mounted to form the shaft hole 42 for micromechanical part 41 immediately during galvanoplasty step 5 . This not only has the advantage of avoiding the need to machine part 41 once the galvanoplasty has finished, but also means that an inner section of any shape, whether uniform or not, can be made over the entire height of hole 42 . Preferably, rod 29 is obtained, for example, via a photolithographic method using a photosensitive resin.
In the first embodiment, after step 8 , method 3 of fabricating mould 39 is finished and method 1 of fabricating the micromechanical part continues with galvanoplasty step 5 and step 7 of releasing part 41 from mould 39 .
Galvanoplasty step 5 is achieved by connecting the deposition electrode to bottom layer 23 of mould 39 to grow, firstly, an electrolytic deposition in cavity 25 of said mould, and then exclusively in a second phase, in recess 28 , as illustrated in FIG. 6 .
Indeed, advantageously, according to the invention, when the electrolytic deposition is flush with the top part of cavity 25 , it electrically connects top layer 21 , possibly by the adhesion layer thereof, which enables the deposition to continue growing over the whole of recess 28 . Advantageously, the invention enables parts 41 with a high slenderness ratio to be made, i.e. wherein the section of cavity 25 is much smaller than that of recess 28 . This avoids delamination problems, even with a nickel-phosphorus material, containing, for example, 12% phosphorus.
Owing to the use of silicon for conductive layers 21 , 23 , and possibly for their adhesion layer, delamination phenomena at the interfaces decreases, which avoids splitting caused by internal stresses in the electrodeposited material.
According to the first embodiment, fabrication method 1 ends with step 7 , in which part 41 , formed in cavity 25 and then in recess 28 , is released from mould 39 . Release step 7 can, for example, be achieved by etching layers 23 and 21 . According to this first embodiment, it is clear, as illustrated in FIG. 7 , that the micromechanical part 41 obtained has two levels 43 , 45 , each of different shape and perfectly independent thickness and including a single shaft hole 42 .
This micromechanical part 41 could, for example, be a coaxial escape wheel or an escape wheel 43 -pinion 45 assembly with geometrical precision of the order of a micrometer, but also ideal referencing, i.e. perfect positioning between said levels.
According to a second embodiment of the invention, method 3 has a second step 11 , consisting in structuring at least one protective mask 24 ′ on the conductive top layer 21 ′ as illustrated in FIG. 8 . As FIG. 8 also shows, mask 24 ′ includes at least one pattern 26 ′, which does not cover top part 21 ′. This mask 24 ′ can, for example, be obtained by photolithography using a photosensitive resin.
In a third step 12 , top layer 21 ′ is etched until it reveals intermediate layer 22 ′. According to the invention, etching step 12 preferably includes a dry anisotropic attack of the deep reactive ion etching type (DRIE). The anisotropic etch is performed on top layer 21 ′ in pattern 26 ′ of mask 24 ′.
In a fourth step 14 , mask 24 ′ is removed. Thus, as FIG. 9 shows, at the end of fourth step 14 , the entire thickness of top layer 21 ′ is etched with at least one cavity 25 ′.
In a fifth step 16 , an electrically insulating coating 30 ′ is deposited, covering the whole top of substrate 9 ′ as illustrated in FIG. 10 . Coating 30 ′ is preferably obtained by oxidising the top of the etched top layer 21 ′ and intermediate layer 22 ′.
According to a sixth step 18 , coating 30 ′ and intermediate layer 22 ′ are directionally etched. Step 18 is for limiting the presence of insulating layers exclusively at each vertical wall formed in top layer 21 ′, i.e. walls 31 ′ of said at least one cavity 25 ′. By performing this step 18 and as illustrated in FIG. 11 , it is clear that the bottom of cavity 25 ′ reveals the electrically conductive bottom layer 23 ′ and the top of top layer 21 ′, which is also conductive.
As in the first embodiment, in order to improve the adhesion of the future galvanoplasty, an adhesion layer can be provided on the bottom of each cavity 25 ′ and/or on the top of top layer 21 ′. The adhesion layer could then consist of a metal, such as the alloy CrAu.
During sixth step 18 , as explained for the first embodiment of FIGS. 1 to 7 , a rod can be mounted to form the shaft hole for the micromechanical part straight away in galvanoplasty step 5 , with the same advantages indicated above.
In the second embodiment, after step 18 , method 3 of fabricating mould 39 ′ ends and method 1 of fabricating the micromechanical part continues with galvanoplasty step 5 and step 7 of releasing the part from mould 39 ′.
Galvanoplasty step 5 is performed by connecting the deposition electrode to bottom layer 23 ′ of mould 39 ′ to grow an electrolytic deposition in cavity 25 ′ of mould 39 ′.
According to the second embodiment, fabrication method 1 ends with step 7 , which is similar to that explained in the first embodiment, and in which the part formed in cavity 25 ′ is released from mould 39 ′. According to this second embodiment, it is clear that the micromechanical part obtained has a single level of identical shape throughout the entire thickness thereof and it may contain a shaft hole.
This micromechanical part could, for example, be an escape wheel, or escape pallets or even a pinion with geometrical precision of the order of a micrometer.
According to an alternative of this second embodiment illustrated by a double line in FIG. 13 , after step 18 , method 3 of fabricating mould 39 ′ includes an additional step 20 for forming at least a second level in mould 39 ′ as illustrated in FIG. 12 . Thus, the second level is made by mounting a part 27 ′, which includes electrically insulating walls 32 ′, on top layer 21 ′, which was not removed during step 12 .
Preferably, the added part 27 ′ forms at least one recess 28 ′ of larger section than the removed parts 25 ′, for example, via a photolithographic method using a photosensitive resin. However, part 27 ′ could also include an insulating, silicon-based material that is pre-etched and then secured to conductive layer 21 ′.
Consequently, according to the alternative of the second embodiment, after step 20 , method 3 of fabricating mould 39 ′ ends and method 1 of fabricating the micromechanical part continues with galvanoplasty step 5 and step 7 of releasing part 41 ′ from mould 39 ′.
Galvanoplasty step 5 is performed by connecting the deposition electrode to bottom layer 23 ′ of mould 39 ′ in order, firstly, to grow an electrolytic deposition in cavity 25 ′ of said mould, then, exclusively in a second phase, in recess 28 ′, as illustrated in FIG. 12 .
Indeed, advantageously, according to the invention, when the electrolytic deposition is flush with the top part of cavity 25 ′, it electrically connects top layer 21 ′, possibly by the adhesion layer thereof, which enables the deposition to continue growing over the whole of recess 28 ′. Advantageously, the invention enables parts 41 ′ with a high slenderness ratio to be made, i.e. wherein the section of cavity 25 ′ is much smaller than that of recess 28 ′. This avoids delamination problems even with a nickel-phosphorus material, containing, for example, 12% phosphorus.
Owing to the use of silicon for conductive layers 21 ′, 23 ′, and possibly for their adhesion layer, delamination phenomena at the interfaces decreases, which avoids splitting caused by internal stresses in the electrodeposited material.
According to the second embodiment alternative, fabrication method 1 ends with step 7 , as explained in the first embodiment, in which part 41 ′ formed in mould 39 ′ is released. It is clear, as illustrated in FIG. 12 , that the micromechanical part 41 ′ obtained has two levels, each of different shape and perfectly independent thickness and they may include a single shaft hole. This micromechanical part 41 ′ can consequently have the same shape as part 41 obtained with the first embodiment and it can therefore have geometrical precision of the order of a micrometer, but also ideal referencing, i.e. perfect positioning between said levels.
According to a variant (illustrated in double dotted lines in FIG. 13 ) of the two embodiments of method 1 seen in FIGS. 14 to 19 , it is also possible to apply method 3 to bottom layer 23 , 23 ′, to add one or two other levels to mould 39 , 39 ′. To avoid overloading the Figures, a single example is detailed below, but it is clear that bottom layer 23 , 23 ′ can also be transformed in accordance with the first and second embodiments (with or without the variant) explained above.
The variant remains identical to method 1 described above until step 8 , 18 or 20 , depending upon the embodiment used. In the example illustrated in FIGS. 14 to 19 , we will take the example of the first embodiment, illustrated in triple lines in FIG. 13 , as the starting point of the method 1 .
Preferably, according to this variant, bottom layer 23 will be etched to form at least a second cavity 35 in mould 39 ″. As can be seen, preferably between FIG. 5 and FIG. 14 , a deposition 33 has been made in one part of the first cavity 25 to provide a galvanoplastic start layer. Preferably, this deposition 33 starts at step 5 up to a predetermined thickness. However, this deposition can be performed in accordance with a different method.
As illustrated in double dotted lines in FIG. 13 and FIGS. 14 to 19 , the variant of method 1 applies steps 11 , 12 , 14 , 16 and 18 of the second embodiment of method 3 to bottom layer 23 .
Thus, according to the variant, method 3 includes a new step 11 , consisting in structuring at least one mask 34 on the conductive bottom layer 23 , as illustrated in FIG. 15 . As FIG. 15 also shows, mask 34 includes at least one pattern 36 , which does not cover bottom layer 23 . This mask 34 can, for example, be obtained by photolithography using a photosensitive resin.
Next, in the new step 12 , layer 23 is etched in pattern 36 until the electrically conductive deposition 33 is revealed. Then, protective mask 34 is removed in a new step 14 . Thus, as FIG. 16 shows, at the end of step 14 , the entire thickness of bottom layer 23 is etched with at least one cavity 35 .
In a new step 16 , an electrically insulating coating 38 is deposited, covering the whole of the bottom of substrate 9 ″ as illustrated in FIG. 17 . Coating 38 is preferably obtained by depositing a silicon oxide on the top of bottom layer 23 , for example, using a vapour phase deposition.
A new step 18 is preferably unnecessary if a single level is added to mould 39 ″. Otherwise, directional etching of coating 38 is performed. The new step 18 would be for limiting the presence of the insulating layer exclusively at each vertical wall 39 formed in bottom layer 23 , i.e. the walls of said at least one cavity 35 . In our example of FIGS. 14 to 19 , a new step 18 is only carried out to remove the oxide layer present in the bottom of said at least one cavity 35 .
In the new step 18 , as explained previously, a rod 37 can be mounted to form shaft hole 42 ″ in the micromechanical part 41 ″ immediately during galvanoplasty step 5 , with the same aforecited advantages.
In the variant of method 1 , after step 18 , method 3 of fabricating mould 39 ″ ends and method 1 of fabricating the micromechanical part continues with galvanoplasty step 5 and step 7 for releasing part 41 ″ from mould 39 ″. Preferably, if rods 29 and 37 are respectively formed in cavities 25 and 35 , they are aligned. Rod 37 is preferably obtained, for example, via a photolithographic method using a photosensitive resin.
After new steps 8 , 18 or 20 , galvanoplasty step 5 is performed by connecting the deposition electrode to bottom layer 23 to grow an electrolytic deposition in cavity 35 , but also to continue the growth of the deposition in cavity 25 , then, exclusively in a second phase, in recess 28 , as illustrated in FIG. 18 . Fabrication method 1 ends with step 7 , in which part 41 ″ is released from mould 39 ″, as explained above.
According to this variant, it is clear, as illustrated in FIG. 19 , that the micromechanical part 41 ″ obtained has at least three levels 43 ″, 45 ″ and 47 ″, each of different shape and perfectly independent thickness with a single shaft hole 42 ″.
This micromechanical part could, for example, be a coaxial escape wheel 43 ″, 45 ″ with its pinion 47 ″, or a wheel set with three levels of teeth 43 ″, 45 ″, 47 ″ with geometrical precision of the order of a micrometer, but also ideal referencing, i.e. perfect positioning between said levels.
Of course, the present invention is not limited to the example illustrated, but is open to various alterations and variants which will be clear to those skilled in the art. Thus, several moulds 39 , 39 ′, 39 ″ are fabricated on the same substrate 9 , 9 ′, 9 ″ to achieve series fabrication of micromechanical parts 41 , 41 ′, 41 ″, which are not necessarily identical to each other. Likewise, one could envisage changing silicon-based materials for crystallised alumina or crystallised silica or silicon carbide. | The invention relates to a method ( 3 ) of fabricating a mould ( 39, 39′, 39″ ) that includes the following steps:
a) providing ( 10 ) a substrate ( 9, 9′ ) that has a top layer ( 21, 21′ ) and a bottom layer ( 23, 23′ ) made of electrically conductive, micromachinable material, and secured to each other by an electrically insulating, intermediate layer ( 22, 22′ ); b) etching ( 11, 12, 14, 2, 4 ) at least one pattern ( 26, 26′, 27 ) in the top layer ( 21, 21′ ) as far as the intermediate layer ( 22, 22′ ) to form at least one cavity ( 25, 25′ ) in said mould; c) coating ( 6, 16 ) the top part of said substrate with an electrically insulating coating ( 30, 30′ ); d) directionally etching ( 8, 18 ) said coating and said intermediate layer to limit the presence thereof exclusively at each vertical wall ( 31, 31′, 33 ) formed in said top layer.
The invention concerns the field of micromechanical parts, in particular, for timepiece movements. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a man-machine interface which may be utilized to convey a direction of a detected target to a crew of an aerospace craft or a flight simulator, but it will be appreciated that this invention is also useful in other applications.
2. Description of the Prior Art
As a means of conveying detected information to a crew of an aerospace craft, displays have been often used. A CRT(Cathode-Ray Tube) is usually incorporated in a display and the detected information is shown on the CRT to the crew. Also, in aircraft which need to move vigorously, a HUD(Head Up Display) or a HMD(Head Mounted Display) has been used to present the detected information so that a pilot can get the information while looking ahead.
Detectors utilizing radar, infrared or laser aid crew in visual recognition. For instance, the crew can recognize targets in the distance which are invisible to the naked eye. The detectors can locate targets even under low visibility due to rain or cloud and check behind and to the sides where the crew can not look. One example making good use of such detectors is the F-15E fighter of the US Air Force. The F-15E fighters are usually fitted with LANTIRN(Low Altitude Navigation and Targeting Infrared for Night) pods in addition to radar. The LANTIRN pods include various sensors such as FLIR(Forward Looking Infrared) system, TFR(Terrain Following Radar), LTD(Laser Target Designator). Information about distance to target, azimuth angle and elevation angle captured by the sensors is displayed on the HUD situated in front of the crew. Thus, the crew can obtain information captured by the detectors via display as well as recognize targets by the unaided eye. However in either case, the crew obtains the information by visual perception. Though an audible alert is often used to inform the crew of the detected information, it is used mainly to call the crew's attention to an instrument panel or a display. Accordingly, the crew's eyes are always under a lot of stress.
Then, a known technology regarding sound, more specifically, binaural sound localization is explained as follows: binaural listening means listening by both ears and it is a usual situation in which we hear sound around us. We perceive the direction of and distance to a sound source binaurally and it is called sound localization. The theory and technology of binaural sound localization may be found in the literature, "Application of Binaural Technology" written by H. W. Gierlich in Applied Acoustics 36, pp.219-243, 1992, Elsevier Science Publishers Ltd, England; "Headphone Simulation of Free-Field Listening I: Stimulus Synthesis" by F. L. Wightman and D. J. Kistler in J. Acoust. Soc. Amer., Vol.85, pp.858-867, 1989; and "Headphone Simulation of Free-Field Listening II: Psychophysical Validation" by F. L. Wightman and D. J. Kistler in J. Acoust. Soc. Amer., Vol.85, pp.868-878, 1989. Furthermore, "Process and apparatus for improved dummy head stereophonic" by Peter Schone, et al, U.S. Pat. No. 4,388,494; "Three-dimensional auditory display apparatus and method utilizing enhanced bionic emulation of human binaural sound localization" by Peter Myers, U.S. Pat. No. 4,817,149; and "Surround-sound system with motion picture soundtrack timbre correction, surround sound channel timbre correction, defined loudspeaker directionality, and reduced comb-filter effects" by Tomlinson Holman, U.S. Pat. No. 5,222,059 have disclosed the technology. Thus, binaural sound localization is a technique for duplicating a more realistic sound in the audio industry. Still further, "Binaural Doppler radar target detector" by Ralph Gregg, Jr., U.S. Pat. No. 4,692,763 is related to a radar target detector and binaural technology.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a man-machine interface which enables the crew of an aerospace craft to perceive a direction of a detected target aurally.
It is another object of the invention to provide a man-machine interface which enables the crew of a flight simulator to perceive a direction of a detected pseud-target aurally.
In the invention, the man-machine interface in the aerospace craft conveys the direction of the detected target to the crew of the aerospace craft by a localized sound comprising the steps of:
obtaining the direction of the detected target;
detecting a crew's facial direction;
calculating a direction of the detected target with respect to the crew's facial direction from the direction of the detected target and the crew's facial direction;
producing the localized sound by localizing a sound used as a sound source in the direction of the detected target with respect to the crew's facial direction; and
outputting the localized sound binaurally to the crew by a sound-output device.
Alternatively, in the invention, the man-machine interface in the flight simulator conveys the direction of the detected pseud-target to the crew of the flight simulator by a localized sound comprising the steps of:
obtaining the direction of the detected pseud-target;
detecting a crew's facial direction;
calculating a direction of the detected pseud-target with respect to the crew's facial direction from the direction of the detected pseud-target and the crew's facial direction;
producing the localized sound by localizing a sound used as a sound source in the direction of the detected pseud-target with respect to the crew's facial direction; and
outputting the localized sound binaurally to the crew by a sound-output device.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 shows a block diagram of one embodiment of the invention;
FIG. 2 shows a block diagram of another embodiment of the invention;
FIG. 3 is a reference drawing illustrating one embodiment of the invention;
FIG. 4 is a reference drawing illustrating one embodiment of the invention;
FIG. 5 is a reference drawing illustrating one embodiment of the invention; and
FIG. 6 is a reference drawing illustrating one embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In implementing this invention, the following patent literature on public view can prove that the technology illustrated in the invention is workable: "Stereo headphone sound source localization system" by Danny Lowe, et al, U.S. Pat. No. 5,371,799; "Simulated binaural recording system" by Michael Billingsley, U.S. Pat. No. 4,658,932; "Head diffraction compensated stereo system with loud speaker array" by Duane Cooper, et al, U.S. Pat. No. 5,333,200; "Method of signal processing for maintaining directional heating with hearing aids" by Sigfrid Soli, et al, U.S. Pat. No. 5,325,436; "Acoustic transfer function simulating method and simulator using the same" by Yoichi Haneda, et al, U.S. Pat No. 5,187,692; and "Method and apparatus for measuring and correcting acoustic" by Yoshiro Kunugi, et al, U.S. Pat. No. 4,739,513. These patents have disclosed particularly the technology of sound localization with the aid of head related transfer function and the technology of binaural recording and playback.
The constituents of the invention fall into the following broad parts:
finding the direction of a detected target;
detecting the crew's facial direction;
calculating the direction of the detected target with respect to the crew's facial direction from the direction of the detected target and the crew's facial direction;
localizing a sound used as a sound source in the direction of the detected target with respect to the crew's facial direction to produce the localized sound; and
outputting the localized sound binaurally to the crew by a sound-output device.
Although each part can be embodied in various ways, the preferable embodiments are described as follows.
In FIG. 1, detected information 1 is information about detected targets. The targets to be detected vary. For instance, as regards civilian aircraft, a bad-weather zone should be found on and around its course and the aircraft needs to avoid the zone. A system such as ACAS(Airborne Collision Avoidance System) to detect an aircraft on a possible collision course and provide the crew with traffic advisory exists. On the other hand, as to military aircraft, the directions of friendly aircraft and foe aircraft should be indicated from one moment to the next to the crew and information about the direction of facilities on the ground or the sea may be necessary, depending on the purpose of the flight. Moreover, spacecraft need to determine the direction of an artificial satellite and an obstacle floating in outer space. Accordingly, the direction of detected target 2 is important information when an aerospace craft flies. While a direction is determined by an azimuth angle and an elevation angle, this invention needs at least an azimuth angle and if possible, both an azimuth angle and an elevation angle are considered, Then, if the distance from the aerospace craft to a detected target is measured, the location of the detected target can be tracked down. As a means for finding direction of detected target 2, a detector aboard an aerospace craft such as a radar detector, an infrared detector or a laser detector can be used according to a use environment. For cases where a radar is used, the direction of a detected target can be obtained by converting signals indicating the angle of a radar antenna with S-D (Synchro-Digital) converter or by checking the direction of radar beam scanning emerging from Phased Array Radar. In addition, it is known that the distance to a detected target can be measured with a radar detector. Generally, the direction of a detected target with respect to an aerospace craft heading is conveyed to the crew and the heading is obtained by detecting each angle of roll, pitch, and yaw with the gyroscope. As another means, a data link system can be used to acquire direction of detected target 2; that is to say, information captured by a ground-located detector, or a detector aboard a ship, an artificial satellite or another aerospace craft, not by a detector aboard the aerospace craft may be received via the data link system. As a result, the crew of the aerospace craft can know the direction of the detected target.
On the other hand, the direction in which crew 17 is facing can be found by various known means. As a means done by machine, a rotary encoder or a potentiometer is used.
Also, a magnetic sensor fixed to a head of the crew measures the strength of a magnetic field and the position of the head of the crew is determined. In this method, a sensor known by FASTRAK system ("FASTRAK" is the trademark) by Polhemus Inc. (U.S. corporation) has been used. In addition to the above methods, as another embodiment of this invention, TV camera 10 shoots the head of the crew and the crew's facial direction can be detected by performing image processing. The publicly known technology to detect the location of an object by carrying out image processing is practical in that the crew is on an aerospace craft and some airborne instruments are not immune to magnetic fields. In addition, the size of cockpit is suitable for carrying out image processing.
From the crew's facial direction 11 and the direction of detected target 2, the direction of the detected target with respect to the crew's facial direction is calculated with calculator 3. The direction of the detected target with respect to the aerospace craft heading needs to be converted to the direction of the detected target with respect to the crew's facial direction because the crew's facial direction and the aerospace craft heading might not be the same. In other words, the direction of the detected target with respect to the aerospace craft heading dose not always agree with that of the detected target with respect to the crew's facial direction.
Referring now to FIGS. 3 and 4, a little more details can be explained. As FIG. 3 shows, when detected target 21 is detected at an angle of φ21 to the heading of aerospace craft 20 and another detected target 22 is detected at an angle of φ22, if crew 17 of the aerospace craft is facing in the direction which forms an angle of φ with the aerospace craft heading, each direction of the detected target 21 and the detected target 22 with respect to the crew's facial direction can be given by the expressions, φ-φ21 and φ+φ22. Besides, as shown in FIG. 4, when detected target 21 is detected at an angle of θ21 to the heading of aerospace craft 20 and another detected target 22 is detected at an angle of θ22, if crew 17 of the aerospace craft is facing in the direction which forms an angle of θ with the aerospace craft heading, each direction of the detected target 21 and the detected target 22 with respect to the crew's facial direction can be taken by the expressions, θ-θ21 and θ+θ22. However, in the invention, when direction of detected target 2 dose not include target elevation angle and is determined only by target azimuth angle, the azimuth angle of a detected target with respect to the crew's facial direction should be determined on a level surface at the altitude of the aerospace craft.
A man-machine interface in this invention localizes a sound in the direction of a detected target with respect to the crew's facial direction and produces the localized sound. As one embodiment of the invention, sound localization can be performed so that the direction of a sound source may vary continuously proportionally to the amount of change in the direction of the detected target. If sound localization is performed as mentioned above, as the direction of the detected target changes, the direction of a sound source also changes smoothly. However, the resolution of human hearing for direction is very low compared to that of a detector used in the invention. Thus, as another embodiment of the invention, if the resolution for direction of the detected target with respect to the crew's facial direction is programmed at 30 degrees, the direction of the detected target can be perceived by sound localized in discontinuous direction. In this embodiment, the horizontal resolution for azimuth angle of a detected target with respect to the crew's facial direction programmed at 30 degrees or the resolution for both azimuth angle and elevation angle of a detected target with respect to the crew's facial direction programmed at 30 degrees can be chosen.
FIG. 5 shows a three-dimensional view around crew 17. In case the direction of the detected target is determined only by the azimuth angle, regardless of the elevation angle, sound used as a sound source is localized in the same plane or in two dimensions. The two-dimensional plane should be horizontal at the altitude of the aerospace craft, regardless of the crew's facial direction. If the horizontal resolution for the direction is programmed at 30 degrees, 12 different directions can be set in the same plane, centering the crew in the plane, which is convenient in that the azimuth angle is often compared to the face of a clock, and is described such as "2 o'clock position" in the field of aviation. Moreover, as shown in FIG. 5, when the direction of the detected target is determined not only by the azimuth angle but also by the elevation angle, if the resolution for the elevation angle is programmed at 30 degrees as well as that for the azimuth angle, 62 different directions can be set in the space, centering the crew in the space. If sound as a sound source is localized in the set directions, not in every direction, it can reduce the number of head related transfer functions and produce a great and practical effect on the aural perception for the direction of the detected target without burdening a processor and memory means.
When the detected information includes the distance from the aerospace craft to the detected target, if sound localization is performed in such a manner that reflects the distance, the distance can be perceived by a sense of hearing. However, it is not practical to localize a sound source at the actual distance, in an attempt to make the crew perceived aurally that the detected target is at a distance of 100 km from the aerospace craft. As an embodiment of the invention, a scaled-down distance is obtained by scaling down the distance from the aerospace craft to the detected target at between 1 to 10,000 and 1 to 1,000 and the sound used as the sound source is localized at the scaled-down distance from a head of the crew. In the invention, if the distance is scaled to 1 to 10,000, when a target is detected at a distance of 100 km and another target is found at a distance of 10 km, sound localization is performed at a distance of 10 m and 1 m from a head of the crew respectively. In FIG. 6, when detected target 21 flies through detectable scope 19 centered on aerospace craft carrying crew 17, if the direction of the detected target at each point, P1, P2, P3 and P4 detected target 21 passes by is conveyed to the crew by a localized sound, the crew is able to perceive the change in the distance to the detected target aurally, by scaling down the distance from the aerospace craft to each point at between 1 to 10,000 and 1 to 1,000 and localizing the sound used as the sound source at the scaled-down distance, p11, p12, p13 and p14 from the head of the crew. However, since the intensity of sound decreases proportionate to the second power of distance, it is difficult to make the crew perceived the change in the distance to the target in a wide range by outputting an appropriate intensity of sound. It is also not preferable to listen attentively to perceive an attenuated sound in a high-noise environment such as in an aerospace craft. For this reason, in another embodiment of the invention as a more effective way, sound localization is performed at a certain distance of between 10 cm and 10 m, preferably between 50 cm and 5 m from the crew, regardless of the distance to the detected target. As shown in FIG. 6, when detected target 21 flies through detectable scope 19 centered on an aerospace craft carrying crew 17, in an attempt to convey the direction of the detected target at each point, P1, P2, P3 and P4 that the detected target passes by to the crew by a localized sound, if sound localization is performed at a certain distance from the head of the crew, p21, p22, p23 and p24, regardless of the distance to the detected target, the crew is not able to perceive the distance, but is able to perceive the direction of the detected target by a certain appropriate intensity of sound.
In addition, as show in FIG. 1, various kinds of sound can be used as a sound source according to the contents of detected information 1. If the type of the detected target is included as information, voice message which contains the information can be used as a sound source. Then, as stated above, if the sound used as the sound source is localized at the certain distance, regardless of the distance to the detected target, the information about the distance to the detected target can be also provided as a voice message. These functions are made possible by using a publicly known voice synthesis technique. Depending on the contents of detected information 1, the kind of a sound source can be chosen by selector 12. In one embodiment of the invention, after voice message data stored in memory means 13 are designated by selector 12 according to detected information 1, the voice message data are synthesized with synthesizer 14 in order to produce the sound used as the sound source. As another embodiment, a beep as a caution or a warning can be utilized as a sound source. In this case, instead of the electric circuit that carries out voice synthesis which is shown in FIG. 1, the electric circuit that produces a beep is used to synthesize sound as the sound source.
After performing the above steps, a head related transfer function is selected from head ralated transfer function map 4, according to the direction of the detected target with respect to the crew's facial direction calculated by calculator 3 and the sound as the sound source is localized with DSP(Digital Signal Processor) 5 in order to produce the localized sound. Signal processing is carded out on the localized sound with D-A(Digital-Analog) converter 6a and 6b, and amplifier 7a and 7b to output binaurally from right and left speakers 9a and 9b of headphone 8 as sound-output device crew 17 is wearing.
FIG. 2 shows another embodiment where sound localization is performed in the direction of the detected target with respect to the crew's facial direction and the localized sound is produced. The numerals and alphabets in FIGS. 1 and 2 denote the same functions. In this embodiment, sound as the sound source is localized in advance, in all directions that the resolution for direction of the detected target with respect to the crew's facial direction provides and then, the localized sound is produced and is stored in memory means 15. In this way, when the sound localized in advance is used to communicate information to the crew, the head related transfer function and DSP are unnecessary to replay the sound. In the embodiment FIG. 2 illustrates, the localized sound is read out from memory means 15 according to the direction of the detected target with respect to the crew's facial direction calculated by calculator 3, and after signal processing is carried out, the sound is output from sound-output device binaurally. The technology for localizing sound at a specific location and outputting the sound binaurally to listeners has been disclosed by the literatures mentioned already.
Another object of this invention is to provide a man-machine interface that enables the crew of a flight simulator to perceive the direction of a detected pseud-target aurally. The constituents of the invention to serve the object conform to the methods described earlier for conveying the direction of the detected target to the crew of the aerospace craft. Major uses of flight simulators are providing crew with training in maneuvering an aerospace craft and giving experience in an aerospace craft in the field of amusement. Consequently, in the invention, the difference between an aerospace craft and a flight simulator is that detected targets are real or unreal. Pseud-targets are generated electronically. In this embodiment of the invention, detected information 1 and direction of detected target 2 in FIGS. 1 and 2, and detected target 21 and 22 in FIGS. 3, 4 and 6 are imaginary pans. In addition, aerospace craft 20 carrying crew 17 is not a real craft but a flight simulator.
In general, in a flight simulator, since the noises or vibrations caused by the engine in a real aerospace craft can be eliminated, it is practical to use loudspeakers as devices for outputting localized sound in the invention. The technology to use loudspeakers as sound-output devices has been disclosed by the literatures mentioned above.
Embodiments disclosed here are some examples out of many to explain the invention. For instance, though DSP for use in signal processing is a processor mainly for calculating sound signal, MPU(Micro Processor Unit) for use in general calculating can be used to perform signal processing in stead of DSP. Then, as a substitute for ROM(Read Only Memory) or RAM(Random Access Memory) which is suitable for storing sound data as a memory means, a hard disc unit or an optical disc unit may be used if necessary, and moreover, in order to allow various expressions such as, "an angle of 270 degrees", "30 degrees right", "4 o'clock position" or "north-northeast" in explaining an azimuth angle, the scope of the invention should not be restricted by the words and expressions used to describe the embodiments of the invention. Besides, as this invention may be embodied in several forms without departing from the spirit of essential characteristics thereof, the present embodiment is therefore illustrative and not restrictive, since the scope of the invention is defined by the appended claims rather than by the description preceding them, and all changes that fall within meets and bounds of the claims, or equivalence of such meets and bounds are therefore intended to embraced by the claims. | The direction of a target is determined relative to the facial direction of a crew of an aerospace craft and a localized sound is produced in this direction. This localized sound is then output binaurally to the crew to provide an indication of the location of the target. This use of localized sound allows the crew to rapidly locate targets while reducing eye strain. Pseudo-targets can also be located in a flight simulator. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a servo circuit used for a video tape recorder (VTR), and particularly relates to a digital capstan servo circuit.
2. Description of the Prior Art
In general, a capstan servo circuit for a VTR is formed of a rotation speed servo system and a rotation phase servo system. Of the rotation phase servo systems used for the VTR, particularly the rotation phase servo system in a reproducing mode is controlled in such a manner that a control pulse (CTL) having the frequency of 30 Hz recorded on tracks of a tape is reproduced and then this control pulse becomes coincident with an inner reference signal. Although such servo technique is disclosed in detail in, for example, U.S. Pat. No. 4,242,619, such servo technique will hereinafter be described briefly.
FIG. 1 is a block diagram showing an example of a conventional digital capstan servo circuit including a rotation speed servo in the recording system when such rotation phase servo is performed.
In the figure, reference numeral 10S generally designates a rotation speed servo system and reference numeral 10P a rotation phase servo system. A rotation signal FG proportional to the revolution speed of a capstan is generated from a frequency generator mounted to a flywheel of the capstan though not shown. The rotation signal FG is supplied through a terminal 1 to a gate circuit 2 for a clock signal CK 1 and the gate time for the clock signal CK 1 is controlled in response to the rotation speed of the capstan.
The clock signal CK 1 thus gated through the gate circuit 2 is supplied to a counter 3 which measures the rotation speed of the capstan and in which a counter output corresponding to the rotation speed of the capstan is formed. This counter output is supplied to a PWM (pulse width modulation) signal generator 4 as a PWM signal and a PWM output proportional to the rotation speed of the capstan is formed by the PWM signal generator 4. The PWM output is smoothed by a low pass filter 5 and then supplied through an amplifier or driver circuit 6 to a capstan motor 7 as a rotation speed control signal.
On the other hand, the rotation phase servo 10P is a constant phase servo which performs such a servo that the rotation phase of the capstan is locked to the phase of the inner reference signal.
As is known well, the capstan is provided with a pulse generator (not shown) from which a pulse signal PG indicative of the rotation phase of the capstan is generated. This pulse signal PG is supplied through a terminal 11 to a flip-flop 12 which will generate a gate pulse. And, an output from a reference signal oscillator 13 is supplied to a frequency divider 14 which then generates a reference signal PR having the frequency same as that of the pulse signal PG and a reference phase. This reference signal PR is supplied to the flip-flop 12 which thus generates a gate pulse corresponding to a phase difference between the signals PR and PG.
Consequently, an AND gate 16 delivers a clock CK 2 during only the period in which the above gate pulse is supplied thereto. The clock CK 2 delivered from the AND gate 16 is fed to a rotation phase measuring counter 17 to drive it. The counter output is supplied to a PWM signal generator 18 as a PWM signal, thus forming a PWM output corresponding to the rotation phase.
This PWM output is smoothed by a low pass filter 19 and then supplied to the capstan motor 7 as a rotation phase control signal similarly as mentioned above. Thus, the phase servo operation is performed in such a way that the rotation phase of the capstan is locked to the phase of the reference signal PR.
Reference numeral 20 designates an adder or mixer which adds the rotation phase control signal and the rotation speed control signal together.
As set forth above, according to the conventional capstan servo circuit, the rotation speed servo system 10S and the rotation phase servo system 10P are wholly formed independently.
Recently, such a phase servo system is proposed in which a pilot signal being frequency-multiplexed on a video signal is reproduced and this reproduced pilot signal is used as a reference signal for the tracking in a reproducing mode to control the revolution speed of the capstan motor to thereby perform the rotation phase servo.
First to fourth pilot signals S P1 to SP 4 of single frequency (shown in FIG. 2), which are each constant in frequency interval and whose frequencies become high sequentially, are used as the above pilot signal. In order to record one pilot signal on one track being recorded, the first to fourth pilot signals S P1 to S P4 are sequentially frequency-multiplexed on the video signal and then recorded thereon at every fields. Thus, as shown in FIG. 2, frequencies f 1 to f 4 of the pilot signals S P1 to S P4 recorded on the tracks T 1 to T 4 which adjoin to one other become different from one other.
A track width T p in a reproducing mode is wider than a track width T R in a recording mode (see FIG. 3). Then, if as shown in FIG. 3 the crosstalk component of the pilot signals S P1 and S P3 from the adjoining tracks T 1 and T 3 upon playback mode is detected and the rotation speed of the capstan motor is controlled in such a manner that the levels of the pilot signals S P1 and S P3 may become equal to each other, the reproducing tracking can be established and thereby the rotation phase servo system of the capstan in the reproducing mode can be realized.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved digital servo circuit which can obviate the afore-mentioned defects inherent in the conventional capstan servo circuit.
It is another object of the present invention to provide a digital capstan servo circuit capable of simplifying the circuit configuration by common use of servo system and improving the servo characteristic.
It is a further object of the present invention to provide a digital capstan servo circuit capable of reducing the duration of phase lock time by generating a predetermined phase control signal to be held.
It is a yet further object of the present invention to provide a digital capstan servo circuit suitable for use with a video tape recorder (VTR).
According to one aspect of the present invention, there is provided a digital capstan servo circuit used for controlling a rotation of a capstan motor of a magnetic recording apparatus having a recording circuit for recording a plurality of pilot signals mixed with a video signal on video tracks instead of control (CTL) pulses used for a tracking servo circuit in a reproducing mode comprising:
(a) means for generating FG pulses in response to the rotation of said capstan motor;
(b) means for generating clock pulses;
(c) means for generating a window pulse from said FG pulses;
(d) means for counting said clock pulse during the period in which said window pulse is generated and said counter means is self reset during said period;
(e) means for generating a first latch pulse from said FG pulses used for latching a first counting value of said counting means at a first timing position for obtaining a rotation speed information;
(f) means for generating a second latch pulse used for latching a second counting value of said counting means at a second timing position for obtaining a rotation phase information; and
(g) means for producing a control signal by mixing said first and second counting values.
The other objects, features and advantages of the present invention will become apparent from the following description taken in conjunction with the accompanying drawings through which the like references designate the same elements and parts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a previously proposed digital capstan servo circuit;
FIGS. 2 and 3 are respectively track patterns used for explaining the present invention;
FIG. 4 is a block diagram showing an embodiment of a digital capstan servo circuit according to the present invention;
FIGS. 5A to 5G are respectively timing charts for explaining the operation of the digital capstan servo circuit shown in FIG. 4;
FIG. 6 is a block diagram showing an example of a speed and phase control circuit used in the digital capstan servo circuit shown in FIG. 4;
FIG. 7 is a diagram of a practical circuit showing parts of the example shown in FIG. 6;
FIGS. 8A to 8F and FIGS. 9A to 9D are respectively timing charts used for explaining the operation of the circuit shown in FIGS. 6 and 7;
FIG. 10 is a block diagram showing another embodiment of the digital capstan servo circuit according to the present invention; and
FIG. 11 is a block diagram showing a further example of the invention which is applied to a servo circuit of a PWM system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be described hereinafter with reference to the attached drawings.
Firstly, in the digital capstan servo circuit according to the present invention, a rotation signal and a counter are used common and this common counter is operated in time sharing manner so that a rotation speed control signal and a rotation phase control signal can be provided.
To this end, in accordance with the present invention, the speed and phase control systems for the rotating member are partially constructed in the digital fashion and the means or circuit which generates the phase control signal on the basis of the output from the counter to be controlled by the phase signal of the rotating member is associated with the mean value setting means or circuit of the phase control signal so that the mean value setting circuit is being operated until the speed of the rotating member reaches a range of predetermined speed. More particularly, the capstan servo circuit is provided with the servo loop by which the rotation speed and the rotation phase of the capstan motor coincide with the reference speed and the reference phase, respectively. In this case, until the speed servo loop becomes stable, the phase servo loop is held at a certain constant value. And, after the speed servo loop becomes stable, the phase servo loop is operated to effect the phase servo.
The value of the phase control signal to be held is set to a lower or upper limit value of the dynamic range of the phase servo system. Meanwhile, the phase lock point in the phase servo circuit is set to a point near the center of the dynamic range of the phase servo circuit. Thus, when the phase servo operation is started, the phase has to always be pulled in from the endmost point so that it takes a considerably extra time to lock the phase.
For this reason, in such case, the value of the phase control signal to be held is preferably set to the intermediate value of the dynamic range.
Now, an embodiment of the present invention will be described in detail with reference to FIGS. 4 to 9.
FIG. 4 is a systematic block diagram showing an embodiment of the digital capstan servo circuit according to the present invention. In FIG. 4, reference numeral 10 generally designates a digital capstan servo circuit. The above rotation signal FG (see FIG. 5A) is applied to a terminal 1. A monostable multivibrator 21 is triggered by this rotation signal FG to thereby produce a multi-output M 1 shown in FIG. 5B. This multi-output M 1 is supplied to an AND gate 22 as a gate pulse thereof. Accordingly, since a clock CK is supplied from the AND gate 22 to a counter 3 of the next stage during only a period T M shown in FIG. 5B, the counter 3 is operated during only the period T M .
When the rotation speed of the capstan (not shown) is in the stable state, namely, the rotation signal FG having the period T F shown in FIG. 5A is applied to the terminal 1, the counter 3 is so selected that the counting operation of the counter 3 becomes overflow at least once. According to this embodiment, the counter 3 becomes overflow at approximately every 2/3T F and then starts the counting operation again. Thus, the final count output generated from the counter 3 at that time becomes exactly half the maximum value of the count output.
FIG. 5D shows a waveform of this count output which is converted to the form of an analog output.
The count output from the counter 3 is supplied to first and second latch circuits 24A and 24B and respectively stored or latched therein in response to first and second latch pulses P LS and P LP , which are generated at predetermined different timings as will be described later. The latch outputs from the first and second latch circuits 24A and 24B are respectively supplied to first and second D/A (digital-to-analog) converters 25A and 25B thereby converted to the form of analog outputs. Since the first latch output corresponds to the rotation speed control signal and the second latch output corresponds to the rotation phase control signal as will be described later, the above analog outputs are the rotation speed control signal and also the rotation phase control signal.
These control signals are supplied to a capstan motor 7 similarly as described above.
Reference numeral 27 designates a latch pulse generating circuit which generates the first latch pulse P LS (see FIG. 5C). In this embodiment, the first latch pulse P LS is formed on the basis of the rotation signal FG. The first latch pulse P LS is generated in response to the interval during which the multi-output M 1 is at "0", so that the data from the counter 3 is latched in the latch circuit 24A in the interval during which the above multi-output M 1 is at "0".
The rotation signal FG corresponds to the rotation speed of the capstan, the multi-output M 1 for gating the AND gate 22 is obtained in synchronism with this rotation signal FG, and the first latch pulse P LS is also obtained in synchronism with the rotation signal FG and the multi-output M 1 . Then, if the final count output of the counter 3 within the one period T F of the rotation signal FG is latched by the first latch pulse P LS , the first latch output changes in response to the rotation speed of the capstan so that the first latch output becomes the output proportional to the rotation speed of the capstan. As a result, the first analog output can be used as the rotation speed control signal.
After the first latch pulse P LS is obtained, the counter 3 is reset and starts the counting operation at the rising-up or leading edge of the next multi-output M 1 .
Reference numeral 28 designates a latch pulse generating circuit which generates the second latch pulse P LP (see FIG. 5G). In this embodiment, the second latch pulse P LP is formed in such a manner that the oscillatory output from an oscillator 13 is frequency-divided to a predetermined frequency by a frequency divider 29 and then fed to the latch pulse generating circuit 28. In this case, the predetermined frequency is selected to be the same as that of the rotation signal FG, which is selected as the frequency of about 1 kHz in this embodiment. The above frequency-divided output is shifted by a predetermined phase, namely, so as to have a phase difference of approximately π/4 relative to the phase of the rotation signal FG obtained when the rotation speed of the capstan is locked and further, so as to have the similar phase difference of π/4 relative to the phase of the first latch pulse P LS to thereby produce the second latch pulse P LP .
The reason why the above phase relation is selected is as follows. As will be clear from FIG. 5, the resultant count output at this phase relation is selected to be exactly near the half of the maximum value. Thus, the lock point of the phase can be set to approximately the center of the phase lock range.
In this case, the phase of the second latch pulse P LP is the fixed phase.
When the relation between the frequency and phase of the second latch pulse P LP is selected as described above, the second latch pulse P LP is generated during the period in which the first count output within one period T F is overflown so that the count output at that time is latched in the second latch circuit 24B. When the rotation phase of the capstan is not in such a relation as shown in the figure, the counter output latched by the second latch pulse P LP is different. Thus, the second latch output becomes the signal corresponding to the rotation phase of the capstan so that the analog output from the second D/A converter 25B can be used as the rotation phase control signal. Consequently, the rotation phase of the capstan is controlled in such a manner that the phase difference φ between the rotation signal FG and the second latch pulse P LP shown in FIGS. 5A and 5G may become constant without fail.
Reference numeral 30 designates an out-of-lock range detecting circuit which detects whether the count content of the counter 3 is within the lock range or not. When that count content is out of the above lock range, the out-of-lock range detecting circuit 30 respectively controls the latch circuits 24A and 24B independently with the result that in, for example, the rotation speed servo system, the signal waveform becomes a ramp waveform as shown in FIG. 5E, while in the rotation phase servo system, the signal waveform becomes a ramp waveform as shown in FIG. 5F.
As set forth above, with the digital capstan servo circuit 10 in which the pilot signal frequency-multiplexed on the video signal is reproduced and then is employed as the reference signal for the reproducing tracking the frequency of the rotation phase signal for the capstan utilized for the phase servo in a recording mode can be made arbitrary. Therefore, if the latch timing and the latching order of the first and second latch circuits 24A and 24B are determined, the counter 3 can be used in time sharing manner so that the rotation speed and the rotation phase can be measured by only the rotation signal FG and the single counter 3 without being influenced with each other.
The timings of the above first and second latch pulses P LS and P LP are in synchronism with the timing of the clock signal CK which is supplied to the counter 3.
The number of the overflow of the counter 3 within one period T F , namely, the number of idlings is not limited to once as mentioned above. When the counter 3 which performs the idling N times (N is positive integer) per one period T F is utilized, arbitrary one ramp waveform is used as the ramp waveform for the rotation phase control.
When the number of the idling is twice or more, it is possible to make the quantization of the rotation phase rough and then to widen the lock range or while to maintain quantization unchanged, to widen the lock range.
As described above, according to the digital capstan servo circuit of the invention wherein the pilot signal frequency-multiplexed on the video signal is reproduced and used as the reference signal for the playback tracking, since the circuit is used common, the circuit can be simplified much as compared with the conventional capstan servo circuit. In addition, since the sampling period of the rotation phase can be selected to be the same as the sampling period of the rotation speed, the servo characteristic of the rotation phase can be improved greatly.
FIG. 6 is a block diagram showing an example of the speed and phase control circuit 10 used in the digital capstan servo circuit shown in FIG. 4. Reference numeral 10A designates a speed servo system and 10B a phase servo system. In this case, a rotating member to be controlled is a capstan though not shown. Reference numeral 101 designates a capstan motor which is provided with a frequency generator (FG) and a rotation phase signal generator (PG) though not shown. The frequency generator (FG) and the rotation phase signal generator (PG) respectively generate a speed signal (square wave signal) proportional to the rotation speed of the capstan motor 1 and a rotation phase signal (pulse signal) associated with the rotation phase thereof.
In the speed servo system 10A, reference numeral 2A designates a counter supplied with the clock CK and measuring the rotation speed of the capstan motor 101 and 3A a latch circuit for latching the counter output. A set pulse P SS for the counter 2A is formed on the basis of, for example, the rising-edge or leading edge of the speed signal, while a latch pulse (strobe pulse) P LS for the latch circuit 3A is formed on the basis of, for example, the falling-edge or trailing edge of the speed signal. Thus, the counter output proportional to the rotation speed of the capstan motor 101 is latched in the latch circuit 3A, converted to a predetermined analog speed control signal by a D/A converter 4A and then supplied through a drive amplifier 105 to the capstan motor 101.
When the rotation speed of the capstan motor 1 is deviated largely from the reference speed, the output from the counter 2A becomes overflow.
When the output of the counter 2A is in overflow state, the counter output has to be held at a value just before the counter 2A becomes overflow. To this end, the counter 2A is provided with an overflow detection and control circuit 6A.
In the phase servo system 10B, there are provided a counter 7B supplied with the clock CK and measuring the rotation phase of the capstan motor 101 and a latch circuit 8B similarly as in the speed servo system 10A. The counter 7B is set by a rotation phase reference signal P SP (pulse signal having the same period as that of the rotation phase signal). The counter output is latched in the latch circuit 8B in response to a latch pulse P LP which is based on the rotation phase signal. The latch output proportional to the rotation phase difference is converted to an analog phase control signal S P by a D/A converter 9B and then supplied to the capstan motor 101 together with the above speed control signal S S , to perform such control that the rotation phase of the capstan motor 101 is locked to the reference phase. Reference numeral 111 designates an adding circuit or mixer by which both of the analog phase control signal S P and the speed control signal S S are added together and then supplied to the capstan motor 101 through the drive amplifier 105.
The counter 8B and the D/A converter 9B constitute a phase control signal generating means or circuit 12B. And, particularly in this example, there is provided an intermediate value setting means or circuit 15B for the phase control signal S P in association with the phase control signal generating circuit 12B. According to this example, a set circuit which forcibly sets the latched data in the latch circuit 8B to the data of intermediate value of the maximum latch data is used as the above intermediate value setting circuit 15.
FIG. 7 is a diagram showing an example of the latch circuit 8B and the set circuit 15B used as the intermediate value setting circuit shown in FIG. 6.
The example of the latch circuit 8B shown in FIG. 7 is such one which latches the counter output of N+1 bits (N is a positive integer). Gate circuits 16 a to 16 n and flip-flops 17 a to 17 n are respectively provided to correspond to bits each. Each of the gate circuits 16 a to 16 n is formed of a pair of NAND gates 118 and 119 to which the latch pulse P LP and data (data of N+1 bits) being gated thereby are supplied.
Each of the flip-flops 17 a to 17 n , excepting the flip-flop 17 n corresponding to the most significant bit (MSB), is formed of a pair of 3-input NAND gates 120 and 120' and therefore a set pulse P S and a reset pulse P R are supplied in addition to the outputs from the gate circuits 16 a to 16 n-1 to each of the flip-flops 17 a to 17 n-1 . The set pulse P S serves to set each output from the flip-flops 17 a to 17 n-1 to "1", while the reset pulse P R serves to set each of them to "0". The set and reset pulses P S and P R are both the control signals which perform such control that when the output from the counter 7B is converted to the form of analog signal, it has a waveform (ramp waveform) suitable for controlling the rotation phase as will be described later.
The set circuit 15B is associated with the flip-flop 17 n which corresponds to the most significant bit. The set circuit 15B comprises an inverter 121 and a NAND gate 122 as shown in FIG. 7, and a pulse P C shown in FIG. 8C is supplied to the inverter 121. The pulse P C is such a pulse which indicates whether the rotation speed is within the speed lock range or not. In this example, the output from the decoder (not shown) provided within the overflow detection and control circuit 6A (see FIG. 6) is used as the pulse P C . More specifically, the pulse P C is formed of a speed pulse P U (see FIG. 8A) which is obtained when the rotation speed is considerably higher than the speed in the lock range and a speed pulse P D (see FIG. 8B) which is obtained when the rotation speed is considerably lower than the speed in the lock range. Thus, the pulse P C regarding the rotation speed is obtained by supplying both the pulses P D and P U through an OR gate 25A (see FIG. 6). In this pulse P C , the interval T N designates the interval out of the lock range and T L the lock range interval.
A NAND output of a pulse P C (see FIG. 8D) having the phase inverted and a reset pulse P R (see FIG. 8F) from the NAND gate 122 is supplied to one NAND gate 123 which comprises the flip-flop 17 n with other NAND gate 124, and the inverted pulse P C from the inverter 121 is supplied to the other NAND gate 124.
The operation of the latch circuit 8B including the set circuit 15B will be described next. The set pulse P S and the reset pulse P R are selected to have polarities shown in FIGS. 8E and 8F when the rotation speed is out of the lock range, namely, in the interval T N . Therefore, during the interval T N , the outputs from the least significant bit (LSB) of the flip-flop 17 a to the MSB-1 of the flip-flop 17 n-1 all become "0".
Although the output (NAND output) from the set circuit 15B is at "H" level (high level) during the above interval T N , the pulse P C having the phase inverted is "0" so that one input of the 4-input NAND gate 124 becomes "0", thus the output of the flip-flop 17 n being made as "1". That is, in the interval T N where the rotation speed is out of the lock range, only the MSB bit becomes at "1" so that data having the dynamic range half that of the latch circuit 8B is set by the set circuit 15B. Accordingly, the phase control signal S P has the level half the maximum control level.
In the interval T L wherein the rotation speed is within the lock range, the phase of the pulse P C is inverted. Thus, the flip-flop 17 n for the MSB is released from its locked state and the polarities and pulse widths of the set pulse P S and the reset pulse P R are selected in such a manner that the output which results from converting the output of the counter 7B to the analog form may have the ramp waveform as shown in FIG. 9A. In this case, since the set pulse P S and the reset pulse P R both become at "1" during the ramp interval T RL (see FIG. 9D), the latch operation for the data of N+1 bits is carried out in response to the latch pulse P LP .
As described above, since the level of the phase control signal S P when the rotation speed is out of the lock range is made half the maximum amplitude, when the rotation speed becomes within the lock range and thereby the phase servo system is released from its locked state, the phase servo is started to get effective at the phase control signal S P having the level half the maximum amplitude, thus the phase-lock time of the phase servo being reduced. In other words, the pull-in speed of phase becomes high.
In the digital capstan servo circuit which performs the phase servo operation in the digital manner, since the set and reset pulses P S and P R shown in FIGS. 8 and 9 have been used, they do not have to be formed newly and hence the above operation can be carried out by the addition of the set circuit 15B and few other circuits.
FIGS. 10 and 11 are respectively block diagrams showing other embodiments of the digital capstan servo circuit according to the present invention.
FIG. 10 shows an example of the digital capstan servo circuit wherein a measuring counter is used common. In this case, if it is arranged such that the speed control ramp waveform and the phase control ramp waveform may not be overlapped to each other, one counter, for example, the rotation speed measuring counter 2A can be also used as the phase measuring counter. The configuration for the circuit of the above counter being used common is not directly concerned with the subject matter of the present invention and therefore its detailed description will not be made.
Also, in this embodiment, it is sufficient that the set circuit 15B is associated with the latch circuit 8B.
FIG. 11 shows a further example of the digital capstan servo circuit according to the present invention which is applied to the PWM type servo system, and an example of the phase servo circuit. In example of the figure, a clock CK to be supplied to a counter 7B is controlled by a gate pulse P G formed of the rotation phase signal and the reference phase signal. The counter output from the counter 7B is transferred to a memory 130 and the most significant bit of the counter output thus transferred is read out from the memory 130 to thereby allow a flip-flop 131 to be set. Then, the flip-flop 131 is reset by an inverted pulse CK 0 which results from inverting a clock CK 0 having the same bit period as the most significant bit by an inverter 132.
Since the timing at which the most significant bit is obtained changes depending on the counter output from the counter 7B, the set timing of the flip-flop 131 becomes different whereby the pulse width of the clock CK 0 is modulated. Thus, if the clock pulse CK 0 is supplied through a low-pass filter 133, a phase control signal S P corresponding to the rotation phase of the capstan motor 1 is formed.
In the rotation phase servo circuit according to the PWM system as described above, since the memory 130, the flip-flop 131 and the low pass filter 133 constitute the phase control signal generating means or circuit 12B, the intermediate value setting means or circuit 15B is provided in association with this phase control signal generating circuit 12B.
In this embodiment, the intermediate value setting circuit 15B is formed of logic gates. The mean value setting circuit, or the logic gate 15B is formed of first and second AND gates 141 and 142 and an OR gate 143. The first AND gate 141 serves to gate the output data from the memory 130, and a pulse P C resulting from inverting in phase the pulse P C by an inverter 144 is used as the gate pulse thereof. Meanwhile, the second AND gate 142 serves to gate the clock CK 0 , and the pulse P C is used as the gate pulse thereof. The OR output of the first and second AND gates 141 and 142 from the OR gate 143 is used as the set pulse for the flip-flop 131.
With the mean value setting circuit 15B arranged as described above, when the rotation speed enters into the lock range (the interval T L as shown in FIG. 8D), the first AND gate 141 is opened and the flip-flop 131 is set by the output data from the memory 130 so that the same rotation phase servo as mentioned above is carried out. And, in the interval T N (see FIG. 8D) during which the rotation speed is out of the lock range, the second AND gate 142 is opened so that the flip-flop 131 is set and/or reset by the pulse CK 0 of the constant period and hence the flip-flop 131 generates the pulse having the duty, 50%. Since the pulse output having the duty, 50% becomes the analog output having approximately the intermediate value of the dynamic range, the same effect as described above can be achieved.
With the present invention, the rotating member is not limited to the above capstan but can be other rotating member such as a rotary drum and so on.
As described above, according to the present invention, the predetermined phase control signal to be held can be obtained by the circuit of relatively simple configuration so that the phase-lock time can be reduced as was desired.
The above description is given on the preferred embodiments of the invention, but it will be apparent that many modifications and variations could be effected by one skilled in the art without departing from the spirits or scope of the novel concepts of the invention, so that the scope of the invention should be determined by the appended claims only. | A digital capstan servo circuit controls the rotation of a capstan motor used for sending a recording medium of a recording apparatus having a recording circuit for recording a plurality of pilot signals instead of CTL signals used for a tracking servo of the capstan motor in a reproducing mode. The pilot signals have different frequencies respectively and are recorded under being mixed with a video signal on video tracks. In the recording mode, a rotation speed information obtained from a counter of which a counting value is latched by a latch pulse produced from FG signals which are generated synchronously with the capstan motor and a rotation phase information obtained from the counter of which a counting value is latched by a latch pulse produced from an oscillator, an output signal of the oscillator having the same frequency as that of but a different phase from as that of the FG signals, are mixed to be a control signal of the capstan motor. | 7 |
BACKGROUND
The present invention relates to text spacing adjustment for desktop publishing. During desktop publishing of an electronic text, characters of the text are composed into lines, and in each line, spacings are set between adjacent characters. In general, each character has a default spacing value. Default spacing values, however, are only provisional, and spacings can be adjusted during line composition. A different spacing can be set according to the attributes of the text or intentions of a user. For example, the required spacing can depend on one or more of the following: the position of a character in a line or in a word, the preceding and following characters, line justification, language environment, and aesthetic considerations. In texts with Roman characters, a spacing adjustment technique typically uniformly rescales spacings in a line of characters, for example, based on the total number of characters or words in the line. Alternatively, local spacings can be manually changed by a user. In texts with Japanese characters, however, spacings typically follow the guidelines of a government-issued JIS document 4051 for Japanese line composition. According to these guidelines, spacings are based on pre-defined classifications of Japanese characters. When adhering to this classification, each spacing is adjusted individually, because the adjustment depends on the character classes corresponding to the characters preceding and following the spacing.
SUMMARY
In general, in one aspect, this invention provides method and apparatus, including computer program products, implementing and using techniques for adjusting spacing between characters in a line of text. The method includes specifying a plurality of character classes based on user input. A character class from the plurality of character classes is assigned to a character of a pair of characters in the line. Spacing between characters of the pair of characters is adjusted based on the assigned character class.
Advantageous implementations of the invention can include one or more of the following features. A plurality of rules for adjusting spacing between characters of the pair of characters can be defined based on the assigned character class. A priority can be assigned to a rule of the plurality of rules. The priority can characterize a preference to apply the rule of the plurality of rules. A rule of the plurality of rules can define one or more of the following: optimal spacing, maximum compression, and maximum expansion. The plurality of rules can be defined based on user input. A character of the pair of characters can be a Roman character. Spacing between characters of the pair of characters can be adjusted based on a character attribute. The character attribute can include one or more of the following attributes: font face, font type, and font size. Spacing between characters of the pair of characters can be adjusted based on a language environment. A character class in the plurality of character classes can be assigned to a character of the pair of characters based on user input.
In general, in another aspect, this invention provides method and apparatus, including computer program products, implementing and using techniques for selecting rules for spacing adjustment in a line of text. The method includes assigning a character class to a character of a pair of characters in a line of text. A rule from a plurality of rules is selected based on the assigned character class. Each rule in the plurality of rules is operable to adjust spacing between characters of the pair of characters.
Advantageous implementations of the invention can include one or more of the following features. Selecting a rule from the plurality of rules can include assigning priorities to rules of the plurality of rules. The priorities can characterize preferences to apply rules of the plurality of rules.
In general, in another aspect, this invention provides method and apparatus, including computer program products, implementing and using techniques for evaluating a line layout. The method includes selecting a set of rules for adjusting spacing between characters in a line of text. The set of rules includes a plurality of rules operable to adjust spacing between characters of a pair of characters. Each rule in the set of rules has a priority. A line layout of the line is evaluated based on the priorities of the rules of the set of rules.
Advantageous implementations of the invention can include one or more of the following features. A paragraph containing the line can be formatted based on the line layout evaluation.
In general, in another aspect, this invention provides method and apparatus, including computer program products, implementing and using techniques for adjusting spacing between characters of a pair of characters in a line of text. The method includes providing a plurality of rules. Each rule of the plurality of rules is operable to adjust spacing between characters of the pair of characters. Each rule of the plurality of rules has a priority. A preferred rule from the plurality of rules is selected based on the priority of the preferred rule. The preferred rule is applied to adjust spacing between characters of the pair of characters.
Advantageous implementations of the invention can include one or more of the following features. A priority level can be provided for selecting a preferred rule from the plurality of rules. Each rule of the plurality of rules can have a different priority. A preferred rule can be selected from the plurality of rules based on character attributes.
In general, in another aspect, this invention provides a spacing adjustment device for line composition in a desktop publishing device. The spacing adjustment device includes a user input receiving device, a character classification device, and a rule defining device. The character classification device is operable to provide a plurality of character classes based on user input. User input is received by the user input receiving device. The rule defining device is operable to provide a plurality of rules. The rules of the plurality of rules are operable to adjust spacing between characters in a line of text based on character classes.
Advantageous implementations of the invention can include one or more of the following features. The spacing adjustment device can include a prioritization device. The prioritization device is operable to assign priorities to rules in the plurality of rules.
The invention can be implemented to realize one or more of the following advantages. Spacing adjustment rules for electronic line composition can be easily specified when spacing rules are based on character classes. Character classes can be defined (e.g., by the user) in a very flexible manner. A character class can be based on character values, on one or more attributes that can be associated with a character, or on a combination of character values and character attributes. Character class-based rules allow the user to automatically and individually adjust each spacing between adjacent characters in a line. Different spacing rules can be defined for different language environments. When each spacing is individually addressed, spacing can be adjusted based on character attributes, such as font size, font face or font type. Character classes can be defined based on one or more of the attributes. More than one spacing rule can be provided for adjusting the same spacing in a line. More than one rule can be generated implicitly through the character classification, or explicitly by user definition. The spacing rules can be prioritized by the user or by an appropriate device. The priorities of the spacing rules allow the user to control electronic line composition. The user can set a priority level to select spacing rules with a particular priority. The selected spacing rules can be used to adjust spacings in a line or to evaluate a line layout. This line layout evaluation can be used to compose paragraphs.
The details of one or more implementations of the invention are set forth in the accompanying drawings and the description below. Other features and advantages of the invention will become apparent from the description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram of a desktop publishing system.
FIG. 2A is a schematic block diagram of a spacing adjustment device according to an implementation of the invention.
FIG. 2B is a flowchart showing an implementation of class-based spacing adjustment in accordance with the invention.
FIGS. 3A , 3 B, and 3 C are schematic block diagrams showing how character classes, rules, and priorities can be implemented for spacing adjustment in accordance with the invention.
FIG. 4 is a flowchart showing an implementation of a method for adjusting spacing between adjacent characters in a line in accordance with the invention.
FIG. 5 is a flowchart showing a method for calculating line parameters according to an implementation of the invention.
FIG. 6 is a flowchart showing a method for selecting rules for line justification according to an implementation of the invention.
Like symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
As shown in FIG. 1 by a schematic block diagram, a desktop publishing system 100 can be operated in accordance with an implementation of the invention. The desktop publishing system 100 features a desktop publishing device 10 , a display device 120 , an input device 130 , and an output device 140 . The desktop publishing device 110 can be implemented, for example, in a computer program for formatting an electronic text for publishing, as described below. The formatted electronic text can be displayed on the display device 120 , for example a computer screen, for interaction with a user. The user can give instructions and other data to the desktop publishing device by the input device 130 , for example, a keyboard or a computer mouse. The instructions and data can be used to influence the text composition and, in particular, spacing adjustment. The composed text can be sent to the output device 140 , for example, a printer.
The desktop publishing device 110 includes a composition device 112 that can compose lines and paragraphs from characters of an electronic text contained in an electronic document 116 . The composition device 112 uses fonts stored in a font data file 118 to represent the characters of the electronic text. The characters are composed into lines by a line composition device 113 and the lines are composed into paragraphs by a paragraph composition device 114 . During line composition, a spacing adjustment device 115 can adjust spacings between adjacent characters in a line.
As shown in FIGS. 2A and 2B , an implementation 115 ′ ( FIG. 2A ) of the spacing adjustment device 115 can adjust spacings between adjacent characters in a line, for example, as implemented by a method 200 ( FIG. 2B ). The implementation 115 ′ includes a user input receiving device 210 , a character classification device 220 , a rule defining device 230 , a prioritization device 240 , and spacing adjustment means 250 . These devices and means perform the steps of the spacing adjustment method 200 as explained below with reference to FIG. 2 and FIG. 3 .
The user input receiving device 210 first receives user input (step 255 ) from a user, for example, through the input device 130 . The character classification device 220 then specifies character classes based on the received user input (step 265 ). A character class is a user-defined set of one or more characters. As used herein, “character” refers to the general concept of a letter, number, symbol, ideograph or the like, without reference to its particular appearance (e.g., a particular font). The characters in a character class can, but are not required to, share one or more common features. These features can include a character value, for example, a Unicode or ASCII code value representing a particular character, or a character attribute, such as font face, a font type, and a font size. Although characters having different features can be members of the same character class or classes, character classes are preferably defined such that each instance of a character that shares a common set of features (e.g., the same character value and the same attribute values for a given set of character attributes) belongs to the same character class or classes.
The character classification device 220 can specify character classes based on user input. In the user input, the user can, for example: list characters that are part of or excluded from a certain character class; select character attributes that specify a character class; or select a pre-defined character class from a menu. The user can select a language environment (e.g., “American English”, “French”, or the like) for which a set of character classes has already been specified. According to the user input, the character classification device 220 can specify a set of character classes 221 that classify all or only certain characters of the electronic text. A particular character can be a member of only one character class, or belong to more than one character class.
Next, the character classes 221 are used by the rule defining device 230 to define spacing rules 231 for spacing adjustment (step 275 ). Optionally, the rule defining device 230 can define or alter the spacing rules 231 based on user input received, for example, by the user input receiving device 210 in step 255 . In one implementation, the spacing rules 231 are described by one or more of the following rule parameters for adjusting a spacing between adjacent characters: an optimal spacing that describes a desired spacing other than the default spacing; a maximum compression that characterizes the minimum spacing; or a maximum expansion that characterizes the maximum spacing. The spacing rules 231 can adjust the spacing between two characters so that the adjustment depends on the character classes of the preceding character, the following character, or both characters on either side of the spacing. The character-class dependence can be used to group the spacing rules 231 into sub-groups. A sub-group can, for example, include spacing rules that adjust the spacing between members of two character classes. A sub-group of the spacing rules 231 can contain one or more spacing rules.
A prioritization device 240 then assigns priorities 241 to the spacing rules 231 (step 285 ). In particular, if a sub-group has two or more associated spacing rules, the assigned priorities can be used to select what spacing rule to apply during spacing adjustment, for example, as described with reference to FIG. 6 . The priorities 241 can include one or more of the following priorities: an optimal priority that sets a spacing to an optimal spacing; a first priority that adjusts spacing to close to optimal spacing; a second, third, and so on, priorities that describe an order of decreasing preference for using the spacing rules 231 . Optionally, the prioritization device 240 can assign the priorities 241 to the spacing rules 231 based on user input, received, for example, in step 255 by the user input receiving device 210 . Finally, spacings in a line are adjusted (step 295 ), as will be discussed in detail below with reference to FIG. 4 .
FIGS. 3A–3C illustrate an exemplary implementation of character classification and prioritization. In this example, as shown in FIG. 3A , three character classes are defined. A space class 322 , denoted by ‘ ’, has only one member (the space character). A non-space characters class 323 , denoted by ‘X’, includes all characters but the space character. A period class 324 , denoted by ‘.’, has only one member (the period character itself). The character classes 322 – 324 classify all characters of an electronic text, because the non-space characters class 323 includes all non-space characters. In particular, the non-space characters class 323 also includes the period character that is a member of the period class 324 as well.
As shown in FIG. 3B , in an exemplary implementation, spacing rules are divided into two sub-groups. A sub-group 332 contains spacing rules for adjusting spacing between a member of the non-space characters class 323 followed by a member of the space character class 322 . A sub-group 333 contains spacing rules for adjusting spacing between two members of the period class 324 . Spacing rules 332 A, 332 B, and 333 B are described by a maximum compression rule parameter (column “Comp.” in FIG. 3B ) and a maximum expansion rule parameter (column “Exp.” in FIG. 3B ). Spacing rule 333 A only has a maximum expansion rule parameter. These rule parameters describe the maximum compression or expansion of a spacing. In the example shown in FIG. 3B , the numbers represent fractions of the width of a space character. For example, if a non-space character is followed by a space character, the spacing rule 332 A allows that the space character be compressed by 20%, or expanded by 33% of the space character width of the selected font.
In an example of prioritization, illustrated in FIG. 3C , priorities are assigned to the spacing rules 332 A– 333 B: the spacing rule 333 A has optimal priority, the spacing rule 332 A has first priority, and the spacing rules 332 B and 333 B have second priority. From optimal to second priority, this order can describe decreasing preference for applying the spacing rules. In this example, the spacing rule 333 A has optimal priority, and is characterized by a maximum expansion only. During spacing adjustment in a line, the spacing rule 333 A can be applied without further selection to obtain an optimal spacing between two period characters in the line: in this case, 12.5% of a standard space character. If, for some reason, further spacing adjustments are required in the line, spacing rules with first priority can be applied. At this priority level, as shown in FIG. 3C , the spacing rule 332 A can be applied between adjacent pairs of non-space and space characters in the line. If these adjustments are still unsatisfactory, the spacing rules 332 B and 333 B can be applied for corresponding spacings in the line, since these spacing rules have second priority.
As shown in FIG. 4 , in one implementation of the invention, the spacing adjustment means 250 can perform the final step 255 of the process 200 (see FIGS. 2 a – 2 b ), that is, adjust spacing, for example, in order to justify a line of an electronic text. A line is received (step 410 ), and certain line parameters of the line are calculated (step 420 ). The calculation can be implemented as described below with reference to FIG. 5 . In the case of line justification, the line parameters to describe the entire line include: an optimal line width characterizing a line width when all spacings in the line are optimal; a maximum line expansion or compression characterizing a maximum expansion or compression of the line available by the spacing rules for adjusting spacings in the line. Other line parameters can be calculated as well; for example, a composite priority parameter describing the sum of the priorities of all the spacing rules that were applied to obtain a line layout of a line. Optionally, the line parameters can be obtained with the restriction that only spacing rules with a particular priority can be used. Based on the line parameters, spacing rules are selected (step 430 ). The selection can be carried out as will be described below with reference to FIG. 6 . Finally, the selected spacing rules are used to adjust spacing in the line (step 440 ).
As shown in FIG. 5 , in one implementation of the invention, line parameters are calculated for spacing adjustment in a line (see step 420 in FIG. 4 ). An initial value is set for each line parameter to be calculated (step 510 ). A previous character is defined as the first character of the line, and a next character is defined as the second character of the line (step 520 ). Character classes are then assigned to the previous and next characters (step 530 ).
In one implementation of the character class assignment, only one character class is assigned to a character. For example, if a character is a member of only one character class, this character class can be automatically assigned to the character. If, on the other hand, a character is a member of more than one character class, a character class can be assigned to the character based on additional information. For example, class assignment can take into account if there are available spacings rules when a particular character class is assigned to the character. Alternatively, the class assignment can be based on user input.
The assigned character classes are used to select rules to update the line parameters (step 540 ). In one implementation of the line parameter update, the previous and next characters have assigned character classes that also define a sub-group of the spacing rules: this sub-group contains the spacing rules that adjust spacing between characters of the assigned character classes. These spacing rules have rule parameters that can be used to update the line parameters. For example, a spacing rule can have a maximum expansion rule parameter that can update the maximum line expansion parameter of the line. In a similar way, the update step 540 can update other line parameters, such as the optimal line width, the maximum line compression, or a composite priority of the line. By taking into account the priorities of the spacing rules, the line parameters can be updated separately for different priorities.
After the line parameters have been updated, the next character is examined to determine if the next character is the last character in the line (step 550 ). If the next character is not the last character in the line, the previous and next characters are advanced by one character in the line (step 560 ), that is, the next character is advanced to become the previous character, and the next character is now defined as the following character in the line. With the new previous and next characters, steps 530 – 550 are repeated, until it is determined in step 550 that the next character is the last character in the line. The calculation is then finished (step 570 ).
As shown in FIG. 6 , in one implementation of the invention, spacing rules are selected for line justification of a line (see step 430 in FIG. 4 ). First, line parameters are provided for the line justification (step 610 ): an optimal line width, maximum line expansions and compressions that are available for different priorities. These line parameters can be obtained, for example, through the method described above with reference to FIG. 4 . Next, a target line width is compared with the optimal line width, and a difference Δ of the two widths is calculated (step 620 ). The target line width describes the targeted final line width after the line is justified. Depending on the difference Δ, an adjustment table is defined (step 630 ). If the target line width is bigger than the optimal line width (Δ>0), the adjustment table uses the maximum line expansion parameters. Otherwise (Δ<0, or Δ=0), the adjustment table uses the maximum line compression parameters. If the difference Δ is zero, optionally, the adjustment table can use the maximum line expansion parameters as well. The adjustment table can be organized to show the maximum adjustments, that is, expansion or compression, for different priorities. In order to select from these adjustments, a current priority level is defined, and set to first priority, i.e. the priority closest to the optimum priority (step 640 ). By changing the current priority level, different spacing rules can be selected for spacing adjustment.
Next, the spacing rules for spacing adjustment are selected by changing the current priority level to the next priority until the line can be justified. First (step 650 ), the absolute value of the difference Δ is compared with the maximum adjustment for the current priority level, which is the first priority after the step 640 . If the absolute value |Δ| is greater than the maximum adjustment for the current priority level, a priority weight 1.0 is assigned to the current priority level (step 652 ). The priority weight 1.0 means that spacing rules with this priority level are applied with their maximum adjustment. Next, the difference Δ is updated, as if these spacing rules were already applied (step 654 ). Since the updated difference Δ is still not zero, a next priority level is searched for with spacing rules that are operable to justify the line (step 656 ). If there is no such priority level, the available rules fail to justify the line (step 690 ) and the process ends; otherwise, the current priority level is set to the next available priority level (step 658 ), and the process returns to step 650 where a comparison of the updated difference Δ and the maximum adjustment for the new current priority level is performed.
If the comparison step 650 finds that the difference Δ has a smaller value than the maximum adjustment of the current priority level, the process calculates a priority weight (step 660 ). The difference Δ is divided by the maximum adjustment for the current priority level. The priority weight is assigned to the current priority level, and gives a fraction of the maximum adjustment necessary to justify the line. Since the line now can be justified, the difference Δ is set to zero (step 670 ) and the process ends (step 680 ).
When the priority weights are obtained, for example, by the rule selection, the spacing rules can be used to justify the line. In one implementation, the spacing rules can be applied with a method similar to the one described above for calculating the line parameters (see discussion accompanying FIG. 5 ). When the method individually addresses a spacing (steps 530 – 560 ), the spacing can be adjusted according to the spacing rules and the priority weights assigned to the priority, instead of updating the line parameters (step 540 ).
Furthermore, in one implementation of the invention, a line layout can be evaluated based on the total priority of the spacing rules that are selected to justify a line. The layout evaluation can be implemented by a line parameter calculating method, for example, as shown in FIG. 5 . The line parameter can be the composite priority parameter of the line. The composite priority parameter can be updated in step 540 based on priorities of the spacing rules that are selected to justify the line. For example, the update step 540 can add the priority weights of the selected spacing rules to the composite priority parameter. Optionally, the line layout evaluation can be used for paragraph composition.
The invention can be implemented in digital electronic circuitry, or in computer hardware, firmware, software, or in combinations of them. Apparatus of the invention can be implemented in a computer program product tangibly embodied in a machine-readable storage device for execution by a programmable processor; and method steps of the invention can be performed by a programmable processor executing a program of instructions to perform functions of the invention by operating on input data and generating output. The invention can be implemented advantageously in one or more computer programs that are executable on a programmable system including at least one programmable processor coupled to receive data and instructions from, and to transmit data and instructions to, a data storage system, at least one input device, and at least one output device. Each computer program can be implemented in a high-level procedural or object-oriented programming language, or in assembly or machine language if desired; and in any case, the language can be a compiled or interpreted language. Suitable processors include, by way of example, both general and special purpose microprocessors. Generally, a processor will receive instructions and data from a read-only memory and/or a random access memory. Generally, a computer will include one or more mass storage devices for storing data files; such devices include magnetic disks, such as internal hard disks and removable disks; magneto-optical disks; and optical disks. Storage devices suitable for tangibly embodying computer program instructions and data include all forms of non-volatile memory, including by way of example semiconductor memory devices, such as EPROM, EEPROM, and flash memory devices; magnetic disks such as internal hard disks and removable disks; magneto-optical disks; and CD-ROM disks. Any of the foregoing can be supplemented by, or incorporated in, ASICs (invention-specific integrated circuits).
To provide for interaction with a user, the invention can be implemented on a computer system having a display device such as a monitor or LCD screen for displaying information to the user and a keyboard and a pointing device such as a mouse or a trackball by which the user can provide input to the computer system. The computer system can be programmed to provide a graphical user interface through which computer programs interact with users.
The invention has been described in terms of particular embodiments. Other embodiments are within the scope of the following claims. For example, the steps of the invention can be performed in a different order and still achieve desirable results. | Method and apparatus, including computer program products, implementing and using techniques for adjusting spacing between characters in a line of text. A plurality of character classes are specified based on user input. A character class from the plurality of character classes is assigned to a character of a pair of characters in the line. Spacing between characters of the pair of characters is adjusted based on the assigned character class. Method and apparatus, including computer program products, implementing and using techniques for selecting rules for spacing adjustment in a line of text, and method and apparatus, including computer program products, implementing and using techniques for evaluating line layout are also described. | 6 |
BACKGROUND OF THE INVENTION
The conventional method of moving patients from their hospital bed to a wheeled stretcher or transfer unit and vice versa is to assemble a group of 4 to 6 orderlies and nurses and have them physically manipulate the patient from the bed to the stretcher. This operation must be duplicated with a new group of people when the patient is conveyed from the stretcher to a treatment table, for example, in X-ray procedures. This approach is not only extremely wasteful of the limited human resources available in the hospital and extremely disruptive of their other duties, but can be dangerous to the hospital personnel who must perform the awkward lifting operations and to the patient who may not be able to tolerate the twisting and jerking which would normally accompany the procedure.
Although there have been many attempts to mechanize this transfer operation, all have suffered from one or more major shortcomings. In particular, several of the devices use a lifting web which must be slid under the patient. This operation can be somewhat difficult for one person to accomplish and can be extremely painful for patients in delicate condition. Furthermore, many devices can only be unloaded on the same side as they are loaded. Since the most convenient side of the bed for loading may not be the same side as for unloading at the treatment table, either the hospital furniture must be moved around or the patient must be manipulated around on the stretcher. Either solution nullifies much of the value of the lifting device.
It is, therefore, an outstanding object of the invention to provide a mechanical lifting system adapted to transfer a patient from his hospital bed to a wheeled transfer unit.
Another object of this invention is the provision of a lifting device which can be operated by a single individual and which does not require any physical lifting by the operator.
A further object of the present invention is the provision of a lifting system which utilizes the patient's bed sheet as the lifting medium.
It is another object of the instant invention to provide a lifting system with which the transfer unit can be unloaded from the side opposite that at which it was loaded.
A still further object of the invention is the provision of a transfer unit which is simple to operate, relatively inexpensive to manufacture, and which is capable of a long and useful life with a minimum of maintenance.
With these and other objects in view, as will be apparent to those skilled in the art, the invention resides in the combination of parts set forth in the specification and covered by the claims appended hereto.
SUMMARY OF THE INVENTION
In general, the invention consists of a wheeled transfer unit for transferring a patient lying on a sheet to and from a bed or the like. The unit has a frame, a generally rectangular horizontal supporting member, and a lifting means mounted on the frame for clamping opposite ends of the sheet on which a patient is lying and for lifting and lowering the sheet with the patient supported thereon to and from a level above the supporting member. The said lifting means is also effective for extending the sheet-supported patient laterally of the supporting surface between a position where the patient is completely out of vertical alignment with the supporting member and a position where the patient is directly above the supporting member.
More specifically, the transfer unit has an elongated support arm at each end of the supporting surface of the lifting means, and means is provided for mounting each support arm on the frame for movement along its longitudinal axis between a first position where the arm lies along the end edge of the supporting surface and a second position where the arm extends laterally of the supporting surface, said arm being mounted for vertical movement between the level of the supporting table to a level above the supporting table.
BRIEF DESCRIPTION OF THE DRAWINGS
The character of the invention, however, may be best understood by reference to one of its structural forms, as illustrated by the accompanying drawings, in which:
FIG. 1 is a perspective view of a transfer unit incorporating the principles of the present invention,
FIG. 2 is an end elevational view of the unit looking in the direction of arrow II of FIG. 1,
FIGS. 3a and 3b show a patient on a hospital bed and transfer unit in front elevational and plan view, respectively,
FIGS. 4a and 4b show the lifting device extended around the patient and grasping the patient's bed sheet, in front elevation and plan view, respectively,
FIGS. 5a and 5b show the patient being lifted by the lifting device in front elevation and plan view, respectively,
FIGS. 6a and 6b show the patient being lowered onto the transfer unit in front elevation and plan view, respectively,
FIGS. 7a and 7b show the patient resting on the transfer unit in front elevation and plan view, respectively,
FIGS. 8a and 8b show the patient resting on the transfer unit and released from the lifting device, with the arms of the lifting device rotated so that they extend in a direction opposite to their original direction, in front elevation and plan view, respectively,
FIGS. 9a and 9b show the patient resting on the transfer unit with the lifting device retracted, in front elevation and plan view, respectively,
FIGS. 10a and 10b show the lifting device lifting the patient from the transfer unit, in front elevation and plan view, respectively,
FIGS. 11a and 11b show the patient being unloaded from the transfer unit to a treatment table, the unloading occurring on the opposite side of the stretcher from the side of the stretcher on which loading occurred, in front elevation and plan view, respectively,
FIGS. 12a and 12b show the patient deposited on the treatment table, in front elevation and plan view, respectively,
FIG. 13 is a vertical sectional view of the unit taken along line XIII--XIII of FIG. 2 and looking in the direction of the arrows,
FIG. 14 is a fragmentary plan view of one end of the clamping arm mounted on the support arm and showing means for locking the clamping arm in place, and
FIG. 15 is a perspective view of an elongated clamping arm, and
FIG. 16 is a vertical sectional view taken along the line XVI--XVI of FIG. 14.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring particularly to FIGS. 1, 2 and 13, the transfer unit, indicated generally by the reference numeral 10, consists of a supporting table 9 mounted on a frame 12 provided with supporting caster wheels 13. Table 9 has a flat supporting surface 11. The transfer unit 10 is also provided with lifting means, generally indicated by the reference numeral 14, mounted on the frame 12 and having support arms 15 and 16 located at opposite ends of the supporting table. The ends of the support arms 15 and 16 are provided with laterally-extending U-shaped brackets 18 for supporting elongated clamping arms 19 and 20, respectively. The arms 19 and 20 form with the support arms 15 and 16 a generally rectangular horizontal frame, as shown, for example, in FIG. 3b. Arms 19 and 20 are identical, arm 19 being shown in greater detail in FIGS. 14 and 15.
Referring particularly to FIGS. 14 and 15, the clamping arm 19 comprises a housing consisting of two rectangular brackets 22 for supporting a pair of elongated pinch bars 27 and 28 therebetween. A toothed disc 25 with a spindle 24 is attached to each bracket 22. Bracket 22 is shown in section in FIG. 14 to illustrate the manner in which pinch bars 27 and 28 are mounted in the brackets for movement toward and away from each other. A supporting pin 32 extends freely through the pinch bars 27 and 28 so that the pinch bars can be moved toward and away from each other.
Clamping arms 19 and 20 are mounted on support arms 15 and 16 by placing spindles 24 within oppositely facing U-shaped brackets 18, whereby the clamping arms may be freely rotated. The clamping arms 19 and 20 are maintained in a particular position by latching means 34 mounted on each end of each support arm. Each latching means 34 includes a sliding bolt 35 slidable transversely to the plane of the disc 25 and in line with the spaces between the teeth 26 of disc 25. A latch handle 36 is connected to bolt 35 for sliding the bolt.
During use of the invention for transferring patients, the opposite edges of the bed sheet are clamped between the pinch bars 27 and 28 of the clamping arms 19 and 20 by drawing the pinch bars together. As shown in FIG. 14, each disc 25 is provided with holes 30 located between the teeth 26. The clamping arms 19 and 20 are then rotated by inserting a pin or other suitable implement into one of the holes 30 and used as a lever for providing a partial rotation of the clamping bar. The pin is then removed and inserted into a second hole 30, whereupon the disc 25 is given another partial rotation. This procedure is continued until the sheet is wrapped about both clamping arms for a number of wraps sufficient to securely support the sheet between the clamping arms. At this point, bolts 36 are inserted into the spaces between teeth 26 to lock the disc 25 against rotation, as shown in FIG. 14. Each latch 34 is provided with a pair of notches 37 for receiving latch handle 36 to prevent bolt 35 from moving axially after it is in the locking position.
Again referring to FIGS. 1 and 2, support arms 15 and 16 and clamping arms 19 and 20 form part of a lifting means which also includes mounting means 40 and 41 for arms 15 and 16, respectively, and actuating means 42 and 43 for arms 15 and 16, respectively. Mounting means 40 is identical to mounting means 41 and actuating means 42 is identical to actuating means 43. Comparable elements of means 41 and 43 are given the same reference numerals as means 40 and 42, respectively.
Mounting means 40 includes a primary carriage 45 consisting of a lower pair of horizontal guide rails 48 supported by two pairs of vertical rods 50 slidably mounted within guide bearings 52. Rods 50 and rails 48 are attached by connecting blocks 51. Mounting means 40 also includes a secondary carriage 54 consisting of a lower block 58 slidably mounted on lower guide rails 48 and a vertical tubular sleeve 60. Sleeve 60 extends through a round hole 55 in block 58 and is slidingly mounted on a vertical post 61. Sleeve 60 extends through a round hole 53 in upper block 56. The top of sleeve 60 has an upper horizontal extending portion 60'. Support arm 15 is slidingly mounted on portion 60' to vary the effective length of the arm. A set screw 66 locks arm 15 to extending portion 60' in any desired position.
The lower end of vertical post 61 has a lower horizontal extending portion 59 provided with a small caster wheel 63 at its extreme end. The lower portion of post 61 extends through a bearing unit 65 at a point between block 58 and extending portion 59. Bearing member 65 is slidingly mounted within a horizontal channel member 67 attached to the frame 12 by means of connectors 69.
Block 56 is slidingly mounted on a pair of upper horizontal guide rails 46 that are supported from the top of guide bearings 52, which are, in turn, supported by the frame 12. By sliding blocks 56 and 58 on guide rails 46 and 48, respectively, post 61 (together with sleeve 60) are moved from the right-hand position shown in FIG. 2 to the extreme left of the guide rails as shown in FIG. 4a. Sleeve 60 is located centrally within holes 53 and 55 of blocks 56 and 58, respectively, so that the sleeve 60 can be rotated about its central longitudinal axis within blocks 56 and 58 as shown for example in FIG. 8b. However, sleeve 60 and block 58 and 56 move vertically together. Sleeve 60 and post 61 have a square cross-section so that they rotate together. Bearing member 65 allows post 61 to rotate with sleeve 60. Extending portion 57 and arm 15 also have a square cross-section as shown in FIGS. 1 and 16.
Referring to FIGS. 1 and 2, actuating means 42 consists of a hydraulic cylinder 62 supported by the frame 12 and located between each pair of guide bearings 52. Piston rods 64 extend from pistons (not shown) in cylinders 62 and are connected to connecting blocks 51. Actuation of cylinder 62 to draw piston rods 64 into the cylinders causes the primary carriage 45 at each end of the transfer unit, together with arms 15 and 16, to be lifted from the lower position shown in FIG. 1 to the upper position shown in FIG. 6a.
Hydraulic cylinders 62 of actuating means 42 and 43 are connected to a hydraulic control unit 68 by means of a plurality of hydraulic lines 70. Control unit 68 contains a resevoir of fluid and is provided with a pump pedal 72 and a release pedal 74. Pedals 72 and 74 are foot-actuated and are connected to appropriate valves within the control unit. Control unit 68 functions in a manner similar to a hydraulic jack in which the pump pedal 72 functions in the same manner as the crank arm of a hydraulic jack for pumping hydraulic fluid from the resevoir in the unit 68 to the cylinders 62. The hydraulic lines 70 are connected to the lower ends of cylinders 62 so that the pumping of hydraulic fluid into the cylinders causes their pistons and rods to be driven upwardly, thereby lifting rails 48, block 58 and sleeve 60 of mounting means 41 and 42. This raises arms 15 and 16 from a lower position at approximately the top of supporting surface 11 (as shown in FIG. 1) to an upper position above the supporting surface (as shown in FIG. 6a). Arms 15 and 16 are lowered by depressing pedal 74 which functions as a release lever, allowing fluid to flow from cylinders 62 to the resevoir in the control unit 68. A similar hydraulic unit is located on the opposite side of transfer unit 10 and the control units are hydraulically inter-connected so that the lifting apparatus can be operated from either side of the transfer unit.
Arms 15 and 16 can be moved laterally of the supporting table by sliding upper blocks 56 and lower blocks 58 on rails 46 and 48, respectively. Arms 15 and 16 can be moved from a first position at the top of flat surface 11 along the edges of the surface to a second position at the same level and to one side of the flat surface 11, as shown, for example, in FIGS. 4a and 4b. Arms 15 and 16 can also occupy a third position directly above the second position by raising the primary carriage 45 through the actuation of hydraulic cylinders 62 as previously described. This position is shown, for example, in FIGS. 5a and 5b. Finally, the arms 15 and 16 and occupy a fourth position at the higher level directly above the first position by sliding secondary carriage 54 relative to the primary carriage 45 to the original relative position shown in FIG. 1. The fourth position of arms 15 and 16 is shown in FIGS. 6a and 6b. Preferably, wheels 63 do not touch the floor except when the lifting unit is used for lifting or supporting a patient. When this happens, the weight of the patient on the cantilevered arms 15 and 16 acts through the primary and secondary carriages to force wheels 63 against the floor wherein they provide additional support for the lifting assembly.
The operation and advantages of the present invention will now be readily understood in view of the above description. Referring to FIGS. 3a-12a and 3b-12b, respectively, show the steps of transferring a patient from one supporting surface such as a hospital bed to a second supporting surface such as an examining table by means of a transfer unit 10 are clearly illustrated.
Referring particularly to FIGS. 3a and 3b, the patient P to be moved is shown lying on a hospital sheet S of a hospital bed B. The transfer unit 10 is positioned along one side of the bed B with support arms 15 and 16 in the first position.
After the transfer unit 10 has been properly positioned along side of the bed, clamping arms 19 and 20 are temporarily removed from arms 15 and 16 and arms 15 and 16 are moved from the first position shown in FIGS. 3a and 3b to the second position shown in FIGS. 4a and 4b. In this position, the patient P lies between arms 15 and 16. Clamping arms 19 and 20 are then placed in supporting position between the supporting arms so that they extend along the sides of the patient and together with arms 15 and 16 form a rectangular frame completely surrounding the patient. After clamping arms 19 and 20 are in place, the pinch bars 27 and 28 of each clamping arm are drawn together to pinch the edges of the sheet and the clamping arms are rotated to accumulate a sufficient number of wraps of the sheet about the clamping arms so as to securely grasp both sides of the sheet. At this point, clamping arms 19 and 20 are locked against sliding bolts 35 of latching means 34 between teeth 26, as shown in FIGS. 14 and 16.
Once that the sides of the sheet are securely held by the clamping arms 19 and 20, arms 15 and 16 are raised to the third position above the hospital bed, thereby lifting the patient from the bed, as shown in FIGS. 5a and 5b. In this position, the patient is fully supported by the sheet.
The patient P, fully supported on sheet S grasped by clamping arms 19 and 20, is moved from the third position shown in FIGS. 5a and 5b to the fourth position shown in FIGS. 6a and 6b by moving arms 15 and 16 to the fourth position above the supporting surface 11. Arms 15 and 16 are then lowered from the fourth position (shown in FIGS. 6a and 6b) back to the first position (shown in FIGS. 7a and 7b) so that the patient P, still lying on sheet S, is now supported on the supporting surface 11. The patient may now be transported to a second location and moved to another bed, operating table, or an examining table. If the orientation of the new supporting medium is similar to that of the bed from which the patient was removed, the patient will be delivered to this medium from the same side of the transfer unit 10 from which the patient was received. In this case the patient will be transferred from the transfer unit 10 to the new supporting medium by reversing the procedure previously described. However, in many cases the new supporting medium is located in a room in such a way that the patient cannot be transferred from the transfer unit 10 from the same side at which the patient was delivered. In such a case, bolts 35 are slid out of engagement with teeth 26 and arms 15 and 16 are rotated 180°, as shown in FIGS. 8a and 8b. This effectively places arms 15 and 16 in the second position relative to the supporting surface 11, whereupon arms 15 and 16 are moved back to the first position by sliding secondary carriages 54 relative to the primary carriages 45. In doing this, clamping arms 19 and 20 are raised slightly to allow arms 15 and 16 to slide beneath them, whereupon the spindles 24 at the end of clamping bars 19 and 20 are inserted within the U-shaped bracket 18 on the opposite side of arms 15 and 16. After the clamping arms 19 and 20 are properly positioned (as shown in FIGS. 9a and 9b) bolts 35 are slid into locking position between teeth 26 of discs 25, to lock clamping arms 19 and 20 in position.
As shown in FIGS. 10a and 10b, the patient is lifted from supporting surface 11 by moving arms 15 and 16 to the fourth position. The arms 15 and 16 are then moved to their third position above the new supporting medium such as an examining table T (as shown in FIGS. 11a and 11b). Finally, arms 15 and 16 are lowered to their second position to the top surface of table T (as shown in FIGS. 12a and 12b) so that the patient, still lying on the sheet S, is supported by the table T. The sheet S is released from clamping bars 19 and 20 and the transfer unit 10 is removed from the table to be used for transferring another patient P or used at a later time for transferring patient P from table T back to the bed B.
It is obvious that minor changes may be made in the form and construction of the invention without departing from the material spirit thereof. It is not, however, desired to confine the invention to the exact form herein shown and described, but it is desired to include all such as properly come within the scope claimed. | A device for lifting a patient from his hospital bed and placing the patient on a wheeled transfer unit. The patient's bed sheet is used as the principle lifting medium. The transfer unit can be loaded and unloaded from either side. The operation can be performed by one person. Support arms are extended from the stretcher to the patient lying in bed. The arms support clamping bars which are capable of securely grasping the patient's bed sheet. | 0 |
TECHNICAL FIELD
The invention concerns panel shaped lightweight structural elements, containing internal reinforcing members, especially for constructing buildings and methods of constructing buildings composed of these elements.
BACKGROUND OF THE INVENTION
At present various kinds of material are used in building construction. Most commonly used are stone, wood, bricks, concrete, metal, plast and similar materials.
Stone buildings are strong and mostly resistant to environmental deterioration, but their principal disadvantages are, that they are a limiting factor in architectural design, that they entail slow progress of construction work, are demanding in material handling efforts, entail costly transport, do not provide a sufficient thermal insulation, etc.
The application of wood as building material opens up more architectural design possibilities, it can easily be used in constructing roofs and floors. The main disadvantages of wood is limited strength, inflammability, shorter service life, limited insulation properties etc.
Brick buildings avoid some of the above mentioned problems. The main disadvantages of bricks are relatively slow progress in construction work, demands on accuracy of workmanship, higher costs in material transport and manipulation, the necessity to provide walls with surface layers etc. Bricks are joined together with mortar (grout), which also covers the gaps between individual bricks and can be used as surface layer of plaster or stucco. Plaster surface (rendering) can be applied to the indoor as well us to the outdoor wall surface. In earlier days brick buildings normally had wooden ceilings and floors, lately concrete has partly replaced wood in these applications.
Concrete—or reinforced concrete—constructions are remarkable for their strength, are sufficiently resilient to external influences, but their heat and sound insulation parameters are rather low, transport is rather demanding, on the building site heavy building mechanisms are unavoidable, up to now the problem of disposal with these buildings after their useful service life has expired, has no satisfactory solution etc. Floors are mostly constructed using beams, external surfaces are treated so as to resist to prevailing climatic conditions, indoor surface are rendered as the customer wishes.
Also, known are some less used kinds of natural materials for building construction: e.g. earth, reeds or rushes, bamboo, straw and similar. The use of these materials is limited to selected territories.
Also known are technologies based on the use of a combination of some of the above mentioned materials. This concerns e.g. wooden or steel basic constructions, where the free spaces are built up with bricks, concrete, wood, glass, plastic or other materials. The central filling may be made of thermo-insulating material, while the external surface layers are of wood, sheet metal, plywood, stucco and other materials. Internal surfaces can be of stucco, various linings, plasterboard etc. During the last decades wooden support structures are mostly being replaced by metal supporting structures, but the basic construction methods have not changed. Floors above ground level are usually of brickwork or of wood.
From the above it can be deduced, that there are two principle classes of building construction technologies: those that are assembled on the construction site of individual construction elements, like stone, wood, bricks etc., and those, which are assembled from prefabricates, transported to the erection site as subassemblies, mostly in the form of various panels.
Prefabricated subassemblies with iron or wooden internal support structures are manufactured in a production factory and transported to the construction site, where the building is assembled either entirely using these prefabricated panels and subassemblies, or partly of subassemblies and partly of components and elements assembled on the construction site.
Panels made of steel reinforced concrete have been widely used in the large scale construction of houses. Panels, with insulating and other surface layers or without them, are used to build complete houses, including floors, ceilings and roofs.
Further are known prefabricated panels using layered elements with a load carrying surface layer. These layered elements as a rule contain load carrying surface layers and between them one or two insulating or other fillers, as for example plywood, honeycomb structures etc. An example of a known arrangement is described in the patent number CA 1,284,571 of the year 1991, filed by Peter Kayne. There is a relatively large number of patents, which are based on this construction. The difference between these patents is in principle only in the materials used, possible in the arrangement or construction of the filler material. Some patents describe also the methods used for the production of these prefabricates, as well as the methods of joining individual layers to each other.
The patent number CA 1,169,625, filed by Jack Slater, concerns the panel itself and the method of building construction using this panel. The panel contains supporting studs of either metal or of wood, between which a polystyrene block is located. These panels can be used for making walls, but also floors. The studs are joined to the fillings by commonly known kinds of glue. The inner surface is usually covered with plaster board and the outer surface with bricks or other claddings. The finishing work on internal and external surfaces is in no way connected to the studs and thus cannot transfer any supporting forces, or forces acting outside the panels, besides their own gravity-related weight.
Another example of the presently known state of the art is to be found in patent CA 2,070,079 filed by Vittorio De Zen. This patent is based on forming hollow profiles of thermoplastic materials, which it is possible to assemble in various ways, possible to fill cavities with suitable material.
An inherent disadvantage of this solution is the high cost of the machinery (tool) needed for the pressing, difficult change of panels produced, more complicated assembly, lower mechanical strength, uneasy surface treatment etc.
In summary it can be said, that building construction using small elements is demanding in time, material, work force, transport etc. Construction based on prefabricated panels will overcome some of these insufficiencies, but are usually demanding on transportation, on-site machinery, qualified personnel etc.
SUMMARY OF THE INVENTION
The above described disadvantages are largely overcome by a lightweight structural element in the shape of a panel, especially for building construction, containing a support structure according to this invention. The lightweight construction element contains at least two supporting rods, which at their end are interconnected by cross-bars, between the supporting rods and the cross bars is a core and/or the surfaces of the supporting rods are interconnected by an adhesive structural skin made from material of thickness between 0.5 and 5 mm, of direct tensile strength from 5 to 35 MPa, tensile strength in bending from 5 to 45 MPa, modulus of elasticity from 2 to 30 GPa, specific density of the matrix material 1 to 2.7 g/cm 3 , the shear bond strength of the junction between the structural skin and the support rods is from 1 to 5 MPa and the compressive strength against pressure of the matrix material is from 10 to 70 MPa.
It is of advantage to make the lightweight structural element of at least two supporting rods of “U” profile, facing each other with their open side, possible of four rods of profile “L”, facing each other with their open side.
It is of advantage, to cover the core and/or the rods with a further layer from 5 to 50 mm thick, of direct tensile strength from 0.1 to 10 MPa, tensile strength in bending from 2 to 15 MPa, modulus of elasticity from 2 to 45 GPa, specific density of the matrix material from 1 to 2.7 g/cm 3 , the shear strength of the junction to the adhesive structural skin is from 0.1 to 5 MPa and the compressive strength against pressure of the matrix material is from 10 to 75 MPa. This further layer may contain plaster, cement, mineral fibres, perlite, vermikulite and other materials, with which desirable parameters can be attained as far as fire resistance, noise insulation etc. are concerned.
It is of advantage to make the core of polystyrene foam, extruded polystyrene, polyuretane foam, mineral wool, poro-cement, poro-silicates, honeycomb construction etc. The core can also be made of paper board, refuse material, earth, cellulose or mineral fibres.
It is of advantage to furnish an additional layer to the structural skin, with grooves for holding applied mortar.
Lightweight structural elements according to this invention can be used in such a way, that a layer identical to the structural skin material is applied to support posts and/or at least two neighbouring panels and it is of advantage to apply a further layer of this material two at least two neighbouring panels.
The advantage of this solution lies in the high value of strength of the lightweight structural element caused by the fact, that the entire lightweight structural element according to this invention behaves like one entity, because the support rods are between them firmly attached to the strong structural skin and therefore all internal and external stresses and loads are transferred to all the remaining components of this element. The ensuing construction—the hollow panel—is capable of transferring high values of stress, from bending as well as from torsion loads, in horizontal as well as in vertical directions. Thus it is possible to exploit this lightweight structural element for walls as well as for floors, ceilings or roofs. In view of the fact, that the structural skin containing anti-corrosion inhibitors firmly adheres to the supporting rods, these are protected from corrosion. Thus it is possible to use also so called “wet” materials as fillers.
The lightweight structural element according to this invention can thus be used in its basic form, i.e. as a hollow panel, but also, and especially so, as a panel with a filler, which can be chosen to meet specific needs and available materials.
The filler improves the strength of the lightweight structural element, but at the same time, using suitably selected filler material, it can be possible to attain desirable properties for the whole element. This concerns for example fire resistance, heat and sound insulation, resistance to environment etc. Buildings erected using these elements will be advantageous in extremely hot regions, e.g. the Sahara, as well as in extremely cold regions, e.g. Antarctica. Under these extreme conditions it is of advantage to use rods of “L” profile. The basic construction element thus manages to transfer loads into all rods and into the entire surface layer of the element (structural skin).
Lightweight structural elements according to this patent are light, compact for storage, strong and therefore involved transport costs are low and during erection work no heavy machinery or special mechanisms or tools are needed. Basic tools and equipment for the erection site will suffice, e.g. a concrete mixer, pump etc. Erection workers need not be fully trained specialists, but can be only superficially trained. For construction work abroad it therefore is not necessary to send out specialists from the factory, but it is possible to use local workers, who have gone through a short training course. If it is found advantageous the filling can be made of material locally available in the region of the construction site.
The lightweight structural element itself, as well as the material used during the erection, are ecologically harmless and it is possibly to reuse them. The service life of the lightweight structural elements is comparable to presently used panels, possibly even longer. Their resistance to climatic impact, including strong wind and earthquake, is comparable to that of buildings erected using classical building material, possibly even greater.
A further advantage is the ease, with which exterior as well as interior surfaces can be adjusted to the customer's desires. It is possible to finish the surfaces in a wide variety of ways, thus giving the final construction different features. These can make the building look anything from modest to luxurious, in any case it is not discernible, that the building has been made of prefabricates. Another advantage is, that the doors, windows etc. can be chosen from local suppliers. Furthermore the material is extremely resistant, fireproof, waterproof, possibly even water tight. A further advantage is, that it is possible to use the panels as substructure for poured floor mortar. This floor will be adequately strong with desired surface parameters.
A great advantage is the speed, with which the erection takes place. A complete house can be erected in 2 to 3 days with the aid of 3 to 4 workers.
A further advantage is the low price. This is caused by the fact, that the support rods are of “U” or “L” cross section. Previously known rods for reason of sufficient mechanical strength had to be of profile “C”, i.e. the open end needed an additional operation of rolling in. That entails high production costs. “U” or “L” profiles are cheap to manufacture and can even be pressed, which is cheaper and simpler than other fabrication operations. In view of the simple shape of the elements used there is no problem in changing the size of the end product according to momentary needs.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention and its advantages will now be explained by means of the following figures.
FIG. 1 shows schematically a horizontal cross section of a lightweight structural element according to this invention.
FIG. 2 shows a side view schematically in part of a wall composed of lightweight structural elements.
FIG. 3 shows, in plan view and cross section, part of the wall as shown in FIG. 2 .
FIG. 4 shows schematically the plan view of how the lightweight structural elements are joined together to form a wall.
In FIGS. 5 and 6 show side views of the lightweight structural elements for use in floors.
FIG. 7 shows the lightweight structural element
FIGS. 7 and 8 show a schematic cross sectional view of a house erected and portions thereof using the lightweight structural elements according to this invention.
FIGS. 9 a-h show adjacent structural elements having different core members.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is described more closely with the aid of the ensuing figures, which show some examples of implementation of the invention.
The lightweight structural element in the form of a panel 10 for building construction is formed by two supporting rods 1 of galvanised steel of cross section “U” of thickness 1.2 mm, wide 100 mm and high 30 mm. The supporting rods 1 are arranged with open sides facing each other. The supporting rods 1 are on their ends mutually joined to each other by cross bars. A structural skin 2 is adhesively mounted to the supporting rods 1 . The structural skin 2 material has the following physical parameters: thickness 2.5 mm, direct tensile strength 7.5 MPa, tensile strength in bending 15 MPa, modulus off elasticity 20 GPa, specific density 2 g/cm 3 , shear strength of the joint between the rods 1 and the structural skin 23 MPa and compressive strength of the matrix material 50 MPa. After the structural skin 2 solidifies a firm, cantilever hollow panel 10 is formed, in which induced stress forces are transferred from one supporting rod 1 to the other and to the entire surface layer of the lightweight structural element.
The material of the structural skin 2 is made of polymer modified cement and webbing. The matrix may contain corrosion inhibitors, glass, polyester, nylon, polypropylene or other fibres, like carbon fibres, etc. The webbing may be woven or not woven.
The supporting rods 1 after mutual interconnection are covered with a further layer 6 of thickness 8.3 mm, of direct tensile strength 3.5 MPa, tensile strength in bending 8.3 Mpa, modulus of elasticity 13.8 GPa, specific density 2 g/cm 3 . The shear strength of the joint between supporting rods 1 and adhesive structural skin 2 is 2.2 MPa and the pressure strength of the matrix material is 25.1 MPa. Another layer 6 can be sprayed on, as is usually done with mortar.
The core 5 , which may, but need not be used, is made of polystyrene foam. The polystyrene block has common dimensions 1200×2400×100 mm.
The lightweight structural element to be used on the roof is produced in similar ways, as the wall element. It has the shape of panel 10 and is formed of two supporting rods 1 of galvanised steel, the structural skin 2 and the core 5 . In this case the structural skin 2 must be made so that it will resist climatic deterioration due to rain, wind etc. The supporting rods 1 of cross section “U” are arranged with their open sides facing each other. Supporting rods 1 are at their ends interconnected by cross burs. To the surface of supporting rods 1 a structural skin 2 is joined adhesively. The material of this structural skin 2 is 1.5 mm thick, has direct tensile strength 5.8 Mpa, tensile strength in bending 11.5 MPa, modulus of elasticity 20.1 Gpa specific density 2.1 g/cm 3 , the shear strength of the joint between the surface layer and the supporting rods 1 is 2.1 MPa and the pressure strength of the matrix material is 35.8 MPa. After the structural skin 2 solidifies a firm, cantilever hollow panel 10 is formed, in which induced stress forces are transferred from one supporting rod 1 to the other and at the same time to the entire surface layer of the lightweight structural element. The core 5 is of lightened material. The roof panels 10 are attached to the wall panels 10 by further mechanical fixtures.
The lightweight structural element for floors is in principle also manufactured in the same way as the wall element. It has the shape of panel 10 and is made of two supporting rods 1 made of galvanised steel, a structural skin 2 and core 5 . In this case the supporting rods 1 are 150 mm high. After the basic layer 7 of material identical with the material of the structural skin 2 material is applied, grooves are made in the upper surface of layer 7 in order to make the poured mortar layer 8 adhere better to the structural skin 2 . The poured mortar layer 8 can be from 10 to 50 mm thick.
In places, where the temperature difference is excessive, stresses could be induced in the lightweight structural element. In this case it is better to replace the supporting rods 1 of profile “U” by supporting rods 1 of profile “L”. Panels 10 of this construction are better able to distribute by means of the structural skin 2 stress induced by external influences. Cold may furthermore induce condensation of moisture and icing on the internal part of the frame. Using rods Cold may furthermore induce condensation of moisture and icing on the internal part of the frame. Using supporting rods 1 of profile “L” prevents this. Structural skin 2 transfers shearing stress as well as pulling stress. Shear stress can be transferred from one “L” supporting rod 1 to its neighbour on the side wall through some other materials like plasts, epoxy impregnated fibres, epoxy resin polyester etc.
The above mentioned facts make it clear, that the lightweight structural element can be implemented and used either in the form of structural skin 2 , possible structural skin 2 and a further layer 7 , i.e. as a hollow element, or with a core 5 without structural skin 2 , core 5 with structural skin 2 , core 5 and a further layer 7 , or in the form core 5 , structural skin 2 and a further layer 7 .
The lightweight structural element according to this invention is manufactured so, that two “U”-profile supporting rods 1 are placed facing each other, their mutual position is fixed by mounting cross bars in place using junction pieces, bolts or screws and nuts and over this assembly structural skin 2 is put in place. In case “L” profile supporting rods 1 are used, the first step is to fix their position and the remaining operations are the same.
Lightweight structural elements according to this invention are assembled to each other so that neighbouring panels 10 are positioned next to each other and fixed in place using junction pieces and bolts or screws., A strip 3 of width about 200 mm of material identical with the material of the structural skin 2 is placed on this assembly of neighbouring elements. Junction pieces and bolts or screws remain in place, but their function is minimised, because the strip 3 firmly joins the elements together. In the next operation further strips 4 of material identical to the material of the structural skin 2 are placed on the remaining exposed parts of the supporting rods 1 and the cross bars 12 . This ensures better adhesive joints between the surface of supporting rods 1 and the further layer 7 . Finally a further layer 7 from 10 to 20 mm thick is applied to the assembled components.
Some panels 10 may contain openings for windows, doors etc. Electrical and other installations are embedded in the wall—in the core 5 the installation is covered by a strip of material identical to the material forming the structural skin 2 .
Industrial Applicability
The lightweight structural element, especially for use in building construction, and the method of constructing buildings using the elements according to this invention, will find use above all in construction of family houses, industrial, commercial, business and dwelling houses of up to about three floors. The lightweight structural elements themselves can also be used as filler panels in constructions using reinforced concrete or steel skelets. | The invention relates to a light weight structural element, in particular in the shape of a panel, especially for building construction, containing a support structure. The light weight structural element contains at least two supporting rods, which at their ends are interconnected by cross-bars. Between the supporting rods and the cross-bars may be a core; wherein the surfaces of the supporting rods are interconnected by an adhesive skin made from a material of a thickness between 0.5 and 5 mm. The invention also relates to the construction technique of constructing buildings using the light weight structural elements. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method for the production marking of liquid crystal displays (LCD) whereby the closure bar of the liquid crystal cell is produced by the screen printing process.
2. Description of the Prior Art
Liquid crystal displays have typically been formed by sandwiching a liquid crystal material between transparent plates. A closure bar, formed by screen printing, has typically been used to seal the peripheral edges of the sandwich. Such a liquid crystal display is illustrated in U.S. Pat. No. 3,995,941 in which the closure bar is a low melting point glass, the disclosure of which is hereby incorporated by reference.
Liquid crystal displays have hitherto generally been marked by means of a lettering machine so that the week number and year of manufacture were printed on them. This lettering is necessary in order to ensure watch identification for customer warranty purposes. With a fairly large production volume, a plurality of lettering machines with a plurality of operators must be employed, otherwise a production bottleneck can result.
Recently it has been proposed to superimpose a production code in the photoresist process for the segmentation of the electrode layer. But this involves two difficulties:
(a) The exposure occurs by multiple process, so that a corresponding multiple pattern must be typed and produced once per week;
(b) Several weeks may elapse between electrode segmentation and further processing.
SUMMARY OF THE INVENTION
Accordingly, one object of this invention is to provide a novel method for the production marking of liquid crystal displays which obviates the above-described difficulties.
Another object of this invention is to develop a method whereby the step of production marking coincides approximately with the decisive step of the manufacturing process.
These and other objects of the present invention are achieved by providing the screen used to print the closure bar of a liquid crystal display with an information code relating to period of manufacture, so that the closure bar is marked with the same code during printing.
Compared to previous methods, the coding system according to this invention has the advantage that only a few patterns are printed per screen printing operation, and that in any event normal wear of the screen necessitates relatively frequent screen renewal, at which time it is advantageous to update the screen coding. Furthermore, experience shows that details of graphics and cell technology are subject to modifications at fairly short intervals, so that unmistakable identification is possible with a minimum of coding.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 is a view of a screen geometry with code projections representative of a production marking;
FIG. 2 is a detailed view of code projection openings in a screen for glass solder paste printing;
FIG. 3 is a table relating to the programming of the code projection openings of FIG. 1; and
FIG. 4 is a table relating to another programming embodiment for code projection openings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, and more particularly to FIG. 1 thereof, a screen geometry 1 is provided for a closure bar 2a and 2b in which all the code cams projections 3a-3h and 4a-4b are initially open. (Open corresponds to binary `0`). The programming of the code is done by selective masking of specific code openings using masking paint.
To enable the week code to be marked, six bits are required in the dual binary system. Two bits, corresponding to a four year cycle, are generally sufficient for the year code. In a practical embodiment, it is advantageous for technological reasons to employ a specific week code. Therefore the code provided is not a straight dual binary code (2 n code), but a code according to the table shown in FIG. 3. In the code shown in FIG. 3, the four least significant bits 3a, 3b, 3c and 3d, are changed consecutively, that is, one opening is closed after the other. The corresponding cycle covers approximately one month. "Wo" in FIG. 3 denotes the week number. The four most significant bits 3e, 3f, 3g, 3h, of the table shown in FIG. 3 represent the month of the year, and are coded as a dual binary code. After the expiration of the four week cycle represented by the least significant bits 3a, 3b, 3c, 3d, the monthly binary code 3e, 3f, 3g, 3h, is increased by one unit. This embodiment has the advantage that with a minimum of bits, only a few already programmed screens become unserviceable at the weekly exchange. On the average, the opening of previously closed code projections would only be necessary at one fifth of the week changes. Because this is technologically difficult, the screens already programmed are replaced in these cases if necessary.
FIG. 1 illustrates an embodiment wherein the weekly code 3a . . . 3h is applied along the one edge 2a of the closure bar, while the yearly code (dual binary code) 4a, 4b is arranged along the opposite edge 2b of the closure bar 1. This facilitates the reading of the entire code. Furthermore, projections 5 and 6 are used to define the starting points of weekly code 3a . . . 3h and yearly code 4a, 4b respectively. Projections 5 and 6 are designed to be twice as long as the projections 3 and 4 in order that the code starting point can be easily distinguished.
Typical dimensions of the code cam openings in the screen for glass solder paste printing are, according to FIG. 2:
b=0.1 mm
l 1 =1.0 mm
l 2 =0.5 mm
d=0.5 mm
The width b is chosen minimum so as not to restrict appreciably the field used for the display. It is advantageous to apply a projection of e.g. double length l 1 as reference mark in order to define the starting point.
The table shown in FIG. 4 represents a code more easily legible than table 1, although it requires 10 bits for the week identification. Here the first 4 bits 3a to 3d together with the bit 3e embody the units of the week number and the remaining bits the tens of the week number. Once again, the heading "Wo" in Table 4 denotes the week number.
Obviously, numerous additional modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | A method for the production marking of liquid crystal displays whereby the closure bar of the liquid crystal cell is produced and encoded by a screen printing process. Several coding techniques which minimize production interruptions are also disclosed. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a sewing machine presser foot which is attached to a presser bar of the sewing machine and used to sew a decorative string of wool yarn or the like on a cloth, and which makes it easier to pass the decorative string through a needle guiding hole while reducing the probability of the decorative string detaching from the needle guiding hole.
[0003] 2. Description of the Related Art
[0004] Some conventional home sewing machines are designed for what is called “couch stitching”, which is a type of stitching means for sewing decorative wool yarn, embroidery threads, ribbons, etc. on a cloth. A couch stitching operation involves setting an upper thread, a lower thread, and an embroidery frame, passing a third decorative string through a presser foot attached to a sewing machine, and then performing stitching. In this couch stitching operation, a presser foot dedicated for the couch stitching is used.
SUMMARY OF THE INVENTION
[0005] As disclosed in Japanese Patent Application Publication No. 2007-130056, a presser foot dedicated for couch stitching typically includes a pressing portion in which a circular needle guiding hole is formed at the center of a disk and an attachment portion that is connected to a presser bar attached to a sewing machine body. In this type of presser foot, a decorative string needs to be inserted through the needle guiding hole, and especially when wool yarn or the like is used as the decorative string, inserting the string through the needle guiding hole of the presser foot becomes extremely difficult, because of the fluffiness of the string.
[0006] In Japanese Utility Model Application Publication No. H5-60477, a passage that provides communication between the inside and outside of a needle guiding hole of a pressing plate is provided so that a decorative string can be inserted from a horizontal direction in relation to the presser foot, thereby facilitating insertion of the decorative string into the needle guiding hole. This type of presser foot can make it easier for the decorative string to be inserted into the needle guiding hole of the presser foot, but unfavorably, the decorative string also detaches more easily from the needle guiding hole.
[0007] Under these circumstances, an object of the present invention is to provide a sewing machine presser foot dedicated for couch stitching, with which it is easier to insert the decorative string into a needle guiding hole of the presser foot in the setup process of couch stitching, while it is also possible to reduce the probability of the already-inserted string detaching from the needle guiding hole.
[0008] As a result of intensive studies to solve the above problems, the present inventor solved the problems by providing, as a first embodiment of the present invention, a sewing machine presser foot including: a presser foot body including an attachment portion attached to a presser bar of a sewing machine, a supporting portion extending downward from the attachment portion, and a pressing portion in which, at a lower end of the supporting portion, a needle guiding hole having a string guiding groove for guiding a string is formed; and a cover member including a groove covering portion that crosses and covers the string guiding groove of the pressing portion, a supporting plate portion formed along the supporting portion continuously from the groove covering portion, and an attachment portion formed at an end of the supporting plate portion so as to be attached to the presser foot body, wherein a right-side portion of the supporting plate portion of the cover member fixed to the presser foot body by the attachment portion is configured to be displaced from the supporting portion.
[0009] A second embodiment of the present invention solves the problems by the bobbin holder according to the first embodiment, in which a bent portion provided in the supporting plate portion is formed to be bent in such a direction that the supporting plate portion is displaced from the supporting portion in a left-right direction of the supporting plate portion of the cover member. A third embodiment of the present invention solves the problems by the bobbin holder according to the first or second embodiment, in which a string guide is formed to be erected continuously from the groove covering portion of the cover member so as to correspond to a thread insertion opening of the string guiding groove of the pressing portion.
[0010] A fourth embodiment of the present invention solves the problems by the bobbin holder according to the first or second embodiment, in which a front-rear deflection restricting portion is provided in the supporting plate portion of the cover member fixed to the supporting portion of the presser foot body, the front-rear deflection restricting portion restricting deflection of the supporting plate portion in a front-rear direction and having a rear restricting plate that is bent toward a rear side of the supporting portion and is positioned so as to be separated from a rear surface of the supporting portion.
[0011] In the present invention, the sewing machine presser foot includes: a presser foot body including an attachment portion attached to a presser bar of a sewing machine, a supporting portion extending downward from the attachment portion, and a pressing portion in which, at a lower end of the supporting portion, a needle guiding hole having a string guiding groove for guiding a string is formed; and a cover member including a groove covering portion that crosses and covers the string guiding groove of the pressing portion, a supporting plate portion formed along the supporting portion continuously from the groove covering portion, and an attachment portion formed at an end of the supporting plate portion so as to be attached to the presser foot body, in which a right-side portion of the supporting plate portion of the cover member fixed to the presser foot body by the attachment portion is configured to be displaced from the supporting portion.
[0012] Thus, the upper side of the string guiding groove of the pressing portion is covered by the groove covering portion and the groove covering portion can always put the string guiding groove in a closed state by the elastic property of the supporting plate portion. Moreover, a bent portion is provided in the supporting plate portion of the cover member fixed to the presser foot body by the attachment portion, and the right-side portion of the cover member is displaced from the supporting portion.
[0013] Due to this, in the process of inserting the decorative string into the needle guiding hole, the groove covering portion is moved from the left side toward the right side by pressing force of the decorative string, and due to the bent portion provided in the supporting plate portion, the right-side region of the supporting plate portion is displaced from the supporting portion of the presser foot body. In this case, the groove covering portion also floats from the pressing portion.
[0014] In this case, when the decorative string is inserted into the string guiding groove, the right-side portion of the groove covering portion in relation to the cover member serves as a refuge for overall deformation of the groove covering portion, and the groove covering portion can be easily deformed. Thus, a gap in which the decorative string can be inserted is formed between the string guiding groove and the groove covering portion. In this manner, a state in which the decorative string can be easily moved to the position of the string guiding groove can be created. Therefore, a state in which the decorative string is easily inserted into the needle guiding hole is created, and the inserting operation can be performed easily and quickly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1A is a schematic view illustrating a state in which a presser foot of the present invention is attached to a sewing machine, FIG. 1B is an enlarged view of (a)-part in FIG. 1A , FIG. 1C is an enlarged perspective view of the presser foot of the present invention, and FIG. 1D is an enlarged perspective view illustrating a presser foot body of the presser foot of the present invention and a cover member in a separated state;
[0016] FIG. 2A is a front view of the presser foot of the present invention, FIG. 2B is a partial cross-sectional view along arrow Y 1 in FIG. 2A , FIG. 2C is a partial cross-sectional view along arrow Y 2 in FIG. 2A , FIG. 2D is an enlarged cross-sectional view along arrow X 1 -X 1 in FIG. 2A , and FIG. 2E is an enlarged cross-sectional view along arrow X 2 -X 2 in FIG. 2A ;
[0017] FIG. 3 is an enlarged side view of main parts, illustrating a state in which a supporting plate portion and a groove covering portion of a cover member of the present invention are displaced from a supporting portion and a pressing portion of a body portion;
[0018] FIG. 4 is an enlarged front view of main parts, illustrating another embodiment of the shape of a string guide of the presser foot of the present invention;
[0019] FIG. 5A is a plan view of main parts associated with a first cycle of inserting a decorative string into the presser foot of the present invention, FIG. 5B is a cross-sectional view along arrow X 3 -X 3 in FIG. 5A , and FIG. 5C is a view along arrow Y 3 in FIG. 5A ;
[0020] FIG. 6A is a plan view of main parts associated with a second cycle of inserting a decorative string into the presser foot of the present invention, FIG. 6B is a cross-sectional view along arrow X 4 -X 4 in FIG. 6A , and FIG. 6C is a view along arrow Y 3 in FIG. 6A ; and
[0021] FIG. 7A is a plan view of main parts associated with a third cycle of inserting a decorative string into the presser foot of the present invention, FIG. 7B is a cross-sectional view along arrow X 5 -X 5 in FIG. 7A , and FIG. 7C is a view along arrow Y 3 in FIG. 7A .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. The present invention relates to a sewing machine presser foot which is used as a presser foot dedicated for couch stitching, particularly. As illustrated in FIGS. 1A to 1D and FIGS. 2A to 2E , the presser foot of the present invention mainly includes a presser foot body A and a cover member B. In the description of the presser foot of the present invention, the directions such as left and right sides and the up-down direction are defined when an operator sees a sewing machine on the front side. The front and rear sides, the left and right sides, the up-down direction, and the like are described in major drawings. These wordings indicating the directions are described in FIGS. 1A and 1B .
[0023] The presser foot body A includes a pressing portion 1 , a supporting portion 2 , and an attachment portion 3 (see FIGS. 1C and 1D and FIGS. 2A, 2B, and 2C ). The pressing portion 1 , the supporting portion 2 , and the attachment portion 3 are integrally molded by bending a metal plate, for example. The pressing portion 1 includes a pressing plate 11 , a needle guiding hole 12 , and a string guiding groove 13 connected to the needle guiding hole 12 .
[0024] The pressing plate 11 is an approximately circular plate and the needle guiding hole 12 is formed substantially at the center of the plate. A sewing machine needle 93 passes through the needle guiding hole 12 (see FIG. 1B ). A string guiding groove 13 is formed in a predetermined portion of the needle guiding hole 12 , the peripheral portion of the pressing plate 11 and the needle guiding hole 12 communicate with each other through the string guiding groove 13 , and a decorative string n is inserted into the needle guiding hole 12 through the string guiding groove 13 from the outside of the pressing portion 1 .
[0025] The width of the string guiding groove 13 is slightly smaller than the diameter of the needle guiding hole 12 (see FIG. 2E ) and has such a size that one decorative string n such as wool yarn can pass through the string guiding groove 13 . Moreover, the string guiding groove 13 is formed on a left side surface of the pressing portion 1 as a groove which faces toward the front side from the vicinity of the rear side. The supporting portion 2 is formed continuous with the rear side of the pressing plate 11 so as to extend upward. Further, the supporting portion 2 is formed so as to extend upward from the rear side of the pressing portion 1 in a state of being inclined toward the rear side.
[0026] Moreover, the attachment portion 3 is formed so as to extend upward from the upper end of the supporting portion 2 . The attachment portion 3 is a portion which plays a role of attaching the presser foot to the presser bar 92 . The attachment portion 3 is formed in a vertical form in a state of being shifted to the right side of the supporting portion 2 so as to extend from the upper end of the supporting portion 2 with the interposition of an inclined plate piece 31 . Fixing pieces 32 for attaching and fixing the presser foot to the presser bar 92 are formed in an upper portion of the attachment portion 3 (see FIGS. 1C and 1D and FIGS. 2A to 2C ).
[0027] The cover member B includes a groove covering portion 4 , a supporting plate portion 5 , a front-rear deflection restricting portion 51 , and a width-direction deflection restricting portion 52 (see FIGS. 1C and 1D and FIGS. 2A to 2C ). The cover member B is formed by bending an elastic thin metal plate. The groove covering portion 4 has a circular arc-shaped edge 41 , the front edge of which has a circular arc shape. When the groove covering portion 4 is disposed on the string guiding groove 13 of the pressing portion 1 , this circular arc-shaped edge 41 plays a role of compensating for the missing peripheral portion of the needle guiding hole 12 resulting from the formation of the string guiding groove 13 .
[0028] A string guide 42 which is bent to be erected is formed on the left side surface of the groove covering portion 4 . Specifically, the string guide 42 is formed to be erected continuously from the groove covering portion 4 of the cover member B so as to correspond to an insertion opening 13 a for a thread (the decorative string n), of the string guiding groove 13 of the pressing portion 1 (see FIG. 2E ). The string guide 42 is a portion that plays such a role that the decorative string n to be inserted into the needle guiding hole 12 makes contact with the string guide 42 so that the string guide 42 is pressed by pressing force P of the decorative string n and the groove covering portion 4 is moved on the pressing portion 1 . The string guide 42 is erected by being bent at an acute angle. Moreover, as another embodiment, the string guide 42 may be formed in an arc form (see FIG. 4 ).
[0029] The supporting plate portion 5 is formed so as to extend further upward than a portion of the groove covering portion 4 . Moreover, the front-rear deflection restricting portion 51 and the width-direction deflection restricting portion 52 are formed on the supporting plate portion 5 (see FIGS. 1C and 1D and FIGS. 2A to 2C ). An attachment portion 6 is formed in a vertical form to be continuous from the upper end of the supporting plate portion 5 .
[0030] The attachment portion 6 is fixed to the attachment portion 3 of the presser foot body A by a fixing tool 7 such as a rivet. In a state in which the cover member B is fixed to the presser foot body A, the groove covering portion 4 is arranged on the pressing portion 1 and the supporting plate portion 5 is arranged on the supporting portion 2 .
[0031] In a state in which the cover member B is fixed by the fixing tool 7 with an operation of inserting the decorative string n, the supporting plate portion 5 and the groove covering portion 4 float by being displaced from the supporting portion 2 and the pressing portion 1 . By the elastic force of the supporting plate portion 5 , the groove covering portion 4 is provided so as to always cover the string guiding groove 13 of the pressing portion 1 . In this case, the groove covering portion 4 is in a state of making contact with or approaching the pressing portion 1 (see FIG. 3 ).
[0032] The front-rear deflection restricting portion 51 of the supporting plate portion 5 includes a front restricting plate 51 a, a rear restricting plate 51 b, and a connecting piece 51 c that connects both restricting plates (see FIG. 2D ). The front-rear deflection restricting portion 51 is formed at the left end of the supporting plate portion 5 and is configured to restrict the movement in the front-rear direction of the supporting portion 2 with allowance with the aid of the front restricting plate 51 a and the rear restricting plate 51 b of the front-rear deflection restricting portion 51 (see FIG. 2D ). The rear restricting plate 51 b is normally separated from the rear surface of the supporting plate portion 5 and plays a role of restricting the amount of torsion of the supporting plate portion 5 to fall within a predetermined range when torsion occurs in the supporting plate portion 5 with an operation of inserting the decorative string n.
[0033] The interval L between the front restricting plate 51 a and the rear restricting plate 51 b is set to be larger than the thickness T of the supporting portion 2 .
[0034] That is, L>T.
[0035] Due to this, the supporting plate portion 5 is configured to be deformable within the range restricted by the front-rear deflection restricting portion 51 .
[0036] Further, the width-direction deflection restricting portion 52 is formed on the right side of the supporting plate portion 5 . The width-direction deflection restricting portion 52 and the front-rear deflection restricting portion 51 sandwich both sides in the width direction of the supporting portion 2 . The interval between the width-direction deflection restricting portion 52 and the connecting piece 51 c of the front-rear deflection restricting portion 51 is larger than the width of the supporting portion 2 and is set to increase on the side where the connecting piece 51 c is formed (see FIG. 2D ).
[0037] Due to this, the movement in the left-right direction and the front-rear direction of the cover member B in relation to the presser foot body A is elastically restricted at the position of the fixing tool 7 . That is, although the position of the groove covering portion 4 can be moved by elastic deformation of the supporting plate portion 5 , the cover member B restricts the magnitude of deformation of the supporting plate portion 5 . Due to this, the cover member B can be prevented from being unnecessarily elastically deformed when the decorative string n is inserted into the needle guiding hole 12 of the pressing portion 1 , and durability of the cover member B can be secured.
[0038] Moreover, a bent portion 53 is formed at a position close to the left side of the supporting plate portion 5 of the cover member B (see FIGS. 1C and 1D and FIGS. 2A and 2D ). Specifically, the bent portion 53 is formed as a linear bent line at the boundary of the front restricting plate 51 a of the supporting plate portion 5 .
[0039] A right-side region of the supporting plate portion 5 about the bent portion 53 as a boundary is set to float by being displaced from the supporting portion 2 of the presser foot body A (see FIGS. 2C and 2D ). Due to this, in an operation of inserting the decorative string n into the needle guiding hole 12 , when the groove covering portion 4 is moved from the left side to the right side, the groove covering portion 4 is easily displaced from the string guiding groove 13 .
[0040] Next, a cycle of inserting the decorative string n into the needle guiding hole 12 of the presser foot of the present invention will be described with reference to FIGS. 5A to 5C and FIGS. 6A to 6C . First, the groove covering portion 4 of the cover member B is disposed so as to cover the string guiding groove 13 of the pressing portion 1 of the presser foot body A. In this state, the decorative string n such as wool yarn is brought into contact with the string guide 42 of the groove covering portion 4 . Moreover, the decorative string n is stretched to create pressing force P (see FIGS. 5A to 5C ). The decorative string n is bent at the position of the string guide 42 (see FIG. 5B ).
[0041] Subsequently, when the decorative string n having the pressing force P is continuously pressed against the string guide 42 , the groove covering portion 4 and the string guide 42 start moving from the left side (the side close to the insertion opening 13 a ) toward the right side (the side close to the needle guiding hole 12 ) through the string guiding groove 13 of the pressing portion 1 (see FIGS. 6A to 6C ). In this case, the decorative string n is bent at the position of the string guide 42 , the pressing force P is applied to the groove covering portion 4 to raise the groove covering portion 4 upward. The groove covering portion 4 disposed to cover the string guiding groove 13 of the pressing portion 1 is displaced upward from the string guiding groove 13 (see FIGS. 6B and 6C ).
[0042] Subsequently, when the decorative string n is further moved from the left side of the pressing portion 1 toward the right side, the groove covering portion 4 moves while being displaced further from the string guiding groove 13 and the decorative string n reaches the needle guiding hole 12 from the string guiding groove 13 (see FIGS. 7A to 7C ). When the decorative string n is completely inserted into the needle guiding hole 12 , the decorative string n detaches from the string guide 42 and the groove covering portion 4 approaches the string guiding groove 13 to close the string guiding groove 13 . In this way, the decorative string n is prevented from detaching from the needle guiding hole 12 .
[0043] Here, in the process of inserting the decorative string n into the needle guiding hole 12 , the groove covering portion 4 is moved from the left side toward the right side by the pressing force P of the decorative string n, and the right-side region of the supporting plate portion 5 is displaced from the supporting portion 2 of the presser foot body A by the bent portion 53 formed in the supporting plate portion 5 . In this case, the groove covering portion 4 also floats from the pressing portion 1 .
[0044] In this way, when the decorative string n is inserted into the string guiding groove 13 , the right-side portion of the groove covering portion 4 in relation to the cover member B serves as a refuge for overall deformation of the groove covering portion 4 , and the groove covering portion 4 can be easily deformed. Thus, a gap in which the decorative string n can be inserted is formed between the string guiding groove 13 and the groove covering portion 4 . In this manner, a state in which the decorative string n can be easily moved to the position of the string guiding groove 13 can be created.
[0045] In the second embodiment, since the bent portion is formed at a position near the left end in the left-right direction of the supporting plate portion of the cover member, substantially the entire portion of the supporting plate portion except the left end in the left-right direction floats by being displaced elastically from the supporting portion of the presser foot body. Due to this, the groove covering portion can be more easily displaced in relation to the upper side of the string guiding groove of the pressing portion and the operation of inserting the decorative string can be performed more easily and quickly.
[0046] In the third embodiment, since the string guide is formed at the left end of the groove covering portion of the cover member, in the process of inserting the decorative string into the needle guiding hole, the decorative string makes substantially surface-contact with the string guide. Thus, it is possible to protect the decorative string so that intensive load is not applied to the decorative string especially during the insertion operation.
[0047] In the fourth embodiment, the restricting portion which includes the front restricting plate and the rear restricting plate and has a C-shaped cross-sectional shape is formed on the left side in the width direction of the supporting plate portion of the cover member, and the interval between the front restricting plate and the rear restricting plate is larger than the thickness of the supporting portion. Thus, it is possible to restrict a separation distance of the cover member from the supporting portion of the presser foot body, restrict a separation distance of the groove covering portion from the upper surface of the string guiding groove, and prevent deformation resulting from too much displacement. | A sewing machine presser foot includes: a presser foot body including an attachment portion attached to a presser bar of a sewing machine, a supporting portion extending downward from the attachment portion , and a pressing portion in which, at a lower end of the supporting portion, a needle guiding hole having a string guiding groove for guiding a string is formed; and a cover member including a groove covering portion that crosses and covers the string guiding groove of the pressing portion, a supporting plate portion formed along the supporting portion continuously from the groove covering portion, and an attachment portion formed at an end of the supporting plate portion so as to be attached to the presser foot body. A right-side portion of the supporting plate portion of the cover member is fixed to the presser foot body A by the attachment portion. | 3 |
TECHNICAL FIELD
[0001] This invention relates to a gas and aerosol device for detecting human's breathing; it specifically relates to a sensor device that is hung around the nose end using carbon nanotubes for the detection of gas and aerosol; furthermore, it is relates to a device, which is in association with signal processing circuit and wireless transmitting/receiving module, for measuring, warning, transmitting and receiving physiological signal.
BACKGROUND OF THE INVENTION
[0002] The gas exhaled from human body reflects the condition of organ and tissue in human body. For example, inflammation and oxidation stress can be monitored through the measurement of the concentration changes of the NO gas; the exhaled CO is a marker of cardiovascular diseases, diabetes, nephritis and bilirubin production; the exhaled low molecular weight hydrocarbon, for example, ethane and n-pentane, ethylene and isoprene; isoprene comes from the cholesterol synthesis process in human body and its concentration is related to the food; therefore, through the exhalation, the exhaled gas can be used as a special marker of the cholesterol concentration in the blood. [Reference: Karl T., Prazeller P., Mayr D., Jordan A., Rieder Fall J. R. and Lindinger, W., 2001, Human breath isoprene and its relation to blood cholesterol levels: new measurements and modeling, J. Appl. Physiol., 91, 762-70]
[0003] Acetone is a marker for diabetes; formaldehyde, ethanol, hydrogen sulfide and carbonyl sulfides shows the damage of the liver; however, for ammonia/amines—the later is a marker of renal diseases [Refer to literature by Smith A D, Cowan J O, Filsell S, McLachlan C, Monti-Sheehan G, Jackson P and Taylor D R, 2004, Diagnosing asthma: comparisons between exhaled nitric oxide measurements and conventional tests, Am. J. Resp. Crit. Care Med., 169, 473-8 and literature by Risby T H and Sehnert S S, 1999, Clinical application of breath biomarkers of oxidative stress status, Free Rad. Biol. Med., 27, 1182-92].
[0004] The odor of gas is due to infection and disorder, which provides a path for the application of chemical sensor in the biological field. The generation of NO 2 is related to the bronchial epithelial infection, which is caused by smoking. Besides, ammonia is a product of the decomposition of urea. [Studer S M, et al, 2001, Patterns and significance of exhaled-breath biomarkers in lung transplant recipients with acute allograft rejection, J. Heart Lung Transplant, 20, 1158-66].
[0005] Therefore, a sensor that can effectively monitor the gas exhaled by human being in the long term is very important. In addition, there are many contagious diseases or allergic diseases are from the external bioaerosol; if one is a carrier, the corresponding bioaerosol will be exhaled out of his body through mouth and nose and enters the external air; therefore, a device that can detect the gas exhaled from human body and aerosol is proposed in this invention, it more specifically relates to a sensor device that is hung around the nose end which uses carbon nanotubes for the detection of gas and aerosol; moreover, it is a device that can measure, warn and transmit and receive physiological signal in association with signal processing circuit and wireless transmitting/receiving module. Furthermore, the invented sensor through a way like a face mask, the gas and aerosol in and out of the mouth and nose can also be detected as long as the packaging method is changed accordingly.
SUMMARY
[0006] This invention provides a device for detecting the gas inhaled and exhaled by human body and the detection includes the species, concentration, temperature and humidity of the gas inhaled and exhaled by human body; in the device, carbon nanotube is used as the sensor material; it is known that purified carbon nanotubes or surface-modified carbon nanotubes will react with specific gas to generate mass and electrical property change, for example, resistance, capacitance, and transistor characteristics; for foreign hazardous gas, the features of carbon nanotube sensor such as high sensitivity and high response speed can be used to inform the user to escape from the environment once hazardous substances are detected so as not to be injured by the hazardous gases, for example, CO and methane, etc.; moreover, it can detect species, rate of change of concentration, temperature and humidity of the gas exhaled by human body to be used as reference for monitoring physiological status or the purpose of diagnosis. If we perform further adsorption modification by using DNA or antibody or aptamer or carbohydrate on carbon nanotubes, we can detect the aerosol inhaled or exhaled by human body, for example, the detection of flu virus and tuberculosis bacteria, etc.
[0007] A device that can achieve the objective of the above mentioned invention for detecting the gas and aerosol exhaled by human body comprising of at least: a substrate, a carbon nanotube gas sensor device, a signal processing circuit, a wireless transmitting/receiving module or a body-network transmitting/receiving module, and a power supply.
[0008] The user can wear the device for detecting the gas and aerosol inhaled and exhaled by human body and the device can continuously detect the gas and aerosol inhaled and exhaled by the user; after the reaction of carbon nanotube sensor device with the gas or aerosol, a signal processing circuit will be used for the electrical measurement of carbon nanotube sensor device; then the electrical signal measured will be transmitted to a remote monitoring device or another warning device through wireless transmitting/receiving module or a body-network transmitting/receiving module for the monitoring or recording purpose as required by a user or a monitoring person; if the user has been detected with the inhalation or exhalation of hazardous gas or aerosol, high inhaled or exhaled temperature or the exhaled gas has very low content of water which is suspicious of dehydration, then the user or the remote monitoring personnel can get the warning immediately.
BRIEF DESCRIPTION OF DRAWINGS
[0009] The invention may best be understood by reference to the following description taken in conjunction with the accompanying drawings that illustrate specific embodiments of the present invention.
[0010] FIG. 1 is a system architecture of the present invention for a gas and aerosol detection device to detect the gas and aerosol inhaled or exhaled by human body.
[0011] FIG. 2 is a detection device of the present invention that can be used to detect the gas and aerosol inhaled and exhaled by human body and is hung around the nose outer wall of human body.
[0012] FIG. 3 illustrates carbon nanotube sensor device of the present invention.
[0013] FIG. 4 is an embodiment of the device of present invention clamped on the columella between the nostrils of human nose.
[0014] FIG. 5 is the experimental result of the present invention: wherein cross-linking agent is used to modify antibody onto the surface of carbon nanotube and carbon nanotube transistor is used to detect biological particle; when the biological particle is adhered to the surface of the carbon nanotube, the electrical property change is measured, that is, I sd −V gs characteristic diagram is drawn.
[0015] FIG. 6 is the experimental result of the present invention: When PBS mixed solution with salmonella is dropped, it is found immediately that there is an obvious drop in the current, when it drops to about 1.4×10 −6 A, it will restore to a stable status; later on, add other types of cells ( Pseudomonas aeruginosa ) into the buffer solution, the current won't change. Therefore, through such an electrical signal experiment, it is found that the reaction of the combination of salmonella with the corresponding antibody will cause an obvious drop in the electrical conductivity of the carbon nanotube.
[0016] FIG. 7 is the experimental result of the present invention: Wherein CNTFET is used as biomedical sensor (ssDNA) and gas sensor (acetone). (a) is the titration of “A” basic ssDNA, “ON” current will rise and the I sd −V gs curve will shift toward “positive” direction; (b) is the titration of “T” basic ssDNA, “ON” current will drop and I sd −V gs curve will shift toward “negative” direction; (c) is the titration of “C” basic ssDNA, “ON” current will drop and I sd −V gs curve will shift towards “positive” direction; (d) is the titration of “G” basic ssDNA, “ON” current will drop; (e) is the real time measurement of acetone CNTFET sensor surface-modified with DNA.
[0017] FIG. 8 shows that droplet that contains flu vaccine will approach CNTFETs chip easily due to the suction action (for example, the suction action performed by the human nose); when it gets in contact with flu antibody or flu aptamers on multiple single-wall carbon nanotubes (only single nanotube is illustrated in the figure), binding reaction will be generated within the droplet.
DETAILED DESCRIPTION
[0018] Nano sensor device has been widely discussed and researched in recent years mainly because the nano sensor device has the advantages such as high sensitivity and low power consumption; it is especially useful for the application in the biomedical detection field, for example, for bacteria, virus or DNA with dimension smaller than sub-micrometer or even down to nano scale. The dimension of the object to be tested is much smaller than the sensor device dimension of MEMS device. Therefore, sensor device that is made using micron scale can not meet the demand in the detection accuracy and speed. In the present invention, carbon nanotube having semiconductor characteristics is used as nano sensor device (nanosensor) to perform the detection of substance that is harmful to the human body and the monitoring of human health status so as to achieve the purpose of high sensitivity, low energy consumption, capability of repeated measurement and low manufacturing cost; furthermore, this sensor unit can be used massively and at the same time in the environmental monitoring and human health status monitoring; moreover, if there are more people using it, it can be linked together as a wireless sensor network and a large and dead-corner-free protection net is thus formed and besides, it is mobile. This is especially true in the eruption of epidemic disease, for example, avian flu, foot-and-mouth disease, mad cow disease, SARS, etc.; during that period of time, it can be embedded into part of the fowls, pigs or cows and the patient that is suspicious of SARS disease; if it can be further added into wireless sensor network, the protection breadth and density is going to be greatly enhanced.
[0019] In recent years, many research organizations continuously get involved in related researches on electronic device based on carbon nanotube, the research results shows that carbon nanotube electronic device, under shorter channel length, for example, smaller than one micron, will have the characteristic of ballistic transportation; meanwhile, a single carbon nanotube channel can take current of ˜25 μA, and all these superior transistor characteristics could make it replace the present CMOS chip and become the electronic device of the next generation. In addition, carbon nanotube electronic device, when the channel is of longer length, can be used to detect the foreign molecules in the environment (gas molecules and biological molecules, etc.); it not only has high sensitive detection capability, but also has very small detector volume and low power consumption; moreover, after special carbon nanotube surface modification, it can be used as a sensor device that has high sensitivity and is dedicated for specific detection. From the above introductions, it can be seen that electronic device based on carbon nanotube will become potential transistor and sensor device in the future.
[0020] According to a study performed by Kong et al. in 2000 [see: Science 287, 622 (2000)], when semiconductor type carbon nanotube is exposed to gas molecules, for example, NO 2 , NH 3 and O 2 , its resistance value will be changed, and its response speed is about 10 times that of the conventional solid-state sensor; under room temperature, semiconductor type single wall carbon nanotube will have a sensitivity on gas of over 10 3 .
[0021] Due to the high sensitivity of carbon nanotube, in order to prevent the detecting result being affected by the environment, for example, temperature and humidity, there are several solutions provided in many researches, for example, Ashish Modi et al. in 2003 [Letters to Nature , VOL 424, 10 Jul. 2003] tried to use carbon nanotube as gas molecule sensor; different gas will have different breakdown voltage and current to distinguish gas species and concentration, and most importantly, it is not affected by the environment. In the device, there is one aluminum cathode and one anode made up of vertical and multi-wall carbon nanotubes on the SiO 2 substrate through chemical vapor deposition (CVD) method (with diameter of 25˜30 nm, length of 30 nm and spacing of 50 nm) for the detection of different gases in the air; the research result shows that the sensor has very good gas selectivity and sensitivity.
[0022] In addition, Snow et al. in 2005 [Science 307, 1942 (2005)] had proposed a gas detecting mechanism through the use of the measurement of the capacitance value of single wall carbon nanotubes when polarizing the gas nearby, which not only has higher sensitivity but also has larger concentration measurement range. Penza et al. in 2004 [Sensors and Actuators B 100, 47 (2004).] had proposed the deposition of one layer of carbon nanotube on the Surface Acoustic Waves (SAWs) sensor to be used as the detecting device of volatile organic mixed gas, for example, ethanol, ethyl acetate, toluene, etc with result showing high sensitivity. Ong et al. in 2002 [IEEE Sens. J. 2, 82 (2002)] had proposed the use of mixing thin film of SiO 2 and multi-wall carbon nanotube as gas sensor, which used the measurement of thin film capacitance and dielectric constant to judge the gas absorbed. Wong et al. in 2003 [Proc. IEEE Int. Symp. Circuits Sys. 4, IV844 (2003)] used AC electrophoresis force to manipulate multi-wall carbon nanotube, which was crossed and connected to Au micro electrode, to be used as temperature sensor; through the continuous measurement of voltage (V) and current (I), the result showed that the energy consumption was only in the range of several μWs.
[0023] Chopra et al. in 2002 [Appl. Phys. Lett. 80, 4632 (2002)] had deposited single-wall and multi-wall carbon nanotube on the microwave resonant sensor for the detection of ammonia. Someya et al. in 2003 [Nano Lett. 3, 877 (2003)] had used single-wall carbon nanotube field effect transistor (FETs) for the detection of ethanol vapor, when the surface of carbon nanotube absorbs ethanol vapor and gets saturated, the current value measured is going to drop rapidly to a fixed value. Staii et al. in 2005 [Nano Lett. 5, 1774 (2005)] had used single-wall carbon nanotube filed effect transistor as a sensor device and found that it could be used to detect different gases with very rapid response speed and response time; when it was exposed at different gas, it would generate different detecting current; meanwhile, this sensor device had the capability to restore to its detecting capability, and after of a detecting cycle of more than 50 repeated times, it still had very good detecting capability.
[0024] Currently, there are many researches that use carbon nanotube as sensor device, and the gases that have currently been verified to be able to be detected by carbon nanotube include: NH 3 , CO 2 , O 2 , NO 2 , CH 4 , H 2 , N 2 , Ar, CO, NO, He, SF 6 , methanol, ethanol, Organophosphorus pesticides, etc.
Carbon Nanotube Gas Detecting Principle
[0025] Gas detection theory model has been researched for many years, which is mainly proposed through a model of cluster semiconductor sphere with the current between cluster calculated through thermal emission and carrier tunneling. The surface electron density represents the chemical status of the gas adsorbed and the depletion layer width is constructed based on the calculation of abrupt junction model with the consideration of surface status of consistent semiconductor energy band. The sensitivity is calculated through logarithm of surface density and conductivity. Gas detection mainly uses the change of electrical property at different locations due to chemical adsorption effect, and the most commonly used model is to use the strength of the adsorbed particles for qualitative analysis, which involves the conversion relation among gas and solid by charges of conduction electron due to adsorption effect (donor or acceptor).
[0026] In the commonly used metallic oxide sensor, factors such as the existence of oxygen or the reduction of background gas in the environment will all have very obvious effect on the change of electronic conductivity. It can not be purely explained by the change of the conduction electron concentration, the change of energy gap of potential energy formed by the adsorbed acceptor or donor at the interface should be considered at the same time, which in turn controls the electron flow on both sides of the junction. When N-type semiconductor oxide is exposed to environment that contains reduction gas, the adsorbed oxygen will gradually be consumed due to the reaction with reduction gas. The reduction of oxygen ion on the surface of semiconductor oxide will let the electrons trapped by oxygen go back to the crystal grain. This process will lead to the reduction of energy gap, that is, a reduction in the resistance.
[0027] When the gas to be tested is in contact with semiconductor, energy level will be changed. Electron will flow from high Fermi energy level area (the area in the neighborhood of semiconductor surface) to low Fermi energy level area (surface status). The separation of electronic charge will lead to the formation of double layer voltage, which in turn increases the surface energy. When the double layer voltage is large enough to let the Fermi energy level of the entire system become a constant, an equilibrium state is reached. The band movement close to the surface is called “band bending”. This phenomenon is used to represent the adsorption of gas on the crystal surface which in turn cause the change of the surface status; moreover, this phenomenon will cause the change of characteristic of carbon nanotube, for example, electrical inductance, electrical conductivity (or electrical resistance), dielectric constant and mass. Therefore, the measurement of the electrical property after the reaction of carbon nanotube with specific gas can be used as the method to detect the gas.
Carbon Nanotube Temperature Detecting Principle
[0028] Wong et al. had used batch fabrication for the carbon-nanotube-based thermal sensors [ IEEE trans. Automation Science and Engineering , Vol. 3, 3 Jul. 2006, 218-227]. They used Dielectrophoresis (DEP) force manipulation technology to place carbon nanotube across two electrodes with better deployment orientation and contact so as to form a loop and to conduct the electric current, and carbon nanotube here is used as resistance sensor unit to detect the temperature change; furthermore, it is found in the experiment that the temperature coefficient of resistivity (TCR) shows a negative slope, that is, the resistance of carbon nanotube will fall along with the rise in temperature; from the voltage and current measurement, it shows that the power consumption of carbon nanotube is calculated to be about in the range of μW, and the room temperature resistance distribution scope is from several KΩs to several hundreds KΩs. Li et al. had used defined microstructure and the manipulation technology of Dielectrophoresis (DEP) force and carbon nanotube to form a resistor unit, the experimental result shows that the self-heat current needed by carbon nanotube is much smaller than that needed by traditional polysilicon material made by MEMS technology. In addition to that, this device, under constant current mode, has faster frequency response (>100 KHz); meanwhile, it can be used as hot-film anemometry and the power needed by this flow sensor is about 15 μW.
Manufacturing Technology of Carbon Nanotube Sensor
[0029] The synthesis and application of carbon nanotube can be generally divided into the following preparation ways: (1) Arc-discharge method; (2) Laser ablation method; (3) Chemical vapor deposition method. Most of the articles in the literature use chemical vapor deposition method to prepare carbon nanotube sensor device on the substrate with a needed deposition temperature of about 600 degree C. However, at room temperature, the present invention can use DEP force to place carbon nanotube across the electrodes and measure the resistance or dielectric constant of carbon nanotube or prepare a transistor and measure the electrical property; if making surface modification first on carbon nanotube and then placing it across electrodes using DEP force, the present invention can then measure specific gas.
[0030] Please refer to FIG. 1 , it can be seen from the figure that a device 11 that can detect the gas and aerosol inhaled and exhaled by human body is proposed in the present invention, which is mainly a substrate 12 that can be clamped on the columella between the nostrils is used to carry carbon nanotube sensor device 13 , electronic circuit module 14 , wireless transmitting/receiving module 15 , power supply 16 , alarm device 17 and monitoring device 18 .
[0031] Substrate 12 is bio-compatible polymer material, for example, PHA polymer, Lexan HPX8R, Lexan HPX4, PHBHHx, etc., which possesses clamping structure 121 or adhesion structure 122 so that the device is a structure can be hung on the nose wall 19 of human body, which is as shown in FIG. 2 . Meanwhile, we can also make the structure as a nose ring (not shown in FIG. 2 ) so that it possesses a decorative function at the same time.
[0032] FIG. 3 shows all methods using carbon nanotube as sensor device, Among them, carbon nanotube sensor device 31 is at least one carbon nanotube 311 placed across two electrode structures 312 , and the resistance change of carbon nanotube is measured here.
[0033] Another carbon nanotube sensor device 31 is at least a carbon nanotube 313 fixed to an electrode 314 and heads toward another electrode 315 and has a spacing of 316 maintained with the other electrode; furthermore, when we apply voltage across both sides, we can measure the breakdown voltage and breakdown current of carbon nanotube.
[0034] There is yet another carbon nanotube sensor device 31 which is at least a carbon nanotube 317 installed between capacitor structure 318 , then a bias is applied between the capacitor structure and the change in capacitance value and dielectric constant is measured.
[0035] There is further another carbon nanotube sensor device 31 which is a network carbon nanotube 319 (CNT network) installed on a dielectric thin film of a capacitor structure to be used as upper electrode 320 , and the lower electrode is metal installed below the dielectric thin film to measure the capacitance change.
[0036] More another carbon nanotube sensor device 31 is carbon nanotube 321 placed respectively across source electrode 322 and drain electrode 323 , and gate electrode 324 in the neighborhood of carbon nanotube 321 forms together with the above mentioned structure a field effect transistor structure that can be used to control the property of carbon nanotube 321 and the transistor characteristics of carbon nanotube can then be measured.
[0037] There is furthermore a carbon nanotube sensor device 31 which is at least a carbon nanotube 325 deposited on acoustic sensor 326 so as to measure the resonance frequency change of the acoustic sensor. Moreover, the carbon nanotube 325 can be coated on film body acoustic resonator (FBAR) to measure its resonance frequency change.
[0038] To make a conclusion, we know that the above carbon nanotube sensor device 31 is a sensor device that can be used to detect the gas inhaled and exhaled by human body (for example, detecting the gas species, concentration and its rate of change and temperature and humidity) and then send the gas signal into the electronic circuit module 14 for conversion;
[0039] The electronic module 14 is adjacent to carbon nanotube sensor device 31 , wireless transmitting/receiving module 15 and power supply 16 and used as data processing, conversion and exchange center; the data processing includes magnification of signal, signal filtering, analog/digital signal conversion, signal coding or signal decoding.
[0040] The wireless transmitting/receiving module 15 receives the detected gas signal converted from electronic module 14 , and uses wireless way, through antenna 21 , to send the detected signal of gas and aerosol inhaled and exhaled from human body to remote alarm device 17 or monitoring device 18 ; furthermore, the human skin can be used as media for transmitting and receiving the signal to send the signal to the warming device or monitoring device (not shown in the figure) worn or attached on other parts of human body, for example, waist and hand.
[0041] The warning device 17 is used to receive the detected signal of gas and aerosol inhaled and exhaled from human body sent out from wireless transmitting/receiving module 15 . Moreover, warning status can be set up, and warning messages can be sent out in the warning status, for example, by one of the following ways such as: vibration, sound, bright light or a display through a screen, etc.
[0042] The monitoring device 18 is used to receive detected signal of the gas and aerosol inhaled and exhaled by human body and sent out from wireless transmitting/receiving module 15 , the signal is then monitored and recorded.
[0043] Power supply 16 is a battery or wireless power supply module or a power supply module sent through the body surface.
Manufacturing Technology Integration Between Carbon Nanotube and CMOS Chip
[0044] In the present invention, one more method is proposed to deposit in low temperature the carbon nanotube effectively and in large scale and adhere and fix it on the exposed metal of a passivation opening that is previously designed on a CMOS. In order to fix carbon nanotube on the metallic layer, first, take tiny amount of the previously acquired and sorted single wall or multi-wall carbon nanotubes and immerse them in DI (de-ionized) water solution that contains 1-wt % Sodium Dodecylsulfate (SDS) so that the wall of carbon nanotube will be covered by SDS molecules; moreover, carbon nanotube concentration should be diluted to a status depending on application needs, and 0.35-wt % of Ethylene Diamine Tetra Acetic Acid (EDTA) and 4-vol % TRIS-HCl buffer should be added so as to compound the residual transition metal ion and to maintain a stable PH value. First, ultrasonic vibration will be used to vibrate and separate bundled carbon nanotubes, then a centrifugal device is used to let bundled carbon nanotubes that is coated with SDS molecules on the outer wall and impurity precipitate to the bottom; then the low mass single carbon nanotubes with outer wall coated with SDS molecule will be centrifuged to the upper level of the container; then extract carefully the 30%˜80% solution on the upper level of the solution, these carbon nanotubes can then be used for manipulation and fixing. By referring to the literature [Zhi-Bin Zhang et al. “Alternating current dielectrophoresis of carbon nanotubes”, J. Appl. Phys ., Vol. 98, 056103, 2005], we can be sure that after carbon nanotube solution is treated by such method, not only the subsequent manipulation of carbon nanotube by Dielectrophoresis (DEP) force is easier. In addition, since semiconducting carbon nanotubes have the different DEP property from metallic CNTs, they are more favorable to be applied in the application of fixing carbon nanotube, that is, manipulation frequency and electrode design as well as channel design can be used to effectively separate the metallic and semiconducting carbon nanotubes.
[0045] Drop solution containing carbon nanotubes on the exposed metallic pad above CMOS structure and apply DEP force to manipulate carbon nanotube. Through the adjustment of AC frequency, AC peak-to-peak voltage and DC voltage, we can adjust and manipulate the DEP force of carbon nanotube; meanwhile, at the time of the application of DEP force, we can add impedance meter through a model of lock-in amplifier that, at the same time while the DEP signal is applied, impedance measurement can be performed as well; by doing so, the impedance value can be measured at the same time so as to detect the quantity of carbon nanotube attached on the electrode; In addition, through the use of positive DEP and negative DEP force, the extra or not originally targeted number of carbon nanotube on the electrode are excluded by negative DEP force through the use of the adjustment of AC frequency, AC voltage (Peak-to-Peak voltage), DC voltage, etc.; then perform once again the signal and apply signal of positive DEP force range, until the needed carbon nanotube number is reached, then keep the DEP force until the evaporation of the dielectric solution, and finally, blow in N 2 gas to blow dry the water beads remained on the surface. Therefore, through the use of this method, carbon nanotube can be fixed on the CMOS chip through the use of low temperature post-process, the damage of the CMOS won't be caused due to the high temperature problem as mentioned above; moreover, the number of carbon nanotube associated on the electrode can be effectively controlled. By using lift-off process, a comb-shape metal layer of Cr/Au as electrodes can further be deposited on the area of CNTs to make the CNTs firmly be fastened under the electrodes. Consequently a system type chip processor unit, or called as System-on-Chip (SOC) with carbon nanotubes associated on CMOS structure is then achieved. Here please also note that in the present inventions if the sensor device based on carbon nanotubes after manufacturing has a deviation of electrical characteristics from the specification, we still can employ laser trimming technique to cut out part of the CNTs to adjust the sensed signal to meet the required specification, which is similar to the counterpart in analog integrated circuits industry.
[0046] In the followings, the attached drawings and examples will be referred to for the descriptions of the technological means and functions used by the present invention to achieve its goal; the examples as listed in the following figures are only aids for the descriptions so as to facilitate the understanding, but the technological means of the present invention should not be limited by the figures listed.
[0047] Please refer to FIG. 4 , which is an illustration of the device when it is worn on the nose of a person; it can be seen from the figure that the device and system 11 which can detect the gas and aerosol inhaled and exhaled from human body is a structure comprising of a substrate of clamping structure 121 or adhesion structure 122 and is clamped on the columella between the nostrils 19 ; moreover, its carbon nanotube sensor device 13 is aligned to the breathing gas channel 41 so that carbon nanotube sensor device 13 can get contacted with the gas and aerosol inhaled and exhaled through the nose, then the specific gas molecule and aerosol 42 inhaled and exhaled will get in contact with the surface of carbon nanotube 43 of carbon nanotube sensor device 13 and lead to the change of resistance, capacitance, mass, breakdown voltage and current of carbon nanotube. For example, through the use of the resistance measurement structure 44 , we can measure the resistance change of carbon nanotube; through the use of capacitance structure 45 , we can measure the dielectric constant change and the above mentioned methods can be used as the measurement of gas concentration and humidity; network carbon nanotube is used as capacitor structure of upper electrode 46 , that is, carbon nanotube thin film is coated on the dielectric thin film of a capacitance structure as the upper electrode, and the lower electrode is metal which is installed below the dielectric thin film; then a capacitance change due to the reaction between carbon nanotubes and gas can be used as highly sensitive gas concentration measurement; carbon nanotubes 43 are connected to an electrode 471 , and bias voltage is applied at another electrode 472 , then the breakdown voltage and current is measured; carbon nanotubes 43 can be coated on surface acoustic waves sensor 48 and the mass or resonance frequency change of acoustic sensor can be measured; combine carbon nanotubes 43 with three electrodes 491 to form a carbon nanotube transistor 49 , then, through the measurement of the characteristic change of carbon nanotube transistor, for example, the relationship between gate voltage V g and the drain and source electrode current I sd , we can detect the species and concentration of the gas.
[0048] Connect the above mentioned carbon nanotube sensor device 13 with electronic circuit module 14 , wherein the circuit has a structure for amplifying circuit signal, filtering out noise and measuring signals (for example, resistance, dielectric constant, capacitance, inductance, resonance frequency, breakdown voltage and transistor characteristics); then through an analog/digital conversion, an wireless transmitting/receiving module 15 then transmits the signal to warning device 17 or monitoring device 18 , wherein the wireless transmitting/receiving module 15 receives the gas and aerosol detected signal converted from electronic circuit module 14 , and through wireless transmitting method through antenna 21 , the detected result of gas and aerosol inhaled and exhaled by human body can be transmitted to warning device 17 or monitoring device 18 through wireless method; when the species of the specific gas and aerosol or the gas temperature exceed the warning range, the monitoring device 18 will monitor and record the gas and aerosol signal inhaled and exhaled by human body, then the warning device 17 will issue warning message, for example, vibration, sound, bright light or a display through a screen, etc. to inform the user or the nursing personnel or convert the carrier signal into digital data and have it displayed in a monitor screen so as to achieve the purpose of monitoring and to inform the user to move away immediately the environment where the gas and aerosol exist and to avoid the possible hurt caused by the harmful gas and aerosol.
[0049] In order to let the species of gas detected be more diversified, in addition to using highly specific surface modification method, the sensor can also be an array type sensor, that is, the above mentioned sensor devices can be assembled in multiple ways; in other words, different electronic circuit designs and carbon nanotube devices can be constructed on the same chip, or multiple same carbon nanotube devices can be given with different surface-modified recipes so that it can have different level of reaction with different gases; furthermore, through a classifying algorithm, for example, neural network or principal component analysis (PCA), etc., pattern recognition can then be performed and all kinds of different gases can then be distinguished effectively. Generally speaking, the present invention uses the modified materials that are commonly used for traditional gas sensor, for example, metals (Pd or Au, etc.), polymer, metal oxide, hydrogen-ion or OH-ion-containing material, to perform modification on carbon nanotubes so that it can achieve specific judgment on the biomarker gases exhaled from human body through PCA or neural network algorithm.
[0050] In the present invention, electrodes can also be made on standard substrate with electrode patterns other than a CMOS chip. Through the use of masking method, carbon nanotube solution is sprayed or spotting among the electrodes, then the solvent is waited for its natural evaporation to form nano thin film, and finally, all the electrical characteristics of the carbon nanotube thin film are measured and the results are used as comparison reference for bio detection. Since carbodiimidazole-activated Tween 20 (CDI-Tween) is covered on carbon nanotube and its hydrophobic characteristics are used to modify the surface of carbon nanotube; then antibody or aptamer or carbohydrate are going to be combined with CDI-Tween-treated single wall carbon nanotube through covalent bonding. When antibody or aptamer or carbohydrate are successfully adhered to carbon nanotube to modify the carbon nanotube, then the effect and change of antibody or aptamer or carbohydrate on the electrical properties of single wall carbon nanotube transistor (SWNT-FET) will be measured; it is believed that through the use of the special characteristics of antibody or aptamer or carbohydrate, the sensitivity and property of carbon nanotube transistor can be enhanced; furthermore, the antibody or aptamer or carbohydrate are used as carrier to selectively detect the acceptor, that is, carbon nanotube transistor bio sensor device are successfully constructed with antibody or aptamer or carbohydrate as identifying component.
[0051] For the detection device for detecting gas and aerosol inhaled and exhaled by human body as proposed in the present invention has the following advantages as compared to other prior art methods:
[0052] 1. The device and system of the current invention for detecting the gas and aerosol inhaled and exhaled by human body is attached or clamped on the nose wall through clamping structure and can be used to monitor the gas and aerosol inhaled and exhaled by the user for a long time; since it has a small volume and is of light weight, it won't be any load to the user.
[0053] 2. The current invention is installed at the nose end with the gas directly coming from the inhalation or exhalation of the user, which is quite different as compared to other handheld or fixed or wearing type detection methods; therefore, extra gas pumping device is not needed and the harmful gas or bioaerosol in the environment can be effectively grasped.
[0054] 3. Since the present invention is installed at the nose end, another advantage of it is that whether bioaerosol that can spread through breathing exist inside of the human body can be known, for example, the flu virus or tuberculosis bacteria, etc., and of course, the specific odor might possibly represent the symptom of certain disease.
[0055] 4. The present invention detects the gas through the measurement of one of the following properties on the carbon nanotube sensor device, for example, resistance, dielectric constant, resonance frequency, transistor characteristic and breakdown voltage, etc., the accuracy of gas detection can be greatly enhanced.
[0056] 5. In the present invention, DEP force is used to assemble semiconductor carbon nanotube onto specific electrode; since the carbon nanotube is prepared separately with the electronic circuit, hence, before the assembly of carbon nanotube, carbon nanotube can be separated in terms of metallic type and semiconductor type or surface modification (doping) can be done to enhance the sensitivity and specificity of gas detection.
[0057] 6. In the device and system of the present invention for detecting the gas and aerosol inhaled and exhaled by human body, the electronic circuit module can be manufactured through the use of standard CMOS process and the batch manufacturing of this device and system is thus feasible.
[0058] 7. In the device and system of the current invention for detecting the gas and aerosol inhaled and exhaled by human body, since it can be used together with mobile phone or wireless communication, the monitoring distance can then be enhanced.
EXAMPLE 1
Detection of the Change of NO Exhaled by the Human Body
[0059] The management of inflammation of respiratory tract is dependent on appropriate monitoring and curing so as to obtain a long term effect. However, the current method has its limit; therefore, it is very difficult to achieve such goal. Although nitric oxide (NO) has been identified early 200 years ago, yet its physiological importance is really recognized in the beginning of 1980s.
[0060] Many researches have identified NO as one of the major message molecules inside the body system, in addition, many researches also find that the change of NO exhaled is highly related to other markers of the inflammation of respiratory tract. Since the technology of the measurement of NO exhaled is non-invasive, reproducible, sensitive, and easy to implement; therefore, the monitoring of the exhaled NO change can be used to manage asthma and other lung disease. [Choi J et al., Markers of lung disease in exhaled breath: nitric oxide, Biological Research for Nursing, 2006 April, 7(4):241-55.]
[0061] Carbon nanotube is first placed in the reflux of H 2 O 2 and a mixing solution of sulfuric acid and nitric acid (3:1) so as to remove carbon nano particle and to generate functional group on the carbon nanotube to be used as place for the covering of SnO 2 ; next, place this acid-treated carbon nanotube in 80 mL and 0.1 mol/L tin(II)chloride solution and add 1.4 mL of HCl, then use ultrasonic vibration to agitate for 30 minutes, then filter the product and use distilled water to clean it. By doing so, the nanoparticle of SnO 2 will be coated uniformly on carbon nanotube with dimension of about 2-6 nm.
[0062] Then connect the surface-modified carbon nanotube through DEP force to between two electrodes to complete impedance type or transistor type device or the device of the detection method as proposed by the present invention.
[0063] The operation principle is: When sensor is in the air, oxygen molecule will be absorbed to SnO 2 nanoparticle and extract electrons from the SnO 2 nanoparticle to become oxygen ion and SnO 2 will in turn carry positive charge and barriers will be formed among SnO 2 nanoparticles. Since the SnO 2 nanoparticle is very small, there are thus a lot of interstitials to absorb the gas and react with it. When the sensor is placed in NOx gas, easily oxidized gas molecule will be further adsorbed onto SnO 2 nanoparticle and extract electrons to form higher barriers; therefore, for resistance type sensor, the resistance is going to rise a lot; however, when the sensor is placed back into the air again, NOx molecule will be released again from SnO 2 nanoparticle and the electrons will be released back too; therefore, the resistance of the sensor will go back to the original value in the air.
EXAMPLE 2
Detection of Biological Aerosol
[0064] Using cross-linking agent to modify antibody onto the carbon nanotube surface, then the carbon nanotube transistor is used to detect biological particle so as to understand the electrical property change when biological particle is attached to the surface of carbon nanotube. The characteristic diagram of I sd −V gs is shown in FIG. 5 , in the figure, bare CNT represents carbon nanotube transistor that is not modified, ab PEI/PEG CNT represents the use of PEI/PEG to modify the antibody onto the surface of the carbon nanotube transistor; from FIG. 5 , it can be seen that after antibody modification, the transistor I-V characteristic curve has a trend to move horizontally to the left, and the Vg (Threshold Gate voltage) moves from original 5V to the left horizontally to about 1V, the reason is because electrons are transferred to the carbon nanotube through protein, which in turn leads to the horizontal shift of I-V characteristic curve.
[0065] In FIG. 5 , Sal. represents the transistor I-V characteristic curve after Salmonella is combined with carbon nanotube, as compared to that before a combination with Salmonella , it can be seen that there is a dramatic drop in the current, and the threshold gate voltage Vg is maintained at about 1V. The change is because when antigen is combined with the antibody on the surface of carbon nanotube, the surface of the carbon nanotube will get distorted and the surface charge migration of the carbon nanotube will get reduced and I-V characteristic curve will get reduced too.
[0066] When the transistor source and drain electrodes are applied with a bias voltage Vds of 5V and a gate voltage of 5V is fixed, the current shows a change as in FIG. 6 , which is a real time current signal measurement of a transistor. In the beginning, when the carbon nanotube transistor is applied with Vds bias of 5V and −5V of gate bias voltage, transistor will maintain at a current of 8×10 −8 A, and when PBS buffer solution is dropped between the two electrodes, a water bead will be formed to enclose the carbon nanotube because of surface tension, at the moment while the liquid is dropped, there will be a surge current, then the current will go back and maintain stably at 2×10 −6 A; later on, mix PBS mixed solution with Salmonella on the liquid drop, we will find an obvious drop on the current, when it drops to about 1.4×10 −6 A, it will remain stably; later on, add other types of cells ( Pseudomonas aeruginosa ) into the buffer solution, the current won't change. Therefore, through such an electrical signal experiment, it can be found that when Salmonella combines with antibody, the electrical conductivity of carbon nanotube will get dropped obviously.
[0067] The above mentioned Salmonella can be changed to Mycobacterium tuberculosis , or flu virus, and the related antibody should also be changed, then the flu virus or aerobic bacteria which spreads in the air can be detected.
EXAMPLE 3
Detection on the Change of Acetone by DNA Modified CNTFETs
[0068] The major symptom of diabetes is high blood glucose concentration. Therefore, the patient can not take full use of glucose, at the same time, the decomposition of fat will be accelerated and fatty acid will be generated, which in turn is converted into ketone bodies. If the ketone bodies generated are limited, it can be used by the tissue, for example, the muscle tissue; however, if the ketone bodies generated is too much, it can not be fully used by the tissue, it will then be released as ketonuria; therefore, the exhaled gas will smell like rotten apple with acetone-like odor. The present invention can be used to do early stage detection of diabetes in human body in real time way and in the long term; or to do monitoring to see if it get worse after an early stage detection; or to check if the cure is effective; it can be used as a reminder for taking medicine.
[0069] FIG. 7 shows that through carbon nanotube field effect transistor and through the combination of single-strand DNA and carbon nanotube, we can measure acetone effectively.
[0070] As previously described fabrication process of CNTFETs, during the purification and separation of carbon nanotube, carbon nanotube will be immersed in SDS solution so as to coat SDS on the surface of carbon nanotube; however, when carbon nanotube coated with SDS is adhered to the electrode, the contact between carbon nanotube and the electrode metal is for sure going to be affected by SDS; therefore, the removal of SDS coated on carbon nanotube is a key to optimize device characteristics.
[0071] After the completion of the adherence of carbon nanotube and the measurement of I sd −V gs characteristics as well as the removal of SDS, CNTFETs with good characteristics can then be used in the sensor application. In the following, CNTFET with good characteristics is to be used for the detection of DNA and acetone and the electrical property change is going to be measured. As shown in FIG. 7 , CNTFET is used as biomedical sensor (ssDNA) and gas sensor (acetone). FIG. 7 ( a ) is the titration of “A” basic ssDNA, “ON” current will rise and the I sd −V gs curve will shift toward “positive” direction; FIG. 7 ( b ) is the titration of “T” basic ssDNA, “ON” current will drop and I sd −V gs curve will shift toward “negative” direction; FIG. 7 ( c ) is the titration of “C” basic ssDNA, “ON” current will drop and I sd −V gs curve will shift towards “positive” direction; FIG. 7 ( d ) is the titration of “G” basic ssDNA, “ON” current will drop; FIG. 7 ( e ) is the real time measurement of acetone by CNTFET sensor which is surface-modified with DNA; it can be seen that the current invention has very sensitive reaction and very high signal to noise ratio.
[0072] As shown in the literature [Lu, Yijiang; Partridge, Christina; Meyyappan, M.; Li, Jing, “A carbon nanotube sensor array for sensitive gas discrimination using principal component analysis” Journal of Electroanalytical Chemistry Vol: 593, Issue: 1-2, Aug. 1, 2006, pp. 105-110], the present invention uses modified materials which are commonly used in traditional gas sensor, for example, metals (Pd or Au, etc.), polymer, metal oxide or substances containing hydrogen ion or OH ion, to perform modification on the carbon nanotube; meanwhile, an array is formed to perform and achieve specific judgment on all kinds of biomarker gases exhaled by human body through PCA or neural network algorithm; here we take example on the acetone generated by diabetes patient, the present invention can detect in real time and continuously the acetone exhaled by diabetes patient in very early stage and in very low concentration so that the patient can be cared in early stage. Take an example on the volatile organic compound (VOC) such as acetone, the present invention can also employ traditional polymer material, for example, chlorosulfonated polyethylene and hydroxypropyl cellulose polystyrene, polyvinylalcohol, etc. (which is commonly used in the polymer-based organic gas sensor available in the market) to achieve its purpose.
EXAMPLE 4
Detection of Flu Virus
[0073] Since carbon nanotube is ideal material for ultra small sensor and its ultra large surface area has very high sensitivity on the transfer of electronic charge. High quality single-wall carbon nanotube transistor (SWNT-FET) is used to be combined with flu aptamer, and array method is used for the deployment to increase the contact opportunity between the droplet containing flu virus vaccine and the flu aptamer on the surface of the carbon nanotube so as to enhance the detection sensitivity.
[0074] Immerse the flu virus vaccine in dielectric solution through KCL solvent or mannitol with a main purpose to change the dielectrophoretic property to facilitate the manipulation. First, electrodes are prepared on the glass substrate, and the above mentioned DEP force is used to manipulate carbon nanotube on the Source and Drain of the transistor. Take several drops of KCL or mannitol solution containing flu virus vaccine with micro titrator and drop it on the glass substrate that is prepared with electrode and carbon nanotube, then use a lead to connect it to the display. Use optical microscope to observe the current curve of the solution before the adding of flu virus vaccine solution as the reference group. Then add the flu virus vaccine containing solution to the carbon nanotube to let flu virus vaccine adhere to carbon nanotube and observe the current change at the externally added display, the illustration is as shown in FIG. 8 .
[0075] FIG. 8 shows that droplet containing flu vaccine could get close to CNTFETs chip due to the suction action (for example, the suction action of human nose); when it gets in contact with flu antibody or flu aptamer of multiple single-wall carbon nanotubes (only single nanotube is shown in the figure.), since a droplet can contain several flu viruses and the droplet size is about 1-5 um which can enclose the reaction range of flu virus and flu antibody or flu aptamer; that is, the binding environment and condition of virus and antibody or aptamer is in the solution, this matches the condition of water solution for the original manufacturing and artificial synthesis of antibody or aptamer, hence, it has very high specificity and sensitivity.
[0076] For the experiment on other viruses, it is similar to the above mentioned steps and the only difference is the antibody on the carbon nanotube.
[0077] The above detailed descriptions are only some of the possible embodiments of the current invention and the embodiments are not to be used to limit the scope of the current invention, any equivalent embodiment or change that does not depart from the technological spirit of the current invention should all fall within the scope of what is claimed.
[0078] All publications, patent and patent applications cited herein are incorporated herein in their entirety by reference. | An apparatus applied to detect the human breath gas, including a substrate which carries a circuit module, a CNT-based (carbon nanotube) gas sensing element, a wireless transmission/receiver module, and a power supplier, etc. and a clamp structure that could be clamped on the columella between the nostrils. The detectable gas also includes the bioaerosol in the gas. The CNT-based gas sensors react with the breath air and detect whether the specific gas and bioaerosol in the air or not while breathing in and out and the temperature of the air could be measured. This invention can measure the electric response of the CNT-based gas sensor, process the signal by the circuit module and transmit the processed signal to the wireless receiver by wireless transmission/receiver module. And the wireless signal receiver will differentiate the species, concentration and temperature of the gas and provide a warning signal while the specific gas or bioaerosol is detected. The apparatus is portable and has the functions of rapid response and high sensitivity. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of application of U.S. application Ser. No. 10/276,282 filed Nov. 12, 2002 which is the U.S. National Stage Application of International Application No. PCT/SE01/01031 filed May 11, 2001 that claims priority to Swedish Application No. SE0001790 filed May 12, 2000, each of which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to a method for providing surface coatings, for example hydrophobic barriers, in a microchannel. The invention also relates to a device comprising the microchannel to be provided with the surface coating and to the use of the microchannel and of the device after they have been subjected to the inventive method.
BACKGROUND OF THE INVENTION
[0003] It is useful to provide locally modified areas on a surface in microfluidic devices in order to control the flow of fluids, in particular liquids, in such devices or to attract certain reagents or to act as a primer for further processing. For example, it is often useful to provide a microchannel with a hydrophobic coating, which covers all or part of the inner surface of the microchannel. This hydrophobic coating prevents a polar fluid from proceeding along the microchannel unless the fluid is driven by a force that can overcome the blockage caused by the hydrophobic coating. Such a force can be provided by centripetal action or pressurising the fluid. The hydrophobic coating acts as a passive valve or barrier.
[0004] Components that are used to modify surfaces are often dissolved in a solvent to facilitate application of the components to the surface. A hydrophobic component, for instance, is often dissolved in a solvent to lower its viscosity and then sprayed (for example by airbrush through a mask) or painted onto the part of the microchannel which is to be modified. A problem that often occurs when applying this kind of solutions is that due to their wetting properties the solutions do not cover satisfactorily the vertical walls of the microchannel but run down to the bottom of the microchannel and become distributed along the bottom edges of the channel. This increase the risk for unsatisfactory operation of modified surfaces, e.g. as hydrophobic valves when hydrophobic components have been applied.
[0005] In order to simplify the understanding of the present invention, a frame of reference will be defined in which the base (bottom) of the microchannel is considered to extend in a horizontal direction and the side walls to extend up from the base in a vertical direction. This in particular applies to the drawings and the corresponding text. This is not intended to imply any limitation to the present invention, the use of which is not affected by how the walls and base (bottom) are orientated. Once the open side of a microchannel has been covered, the direction-oriented terms “side”, “bottom” and “top” become redundant.
BRIEF SUMMARY OF THE INVENTION
[0006] The object of the invention is to solve the above stated problems.
[0007] The present invention solves the above stated problems by modifying a surface in a microchannel of a device, which surface has the features mentioned in the characterising part of claim 1 . This kind of microchannel and/or device is novel and defines the first embodiment of the invention. The method used defines the second embodiment. It solves the above-mentioned problems and has the features mentioned in the characterising part of claims 4 and 5 . Other features of both embodiments are as defined in the subclaims and elsewhere in this text.
[0008] The first embodiment is a microchannel fabricated in a substrate. The characteristic feature of the internal surface of the microchannel is that it comprises a surface region where there is one or more grooves and/or one or more abutting projections which extend in a wall at least partly from one side of the microchannel to the opposite side, e.g. at least partly from the bottom of the microchannel to the top of the microchannel or vice versa. In subaspects of this embodiment, the grooves and projections may exhibit surface properties that are obtainable by treatment according the second embodiment of the invention. In a further subaspect the microchannel is covered as described below, i.e. has walls in all directions except for inlet and outlet openings, and other openings that provide desired functionalities, e.g. air vents.
[0009] The second embodiment is a method for locally modifying a part of the internal surface of a microchannel fabricated in a substrate. The method is characterized by comprising the steps of:
[0010] (i) providing a microchannel which is manufactured in a substrate and in which a part of the internal surface has one or more grooves and/or one or more abutting projections which extend at least partly from one side of the microchannel to the opposite side, for instance at least partly from the bottom of the microchannel to the top of the microchannel or vice versa; and
[0011] (ii) applying a fluid, i.e. a liquid, comprising a component that is capable of modifying said part of the surface to (a) the bottom of said groove or grooves and/or (b) the junction(s) between said projection or projections and the remaining part of said internal surface.
[0012] Step (ii) (b) means that the liquid can be applied to the junction between two projections, the bases of which are connected edge to edge or to the junction between the base of one projection and the remaining part of the internal surface.
[0013] After volatile components of the applied fluid have been evaporated, possibly followed by one or more post-treatments of the modified surface or of other internal part surfaces of the microchannel, the microchannel can be used as defined below for the third embodiment of the invention. One particular post-treatment procedure is to apply a cover, for instance in the form of a lid, on top of the microchannel (if the microchannel has one open side).
[0014] Various printing and/or stamping and/or spraying techniques etc may be used for applying the fluid in step (ii) above. The equipment selected should ensure proper adherence and coverage of the modifying component to the surface. Examples of useful printing techniques are those that utilize a printer head for the application of drops of liquids, such as in various ink-jet or spray techniques, and of powders, such as in various laser techniques.
[0015] It has been found that printing and stamping techniques with particular emphasis of ink-jet techniques can be used to locally modify internal surfaces in microchannels irrespective of the presence or absence of irregularities, such as grooves or projections. Accordingly the inventive concept presented herein also encompasses the general use of these kinds of printing techniques for local modification of the kind of surfaces mentioned in this paragraph.
[0016] In the method and device in accordance with the present invention, portions of a microchannel which are intended to have a modified surface are provided with one or more grooves and/or one or more abutting projections which extend at least partly from the base of each wall to the top of the wall. The groove(s) and/or projections ensure that when a suitable quantity of surface modifying liquid is applied to the groove(s) and/or projections, capillary attraction causes the liquid to wet substantially the whole length of the groove(s) and/or the joins between the projections and/or between a projection and the remaining part of the internal surface thereby ensuring that when the surface modifying liquid dries it leaves a modified surface which extends substantially from the base of each wall to its top, i.e. the modified surface will be in form of a continuous line from one wall to an opposite wall. This kind of irregularities in the interior surface will thus improve the distribution of a fluid, i.e. a liquid, that is applied in order to locally modify the surface of the microchannel.
[0017] A third embodiment of the invention means that a liquid flow is allowed to pass through a covered form of the microchannel as defined or obtained in the first and second aspect of the invention. This embodiment thus comprises the steps of: (i) providing a device in form of a microchannel as defined for the first aspect or obtained as defined for the second aspect, and (ii) applying a liquid flow through the microchannel, and (iii) possibly halting the front of a liquid at the grooves and/or projections defined in the first aspect of the invention. The force applied to drive the flow determines if the front of the liquid shall pass the channel part containing the surface irregularities (grooves and/or projections). The term “front” includes the borderline between two different liquids, for instance between two unmixed liquids such as between two immiscible liquids, or between a liquid and gas (air). It follows that the liquid flow may comprise a sequence of liquid zones that are different with respect to liquid constituents. The liquid zones may be physically separated by gas (air) zones.
[0018] In one particular type of third embodiment variants, one utilizes a microchannel structure in which the surface modification in the grooves and/or in a joint between two projections and/or between a projection and a remaining internal surface are hydrophobic surface breaks. In this kind of microchannels the driving force for a liquid flow in form of an aqueous solution can be adapted such that a liquid front will stop at the irregularities and pass through by increasing the driving force.
[0019] By the term microchannel is contemplated that the channel in covered form is capable of retaining a liquid by capillary forces. In the most typical cases this means that either or both of the width or depth at the position where the above-mentioned irregularities in the internal walls are present are ≦500 μm, such as ≦100 μm or ≦50 μm or ≦10 μm.
[0020] The invention will be described more closely in the following by means of non-limiting examples of embodiments and with figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a plan view of one embodiment of a device in accordance with the present invention.
[0022] FIG. 2 is a lateral cross-sectional view through line II-II in FIG. 1 .
[0023] FIG. 3 is a plan view of a second embodiment of a device in accordance with the present invention.
[0024] FIG. 4 is a lateral section through line IV-IV in FIG. 3 .
[0025] FIGS. 5 a )-g) show several different possible arrangements of grooves and projections in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] FIGS. 1 and 2 show, respectively, schematically a plan view from above and a cross-sectional view, of a portion of one embodiment of a microchannel 1 provided with an arrangement 3 , in accordance with the present invention, for improving the distribution of a surface modifying coating. Microchannel 1 is formed in any suitable way, for example injection moulding, in a substrate 5 , which substrate 5 is preferably made of a polymer material such as polycarbonate plastic. Microchannel 1 has an internal surface comprised of substantially vertically extending sidewalls 7 , 9 and a substantially horizontal base 11 , which connects the sidewalls 7 , 9 . In this example the microchannel has a quadratic cross-section but other cross-section shapes such as triangular, semicircular, trapezoidal or the like are also possible. In this example of an embodiment of the present invention, it is intended that a region 15 of the microchannel 1 is to act as a hydrophobic valve. The sidewalls 7 , 9 in region 15 are provided with an arrangement 3 in the form of grooves 17 , which are intended to receive a hydrophobic coating 13 . In this embodiment the grooves 17 have a V-shaped cross-section and extend from the base of the sidewalls 7 , 9 to the tops of the sidewalls 7 , 9 . The hydrophobic coating 13 can be dissolved in a solvent and applied to the region 15 in the form of droplets 21 by a computer controlled printer head, such as an ink-jet printer head. A pattern of preferably overlapping droplets is emitted by the ink-jet printer head towards the region 15 (as shown by shaded circles (not drawn to scale) in FIG. 1 ) and any droplets 21 which touch the grooves 17 will tend to flow up the base 19 of the V of the groove 17 due to capillary forces. If the total volume of the droplets which touch a groove is sufficiently large then the whole of the base of the V of the groove 17 will be filled with the hydrophobic solution and when the solvent evaporates a continuous line of hydrophobic material which extends from the base of the groove 17 to the top of the groove 17 will be left in the groove, as shown by shading in FIG. 2 .
[0027] In another embodiment of the invention shown in FIGS. 3 and 4 , grooves 27 also extend across the base 11 of the microchannel 1 ′.
[0028] In a further embodiment shown in FIG. 5 a ), grooves 37 have corrugated cross-sections.
[0029] In yet a further embodiment shown in FIG. 5 b ), grooves 47 have quadratic cross-sections.
[0030] In another further embodiment shown in FIG. 5 c ), sidewall 7 is provided with projections 59 having a corrugated cross-section while sidewall 9 is provided with grooves 57 have corrugated cross-sections. In this embodiment the projections 59 and grooves 57 have complementary shapes and are so positioned that in the length of microchannel encompassing the grooves 57 and projections 59 , the width of the microchannel between the grooves 57 and projections 59 is substantially constant. Any droplets of surface modifying fluid which touch the junction of the bases of the projection(s) and the sidewall will tend to flow up this junction due to capillary forces.
[0031] In a further embodiment shown in FIG. 5 d ), sidewalls 7 , 9 are provided with projections 69 having a corrugated cross-section. In this embodiment the projections 69 are so positioned that the width of the microchannel varies between a minimum value where the peaks of projections 69 in the respective sidewalls 7 , 9 are opposite each other, to a maximum value where troughs between projections 69 are opposite each other.
[0032] In a further embodiment shown in FIG. 5 e ), sidewalls 7 , 9 are provided with alternating grooves 77 and projections 79 with triangular cross-sectional profiles.
[0033] In a further embodiment shown in FIG. 5 f ), sidewalls 7 , 9 are provided with alternating grooves 87 and projections 89 with trapezoidal cross-sectional profiles.
[0034] FIG. 5 g ) and the corresponding section in FIG. 5 h ) show embodiments of grooves 97 and projections 99 that do not have a constant cross-section throughout their lengths.
[0035] The sizes of the grooves and/or projections preferably do not exceed more than 40% of the width/diameter of the microchannel and most preferably lie in the range of between 5% and 20% of the width/diameter of the microchannel.
[0036] The internal angle of the troughs of the grooves can be any angle that is less than 180° and preferably, for ease of manufacturing, should be between 20° and 160°. The angle that the base of the projections make with the sidewall of the microchannel can also be any angle that is less than 180° and preferably, for ease of manufacturing, should be between 90° and 160°.
[0037] Although not shown in the figures, it is of course possible to provide all the embodiments of the invention with grooves or projections in the horizontal base of the microchannel. Although the invention has been illustrate by means of examples with substantially vertical, straight side walls and a horizontal, straight base, it is of course possible that the side walls are inclined to the vertical and/or are curved and/or that the base is curved and/or sloping. Additionally, it is also conceivable that the microchannel has a triangular cross-section formed by just two sidewalls the intersection of which forms the base of the microchannel. Furthermore, if the microchannel is provided with a cover in order to form a closed channel, then it is possible to provide the surface of the cover that faces into the micro channel with similar grooves and/or projections.
[0038] While the invention has been illustrated by examples in which the grooves and projections extend all the way up the sidewalls of the microchannel, it is also conceivable that the grooves and/or projections just extend partly up the sidewalls. Preferably, the grooves and projections extend over at least 50% of the height of the sidewalls.
[0039] Furthermore it is conceivable to have grooves or projections which do not extend straight up from the base of a side wall to its top but which instead are inclined in the longitudinal direction of the microchannel. | The present invention relates to microchannels ( 1 ) in a substrate ( 5 ) wherein said microchannels has an internal surface ( 7, 9, 11 ) that in a region ( 15 ), adapted for distributing fluid, has one or more grooves ( 17, 27,37, 47, 57, 77 ) and/or one or more abutting projections ( 59, 69, 79 ) which extend at least partly from the bottom of the microchannel to the top of the microchannel. | 1 |
This invention relates to the design of compound bows for archery and hunting, and more particularly, to improvements in the accuracy, shootability and energy efficiency of such bows.
BACKGROUND OF THE INVENTION
The concept of the compound bow introduced mechanical advantages over the traditional straight and recurved bow designs whereby a system of cables, cams, and pulleys were interposed between the bowstring and the bow limbs to provide mechanical advantage in the draw and a property called let-off, that is, the force required to hold the bowstring at full draw length is substantially lower than that required to hold said bowstring at intermediate draw length. The force that propels the arrow at any instantaneous position of the bowstring after release is approximately equal to that force required to hold the bowstring stationary in that position, thus in a compound bow, the arrow is subjected to higher acceleration at an intermediate position during release than would have been the case with a traditional bow of the same holding force at full draw. Thus compound bows result in higher arrow velocity. Also, arrows can be shot from such bows with more accuracy, as the archer is subjected to lower stress while aiming at full draw than in the case of traditional bow designs.
Compound bows have changed little in their basic designs although improvements in the eccentric cams and cable arrangements have resulted in increased arrow velocity. Prior art compound bows typically contain a pair of cables that almost span the entire space between the limb tips in such a way that these cables cross over each other and would interfere with the patch of the arrow were it not for the presence of special means to hold the cables aside. One such special means involves the use of a cable guard comprising a rod attached to the bow handle riser, said rod being offset from the centerline of the limbs and positioned between the cables and said centerline, thus holding the cables aside to provide clearance between the cables and the arrow path.
Another such special means involves the use of dual-grooved cams or pulleys at the limb tips with one or both grooves offset from said centerline and arranged in such a way that the primary cable attached directly to the bowstring is disposed in a different groove from that in which is disposed the secondary cable attached to the opposite limb tip. The spacing between the grooves provides the necessary cable clearance to avoid interference with the arrow path.
Both of the above special means to avoid cable interference suffer a common disadvantage that can impact arrow flight accuracy. Any offsetting of the cables, cams, or bowstring from the centerline of the bow limbs can result in an imbalance in cable tensions and a corresponding torque or twisting of the limbs. The energy stored in such twisting is not only wasted as the arrow is released but the relaxation of the torque forces can impart minute sideways motion of the bowstring and consequently cause unstable arrow flight. An additional disadvantage of the crossing over of the cables is that they can touch each other causing chafing and also dissipate energy in the process of rubbing together.
It is thus a desirable feature in a compound bow design to align all cables, cams, and pulleys with respect to the centerline of the limbs in such a way as to balance the forces acting on said limbs to avoid torque or twisting moments. It is also desirable that the bowstring be accurately aligned with said centerline and further that the cables not come in contact with each other.
OBJECT OF THE INVENTION
It is an object of the present invention to provide a compound bow design in which all components involved in energy transfer and storage have centerlines positioned in a common plane.
It is a second object of this invention to provide a compound bow design that contains no interfering components in the vicinity of the arrow path.
It is a further object of this invention to provide means to reduce friction and loss of energy from cable contact and from cable flexing.
SUMMARY OF THE INVENTION
The compound bow of the present invention uses a system of cams, cables, and pulleys arranged in such a way that no cable attached to a given limb tip crosses over to the opposite limb tip to interfere with the arrow path. This positioning of the cables permits the centerlines of the bowstring, cables, cams, pulleys, and limbs to lie in a single plane thus drawing the bowstring imparts no twisting torque forces on the limbs, cams, or pulleys. In a particular embodiment of the invention, all cable attachments are provided through rotatable fittings to minimize cable flexing as the bowstring is drawn.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side elevation view of a simple embodiment of the invention.
FIG. 2 is a rear elevation view of the embodiment of FIG. 1 showing the alignment of the mechanism components.
FIG. 3 is a detail view of the upper eccentric cam in three positions: at rest, at intermediate draw, and at full draw.
FIG. 4 is a rear elevation view of a prior art compound bow with cable guard showing the alignment of the mechanism components.
FIG. 5 shows another prior art bow with dual groove cams.
FIG. 6 shows an alternate embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a compound bow that incorporates the principles of the present invention. In common with bows of the prior art, this embodiment comprises a handle riser 101 with arrow rest point 118 where the arrow rests against the handle riser, a pair of outwardly extending resilient limbs 102 and 103, hereinafter referred to as the upper and lower limbs, respectively, a bowstring 104 with nocking point 105 (with or without a physical marker), a pair of primary cables 106 and 107 attached to said bowstring at one end and disposed in the grooves of cams 108 and 109, respectively, said cables being attached at their opposite ends to said cams at primary cable end fasteners 110 and 111, respectively, said fasteners being near the tip of that portion of said cams of larger radius hereinafter referred to as the primary portion.
In contradistinction from prior art bows, the embodiment of FIG. 1 contains no cables or other components between the bowstring and handle riser in the immediate vicinity of the arrow position. The four-sided figure 121 corresponds to the arrow position region. A pair of cantilever bars 112 and 113 are attached firmly to handle riser 101 and to which are attached secondary cables 114 and 115, respectively. These cables, in turn, are attached at their opposite ends to secondary cable end fasteners 116 and 117 on cams 108 and 109, respectively, said secondary cable end fasteners being located near the outer edge of that portion of said cams being of smaller radius, hereinafter referred to as the secondary portion.
Cams 108 and 109 are affixed to the outer tips of limbs 102 and 103 via axles 119 and 120, said axles allow said cams to rotate when the bowstring is drawn. Cable end fasteners 110, 111, 116, and 117 are similarly attached to said cams via cable end fastener axles that permit said cable end fasteners to rotate and minimize cable flexing at the attachment point. Cable flexing causes friction and loss of energy, and can result in a reduction in the distance of arrow flight.
As illustrated in FIG. 2, all components involved in the storage and exchange of energy are positioned in centerline with respect to each other. That is, the centerlines of the limbs, cams, cables, bowstring and cantilever bars all lie in a single plane perpendicular to the limb faces. As the bowstring is drawn, all vector forces constituting tension in the bowstring and cables and the reactive force vectors of the limbs and cantilever bars similarly lie in the same plane. Therefore negligible torque vectors are imparted to the limbs that would result in sideways motion of the bowstring and would interfere with arrow flight stability.
The upper and lower mechanisms of the bow are near-symmetrically disposed about an imaginary center line that connects arrow rest point 118 with nocking point 105, constituting the arrow position. All motions and forces act in mirror image between the upper and lower mechanisms, thus further description of the bow action will address the upper mechanisms only.
When the archer begins to draw back bowstring 104 at nocking point 105, tension in said bowstring is imparted to upper primary cable 106 causing cam 108 to rotate. This tension is transferred by said cam to secondary cable 114 with amplification derived from leverage between the primary and secondary portions of said cam, said leverage resulting from the larger radius of said primary portion and the smaller radius of said secondary portion. As said secondary cable does not stretch, its tension is further imparted as a bending moment to limb 202 and to cantilever bar 112 which bend to balance forces, storing energy as upper and lower limb tips compress towards each other. As the archer approaches intermediate draw, cam 108 rotates to its intermediate position as shown in FIG. 3b, where maximum leverage exists between primary and secondary portions of said cam, as said primary portion has reached its maximum radius. At about this point primary cable end fastener 110 begins to rotate about axle 301 thus primary cable 106 lifts out of the groove in cam 108 and ceases to flex as the archer continues toward full draw. Tension in said primary cable begins to relax near the intermediate position and the archer experiences "let off" of the force required to hold the bowstring as he approaches full draw. When said archer has reached full draw and cam 108 is in the fully rotated position of FIG. 3c, the mechanical advantage or leverage of the cam stops abruptly and it is virtually impossible for the archer to overdraw the bow and damage the limbs as he must now apply the full force of the limb compression. At the point near full draw where the tension in the bowstring has reached its minimum, the archer can hold the bowstring with substantially reduced force thus taking aim under substantially reduced stress as compared with that from a traditional bow of the same stored energy.
FIG. 4 shows a prior art compound bow employing a cable guard 401. Said cable guard comprises a rod affixed to handle riser 402 and positioned off center from the centerline of limb 403. Secondary cables 404 and 405 are pulled aside and placed on the opposite side of said cable guard from bowstring 407. Cam 406 and bowstring 407 are also offset from said centerline to reduce torque forces on said limb. However, imbalance in the tensions on the cables will occur during draw and will produce a twisting torque, however minute, that can impact arrow flight stability.
FIG. 5 shows another prior art compound bow that utilizes twin cams 508 with spaced grooves to provide separation between the bowstring and secondary cables. As in the case of the bow of FIG. 4, both the bowstring and the secondary cables are offset from the centerline of the limb to minimize twisting moments or torque on said limb. As was the case with the bow of FIG. 4, imbalance in the tensions on the cables will occur during draw which can impart arrow flight stability.
FIG. 6 illustrates an alternate embodiment of the present invention. The mechanical advantage elements are positioned outside the immediate area of the arrow position as in the embodiment of FIG. 1. Cam 601 is positioned on a hanger 602 attached firmly to handle riser 101. Pulley 603 is attached via axles to the tip of limb 102 to carry primary cable 106 disposed in a groove on the outer perimeter of said pulley. Said primary cable is further disposed in the groove of the primary portion of cam 601 and is attached to said cam by a rotatable cable end fastener via an axle. Secondary cable 604 is disposed in the groove of the secondary portion of cam 601 where it is similarly attached by a rotating cable end fastener via an axle affixed to said cam. Said secondary cable at its opposite end is affixed to another rotatable cable end fastener via an axle attached to the limb tip. The embodiment of FIG. 6 has the advantage that there are three cable members over which to distribute the limb compression force, thus this embodiment has more mechanical advantage than that of FIG. 1. A further advantage is that the relatively heavy cams are positioned nearer the center of gravity of the bow.
It should be obvious to those skilled in the art that other embodiments with centerline or planar components can be configured to avoid positioning said components in the area of the arrow position. | A compound bow that uses mechanical advantage for interconnecting the bowstring with the resilient bow limbs is configured in such a way that all components of the mechanical advantage are positioned to lie outside the immediate vicinity of the arrow position, thereby permitting the bowstring to be aligned with the centerline of the limbs and further permitting all vector forces operating on the bowstring, limbs, and mechanical advantage to lie in a common plane, thus minimizing twisting torques applied to the limbs. In an embodiment comprising cables attached to cams as part of the mechanical advantage, the use of rotating cable-end fasteners minimizes the friction from cable flexing. | 5 |
The present application is a continuation of U.S. patent application Ser. No. 08/809,852 filed Apr. 3, 1997, now U.S. Pat. No. 5,971,667, which issued Oct. 26, 1999, under 35 U.S.C. § of PCT/AU95/00667, filed Oct. 6, 1995, with priority from Australia Application No. PN 8650 filed Oct. 7, 1994, priority under 35 U.S.C. §§ 120 and 371 therefrom is hereby claimed.
FIELD OF THE INVENTION
This invention relates to apparatus for movement along an underground passage and to a method of moving an apparatus along an underground passage.
DISCUSSION OF THE PRIOR ART
The invention has been devised particularly, although not exclusively for use in an underground mining operation which utilises a mining head positioned at one end of an elongate element, such as a pipe string, whereby the mining head can be manoeuvred to, and through, an underground formation by movement of the elongate element. The mining head creates a passage along which the elongate element passes. A difficulty with this arrangement is that in situations where the passage is formed in soft sandy deposits and the like, material surrounding the passage can collapse around the pipe string with the result that the pipe string can become jammed in the ground.
Traditionally, underground mining operations of the type described above do not allow hard wiring of the mining head and rely on other means or control and operation of motors and telemetry. For example, “mud” motors running on pressurised bentonite fluid and the use of “mud” pulsing for telemetry purposes has limited the drilling capacity of this form of underground mining. If the mining head were able to be hard wired drilling capacity could be increased by the use of electro/hydraulic power and through direct control of the mining head by the use of telemetry cabling.
It would be advantageous to provide a shroud around the pipe string for lining the passage so as to prevent surrounding material from collapsing onto the pipe string. The apparatus and method of the present invention have as one object thereof to overcome the above-mentioned problems.
BRIEF DESCRIPTION OF THE INVENTION
The present invention provides an apparatus adapted for movement through a passage formed in the ground, characterised by an elongate element and means for positioning a shroud around at least part of the longitudinal periphery of the elongate element for supporting engagement with the periphery of the passage to provide a space through which the elongate element can move, the shroud being of flexible construction and being arranged to be progressively installed in position as the elongate element moves along the passage, and means for introducing an inflation fluid into the region between the shroud and the elongate element for inflating the shroud and maintaining it in supporting engagement with the periphery of the passage, wherein the shroud is delivered to the elongate element from a remote storage point for installation.
The shroud may be assembled from flexible material which turns around a location on the elongate element to provide an inner section which is conveyed with the elongate element and an outer section which is turned back with respect to the inner section and which provides the shroud, the outer section being fixed in relation to the passage whereby the flexible material turns around from the inner section to the outer section to provide the shroud as the elongate element moves along the passage.
The flexible material may comprise two or more elongate sections arranged such that the longitudinal sides thereof are joined one to another at the outer section to provide the shroud.
The longitudinal sections may have complimentary connector elements on their longitudinal sides for joining the longitudinal edges thereof together.
The flexible material may be turned around from the inner section to the outer section at turning means such as rollers moving with the elongate element. Conveniently, the rollers are mounted on the elongate element. The rollers may be accommodated within a protective casing positioned around a leading end of the elongate element.
The inner section of the flexible material may be accommodated in one or more longitudinal passages provided on the outer periphery of the elongate element.
In circumstances where the elongate element is required to be particularly long it is preferable that driving means be provided in or adjacent to the longitudinal passages thereby facilitating the travel of the inner section of flexible material. Still preferably, the driving means may be provided so as to specifically engage and facilitate the travel of the connector elements of the inner section of flexible material thereby facilitating the travel of the flexible material itself.
A seal may be provided between a fixed end of the outer section of the flexible material and the elongate element to define the outermost end of the shroud, the seal permitting sliding movement of the elongate element therethrough as it moves within the passage.
A further seal may be provided between the outer section of the flexible material and the elongate element to define an innermost end of the shroud.
The flexible material may be stored in roll form and unwound from the roll and progressively delivered to the elongate element as it advances through the passage to provide the inner section and thereby allows deployment of the shroud over long distances. The rolls of flexible material may be stored at ground level.
The inflation fluid may comprise a slurry such as Betonite slurry.
The present invention further provides an elongate structure adapted to be moved axially through an underground passage, comprising an elongate element and means for positioning a shroud around at least part of the longitudinal periphery of the elongate element as it advances through the passage for engagement against the periphery of the passage to provide a space through which the elongate element can move, the shroud being assembled from flexible material which is delivered from a remote storage point and turns around a location moving with the elongate element to provide an inner section which is conveyed with the elongate element and an outer section which is turned back with respect to the inner section to provide the shroud, wherein the outer section is fixed in relation to the passage, there being further provided means for introducing as inflation fluid into the region between the shroud and the elongate element.
Preferably, the outer section of the flexible material defines an inner region and an inflation fluid is delivered into the inner region to urge the outer section into supporting engagement with the periphery of the passage.
The present invention still further provides a connector means for use in the releasable hermetic fixing together of elongate sections of flexible material of which is comprised a shroud, the connector means comprising first and second connector elements of complimentary configuration whereby such may be pressed together and force applied to pull such apart acts to strengthen the grip therebetween, the connector elements requiring an unpeeling or unzipping action to separate same.
Each connector is preferably elongate and extends along one longitudinal side of an elongate section of flexible material. The first connector element may be provided in a male configuration with the second connector element provided in a complimentary female configuration.
The first and second connector elements further have complimentary longitudinal ridges and recesses provided thereon and arranged such that force applied to pull same apart acts to strengthen the grip of the second connector element about the first connector element.
The present invention also provides a method for facilitating movement of apparatus underground, characterised by the deployment and positioning of a shroud about at least a part of a longitudinal periphery of that apparatus as it advances through a passage created thereby for supporting engagement with the periphery of the passage, the shroud being assembled from a flexible material delivered to the apparatus from a remote storage point, an inflation fluid fluid being introduced into the region between the shroud and the apparatus for inflating the shroud and maintaining it in supporting engagement with the periphery of the passage.
The flexible material of the shroud is characterised in that the flexible material of the shroud is turned around a location moving with the apparatus to provide an inner section which is conveyed with the elongate element and an outer section which is turned back with respect to the inner section to provide the shroud, the outer section being fixed in relation to the passage.
DESCRIPTION OF THE DRAWINGS
The invention will be better understood by reference to the following description of one specific embodiment thereof as shown in the accompanying drawings in which:
FIG. 1 is a schematic side view illustrating an underground mining operation utilising apparatus according to the embodiment;
FIG. 2 is a schematic view illustrating the head end section of the apparatus according to the embodiment and a mining head associated therewith;
FIG. 3 is a schematic view of a tail end section of the apparatus;
FIG. 4 is a cross-sectional view of part of the apparatus;
FIG. 5 is a cross-sectional view similar to FIG. 4 but showing further detail;
FIG. 6 is a fragmentary schematic view of the head end section of the apparatus;
FIG. 7 is a schematic view of the head end section of the apparatus showing deployment of the shroud;
FIG. 8 is a fragmentary schematic cross-sectional view of the head end section;
FIG. 9 is a schematic view illustrating connection means employed for forming the shroud, the connection means being shown in a separated condition;
FIG. 10 is a view similar to FIG. 9 with the exception that the connection means are shown in a connected position; and
FIG. 11 is a cross-sectional view of a pipe string and longitudinal sections of an apparatus in accordance with a second embodiment of the present invention within a deployed outer section of flexible material; and
FIG. 12 is a view similar to that of FIG. 11 with the exception that driving means are provided in the longitudinal passages to facilitate deployment of the flexible material.
DESCRIPTION
The embodiments are directed to apparatus for use in an underground mining operation for recovering materials from underground formations which are normally extremely difficult to access, such as deep leads covered by an overburden of mud, sand and basalt.
One proposal for accessing the underground formations involves a mining apparatus 10 of the type generally shown in FIG. 1 of the drawings comprising a mining head 11 provided at one end of a pipe string 13 . The mining head 11 is delivered to the underground formation where the mining operation is performed. The mining head 11 progressively excavates material from the underground formation and conveys the excavated material to the ground surface 15 by way of the pipe string 13 . The pipe string 13 and head 11 may be manipulated to manoeuvre the mining head 11 within the underground formation. The head 11 providing the whole or part of the motive power. The path of the mining head provides an access passage 16 , shown in FIG. 3, along which the pipe string 13 extends during the mining operation. The pipe string 13 extends from a structure 17 provided at a station 19 situated at ground level. The structure 17 may be erected on the ground or in a launch pit or recess within the ground.
The pipe string 13 comprises a plurality of pipe string sections which are connected one to another at the station 19 as the mining head 11 and pipe string 13 advance through the ground. Similarly, the pipe string sections are progressively dismantled at the station 19 when the pipe string 13 and mining head 11 are being retrieved from the ground.
The mining head 11 is delivered to the underground formation by progressively excavating material to create a path for itself and the pipe string 13 trailing behind it, as shown in FIG. 2 . The difficulty with this arrangement is that the passage 16 excavated by the mining head 11 can collapse about the pipe string 13 , particularly in circumstances where the surrounding material 14 is unstable, such as in soft sandy conditions.
The present embodiment provides a casing or shroud 20 about the pipe string 13 for lining the passage 16 so as to prevent the surrounding material 14 from collapsing onto the pipe string 13 .
The shroud 20 is formed from flexible material delivered in two sections 21 , 22 and then assembled to form the shroud around the pipe string 13 . Each section 21 , 22 of flexible material is stored in roll form at station 19 on the ground and is unwound from the roll as the pipe string 13 advances.
The pipe string 13 comprises an inner tube 31 , seen in FIGS. 4 and 5, defining a central flow path 33 and an outer tube 35 positioned around, and in spaced apart relation to, the inner tube 31 such that an outer flow path 37 is defined between the inner tube 31 and the outer tube 35 . The inner flow path 33 is provided to convey excavated slurry from the mining head 11 to the ground surface. The outer flow path 37 is provided to convey water under pressure from the ground surface to the mining head 11 for use in the mining operation.
The pipe string 13 further comprises a casing 41 mounted on the exterior of the outer tube 36 , as is best seen in FIG. 5 . The casing 41 provides a longitudinal space 43 which extends along the pipe string for accommodating service lines (such as power and telemetry cabling) which extend between the station 19 at ground surface and the mining head 11 . The space 43 may also incorporate sensing means 44 to measure distance between the pipe string 13 and the shroud 20 to provide a warning of any impending collapse at the shroud.
The space 43 also incorporates two longitudinal passages 48 , 49 along which the sections 21 , 22 of flexible material can be conveyed in a compact condition from the station 19 to the head end section 50 of the apparatus.
At the head end section 50 of the apparatus, shown in FIGS. 6 to 8 , there are provided two rollers 51 , 52 one corresponding to each section 21 , 22 of the flexible material. The rollers 51 , 52 are so positioned that the flexible material which is drawn along the longitudinal passages 48 , 49 in a compact condition each turns about itself on the respective roller to provide an inner section 53 and an outer section 55 . The outer sections 55 emerging from the longitudinal passages 48 , 49 spread from the compact condition and are subsequently brought together in a manner to be described later to form the shroud 20 .
The rollers 51 , 52 are accommodated in a casing 57 which surrounds the head end section 50 . The casing 57 is in spaced apart relationship with the pipe string 13 whereby an annular space 58 is defined therebetween. The casing 57 incorporates protuberances 59 to accommodate the rollers 51 and 52 , as best seen in FIG. 8 of the drawings.
The space 58 provides a path along which the outer section 55 of each section 21 , 22 of the flexible material can be deployed with the longitudinal sides of the sections brought together to form the shroud 20 .
Each flexible section 21 , 22 has two longitudinal sides provided with a connector means 61 , comprising a first connector element being a male element 61 a and a second connector element being a female connector element 61 b . The arrangement is such that the male connector element 61 a of each flexible section is arranged for hermetic engagement with the female connector element 61 b of the other flexible section in the manner of a zipper. In this way, the longitudinal sides of the two flexible sections 21 , 22 can be zipped together to form the shroud, as best seen in FIG. 4 . The longitudinal sections of the two sections 21 , 22 are progressively brought towards each other and then subsequently zipped together by way of guide roller assemblies 58 positioned along the casing 57 .
The male connector element 61 a comprises a head portion 100 and a trail portion 102 . The trail portion 102 is affixed to the longitudinal side of the flexible section 22 . The head portion 100 has provided thereon a series of recesses 104 . The female connector element 61 b comprises a channel portion 106 and a tail portion 108 . The tail portion 108 is affixed to the longitudinal side of the flexible section 21 . The channel portion 106 has provided on an inner surface 110 thereof a series of ridges 112 complimentary to the recesses 104 of the male connector element 61 a . Upon zipping together of the connector elements 61 a and 61 b the head portion 100 is received within the channel portion 106 .
The ridges 112 and recesses 104 engage in a manner such that a force applied to pull the connector elements 61 a and 61 b apart causes the channel portion 106 to grip the head portion 100 with greater force by accentuating positive engagement of the ridges 112 and recesses 104 .
It is envisaged that means be provided to ensure that the connector means 61 is firmly fastened before it is released from the head 11 . These means can cover electrical, magnetic and visual means for checking before release.
A lower seal (not shown) is provided between the outer periphery of the pipe string 13 and the inner periphery of the shroud 20 at a location adjacent the region in the head section 50 at which assembly of the two sections 21 , 22 is completed to form the shroud. The inner seal can be a complex of inflating and flexible seals which in turn can be used to pressure test the shroud 20 and connector means 61 before release from the elongate element. The lower seal is fixed in relation to the pipe string 13 so as to advance and withdraw with the pipe string, and slidingly engages the outer section 55 .
Similarly, an upper seal 81 is provided adjacent ground level or at the water table between the shroud 20 and the pipe string 13 , as shown in FIG. 3 . The upper seal 81 is arranged to permit sliding movement of the pipe string therethrough as it advances along the passage 16 .
The inner and upper seals define a sealed zone 90 within the shroud 20 which provides an inflation chamber 91 , seen best in FIGS. 4 and 5. An inflation fluid such as Betonite slurry is introduced into the inflation chamber 91 for the purposes of inflating the shroud 20 and urging it into engagement against the periphery of the passage 16 around the pipe string 13 . In this way, the shroud 20 provides support for the material 14 adjacent the periphery of the passage 16 for the purposes of preventing collapsing of the passage around the pipe string. The inflation fluid is introduced into the inflation chamber through inlet port 93 which communicates with a delivery line 95 accommodated within the casing 41 on the pipe string 13 . The delivery line 95 extends to the station 19 at ground level to receive the inflation fluid.
In operation, the apparatus according to the embodiment progressively deploys the shield 20 which supports the passage 16 formed by the mining head 11 as it advances through the ground. The shroud 20 is continually deployed as the pipe string 13 advances, the sections 21 , 22 of flexible material being drawn along the longitudinal passages 48 in the casing 41 on the pipe string, and then being turned about themselves on the rollers 51 , 52 and subsequently brought together to form the shroud in the manner described. With this arrangement, the shroud 20 is progressively deployed at the head end section 50 , the outer section 51 of the shroud being stationary with respect to the passage 16 once it has been deployed to form the shroud.
At the completion of the mining operation, the pipe string 13 and mining head 11 can be retracted along the passage 16 . During retraction of the pipe string and mining head, the sections 21 , 22 of flexible material are also retracted and returned to the rolls on which they are stored. During the retraction process, the connecting elements 61 unzip with respect to each other and the sections 21 , 22 are drawn into and along the longitudinal passages 48 within the casing 41 .
A cleaning means (not shown) may be provided for performing a cleaning operation on the sections 21 , 22 of flexible material before they are returned to the roll form. The cleaning means may comprise sprays from which a cleaning fluid such as water is sprayed onto the sections.
In FIG. 11 there is shown a second embodiment of the apparatus of the present invention. The embodiment is substantially similar to that of FIGS. 1 to 10 and like numerals denote like parts. The second embodiment comprises a pipe string 120 substantially circular in cross-section in which is provided the inner tube 31 defining the central flow path 33 .
The pipe string 120 further carries two water lines 122 replacing the outer tube 35 of the first embodiment and the variously required service lines for power and telemetry cabling, shown generally at 124 . Still further, flotation or buoyancy material 126 may be provided therein so as to buoy the pipe string 120 within the inflation chamber 91 .
The longitudinal passages 48 , 49 are provided within the pipe string 120 and such may also have the sections 21 , 22 of flexible material conveyed therethrough in a compact condition. The operation of the second embodiment is substantially the same as that of the first embodiment. A delivery line 128 for cleaning water is shown within the pipe string 120 , the cleaning water being utilised to clean the sections 21 , 22 of the flexible material before they are returned to the roll form.
In FIG. 12 there is shown a modification of the pipe string 120 in which longitudinal passages 130 , 132 have the sections 21 , 22 of flexible material provided with driving means comprising conveyor roller pairs 134 and power means 136 associated therewith. The roller pairs 134 receive therein the connector elements 61 a or 61 b and facilitate the travel of the inner section 53 of the flexible material within the passages 130 , 132 . Such is advantageous when the flexible material is to be conveyed within the pipe string 120 over long distances.
From the foregoing it is evident that the embodiment provides a system for supporting the passage 16 to allow the pipe string 13 to move freely therealong without being jammed by collapsible material.
It is envisaged that the connector means for joining the longitudinal sides of the flexible sections 21 , 22 may alternatively be replaced by a means for achieving either the stitching, welding or bonding together of the longitudinal sides.
It is still envisaged that the present invention will provide advantages in relation to both petroleum exploration and the re-lining of pipe-lines. With regard to the former the present invention should relieve the necessity for multiple sized drill casings and allow use in environments prone to collapse. The reverse telescoping nature of the casings presently used in these applications is prone to jamming in such environments.
The relining of piping presently often involves depositing a fresh surface within an inner surface of the pipe from which an old surface has been removed. Use of the present invention will allow a low friction surface to be deployed within the pipe. Preferably such would be comprised of polyethylene or similar material.
The shroud of the present invention may be deployed with an adhesive and possibly a filler material on the surface exposed to the inner surface of the pipe to facilitate placement.
A still further embodiment of the present invention may allow a soft flexible material to be deployed as the shroud, the material being such that once it is in position, it will harden independently or can, upon exposure to a suitable catalyst, cure or set such that the shroud becomes inflexible or rigid.
It is further envisaged that the apparatus and method of the present invention may be used in applications aimed only at tunnelling. For example, two substantially concentric shrouds may be deployed and between which a settable material can be injected, for example concrete. The concrete sets for form a pipe in situ. The innermost of the shrouds deployed in this manner may or may not be reclaimed. If left in situ the innermost shroud would actively prevent penetration of materials through the settable material and into the void of the pipe being created. | An apparatus adapted for movement through a passage formed in the ground includes an elongate element and means for positioning a shroud around at least part of the elongate element for engagement against the periphery of the passage to provide a space through which the elongate element can move. The shroud is of flexible construction and is arranged to be progressively installed in position as the elongate element moves along the passage. The apparatus is adapted for introducing an inflation fluid into the region between the shroud and the elongate element in order to inflate the shroud and maintain it in engagement against the periphery of the passage. | 5 |
BACKGROUND
[0001] 1. Field
[0002] The invention related to a sexual device for fulfillment of a sexual desire; more specifically, for concealment of one or more sexual devices within an electrically operable deception device.
[0003] 2. Description of the Related Art
[0004] Sexual stimulation is a natural instinct. Sometimes, people may feel the desire for sexual stimulation but may be in an environment that may not be conducive for sexual activity due to social or moral ethics. Therefore, people usually refrain from carrying sexual devices or refrain from leaving them in plain sight. Under certain circumstances, it may be desirable to carry a sexual stimulation device or leave it in plain sight while concealing its true nature.
[0005] U.S. Pat. No. 5,807,360 discloses a device for collection of male sperm. The device includes an outer tubular shell having a hollow inside for collection of sperm. The device may appear as normal device of common utility from outside. The hollow tubular section of the shell provides an access to an inner chamber filed by elastomeric gel having general tactile feel of a human flesh. The outer shell may be designed to accommodate male sex organs and the gel may provide cushioning during masturbation.
[0006] Similarly, U.S. Pat. No. 6,991,600 provides a vibrator device for simulating female sexual organs. The device is composed of a hollow tubular body with two rings disposed on the lateral side of the tubular body that may be worn over male penis and male testis.
[0007] U.S. Pat. No. 6,902,525 describes a device that takes rotary power from another device and translates it into rotary and reciprocating linear motion for simulation of male and female sex organs. Further, US Publication 20090185367 provides a flashlight that is water resistant and includes a storage space for concealment of items.
[0008] Thus, there exists a need for a sexual stimulation device that is concealed as an ordinary electrically operated device commonly used in public places.
[0009] The present invention, discloses an apparatus for providing one or more sexual devices and concealment thereof. The apparatus may include using a device that may include a tubular shell. The tubular shell may be connected to an electrically operable deception section. The apparatus may also include one or more human stimulation devices that are concealed and adapted to fit inside in a device such as the tubular shell. The one or more human stimulation devices may be a male stimulation device, a female stimulation device, and/or a combination of male and female stimulation devices.
[0010] The device may include a power source, a lubrication dispensing device, a vibration device, a heating device, a sperm receptacle device, and/or nodules for enhanced pleasure.
[0011] The device(s) may be used for sexual stimulation and concealed by the electrically operable deception section so as to allow the user to avoid public embarrassment when carrying around or leaving the device in plain sight.
SUMMARY
[0012] An apparatus for one or more sexual devices and carrying around or concealing the sexual devices is provided. The apparatus may include a second device. The second device may, for example, include a tubular shell. The tubular shell may be connected to an electrically operated deception section. The device may also include one or more human stimulation devices that are concealed and adapted to fit inside in the tubular shell. The simulation device(s) may be one of a male stimulation device, a female stimulation device, or a male and female stimulation device. Certain preferred embodiments of the present invention may be where the electrically operable deception section is a flashlight, a torch, a cellular telephone, a radio, or any other portable electrically operated device.
[0013] Further embodiments may include a power source, a lubrication means for lubricating the one or more human stimulation devices. The lubrication means may dispense lubrication on demand, at predetermined interval, or on demand and on predetermined interval.
[0014] Still further embodiments may include a lubrication warming means for warming the dispensed lubrication to enhance pleasure. The lubrication warming means may use an electrical or a chemical heating source.
[0015] Yet further embodiments of the present invention may include a vibration means for vibrating the one or more human stimulation devices. The vibration means may include a means for controlling the speed of the vibration means. The vibration means may include one or more predetermined selectable types of vibrations.
[0016] Yet still further embodiments of the present invention may include a heating means for heating the one or more human stimulation devices. Such heating means may, for example, use an electrical and/or chemical heating source. The heating means may include one or more temperature settings.
[0017] Other embodiments of the present invention may include an electrically operable deception section. The electrically operable deception section may, for example, be a flashlight, a screwdriver, a drill, pocket tooth brush, or any other suitable electronically operated device.
[0018] Yet other embodiments of the present invention may include a sperm collection receptacle to collect male ejaculation and/or a means for extending the sperm life while being collected.
[0019] Yet still other embodiments of the present invention may include a means for extending the one or more sexual devices from the tubular shell to increase overall length of one or more sexual devices.
BRIEF DESCRIPTION OF THE FIGURES
[0020] The invention and the following detailed description of certain embodiments thereof may be understood by reference to the following figures:
[0021] FIG. 1 depicts a perspective view of a first device, a second device, and a third device in an embodiment of the present invention;
[0022] FIG. 2 depicts an exploded view of an embodiment of the present invention;
[0023] FIG. 2 b depicts an embodiment of the present invention in the coupled state;
[0024] FIG. 3 depicts a perspective view of an embodiment of the present invention;
DETAILED DESCRIPTION
[0025] The following systems, methods, objects, features, and advantages of the present invention will be apparent to those skilled in the art from the following detailed description of the preferred embodiments and the drawings. All documents mentioned herein are hereby incorporated by reference in their entirety.
[0026] Referring to FIG. 1 , apparatus 100 is depicted in accordance with an embodiment of the present invention. Apparatus 100 may include, apart from other things, first device 102 (an electronically operated deception section), second device 104 (a concealment/male stimulation section), and third device 120 (a male/female stimulation section).
[0027] In accordance with the present invention, first device 102 may be a flashlight, a radio, a mobile telephone, and/or any other type of commonly used portable electronically operated device. Second device 104 may be any suitable means for concealing one or more stimulation devices and optionally may be used as a male stimulation device. Third device 120 may be a male/female stimulation device.
[0028] In an embodiment of the present invention, first device 102 may be any electrically operable device, for example, device 102 maybe a flashlight as shown in FIG. 1 . First device 102 may use a single power source or may use a plurality of power sources from other powered section of apparatus 100 . First device 102 may be coupled second device 104 by any suitable means. Second device 104 may, for example, be a tubular outer shell having a front end 106 and a distal end 108 . Second device 104 may be threaded at front end 106 as well as at distal end 108 , front end 106 and distal end 108 may also use any other suitable attachment means. Front end 106 and distal end 108 may be collectively referred to as the “ends” hereafter. As shown in FIG. 1 , threaded ends 106 and 108 may be used to couple other devices and/or parts to second device 104 .
[0029] In an embodiment, second device 104 may be fabricated from metal, wood, plastic, rubber, glass or any other suitable material. For example, second device 104 may be fabricated from a plastic that may provide aesthetically pleasing appearance. Likewise, in another example, wood may be utilized for the construction of second device 104 giving it an appearance of a natural object. In certain embodiments, second device 104 may be of different shapes/sizes to accommodate various shaped first devices 102 and second devices 120 .
[0030] In an embodiment, first device 102 may include head section 112 . As shown in FIG. 1 , head section 112 may include cylindrical front panel 114 and conical shaped back portion 118 . Head section 112 may also include, for example, on/off switch 110 . On/off switch 110 may be located in any appropriate place on apparatus 100 . Cylindrical front panel 114 may be affixed to conical shaped back portion 118 by male and female threads (not shown) or any other suitable means. In one embodiment, conical shaped back portion 118 and cylindrical front panel 114 may be attached to each other with male and female threads by performing a twisting action to couple the respective parts. Cylindrical front panel 114 may include a transparent cover 116 that may house and secure, in this embodiment, a light bulb, one or more light emitting diodes, or the like (not shown). Transparent cover 116 may be made of glass, plastic, or any other suitable material having a linear, convex, or concave shape.
[0031] Conical shaped back portion 118 may house, for example, electrical wiring and power source devices (not shown) necessary, in this embodiment, to provide power to a light emitting source housed in cylindrical front panel 114 . In an embodiment of the present invention, head section 112 may be a single structure (not shown) or may be modular and may include one or more sections. For example, as shown in FIG. 1 , head section 112 may be assembled from two different subparts i.e., cylindrical front panel 114 and conical shaped back portion 118 .
[0032] In an embodiment of the present invention, apparatus 100 may include second device 104 . Second device 104 may, for example, be a tubular device that may be removably attached to head section 112 . Second device 104 may be used as a human male stimulation device and/or may be used to conceal either a male stimulation and/or a female stimulation device.
[0033] In an embodiment of the present invention, the sexual device 120 may be removably attached to second device 104 using male/female threads or any other suitable device or means. Sexual device 120 may, for example, include selectable ribbing that may extend from the surface of sexual device 120 to provide a desired length for enhanced stimulation. Second device 102 (which as described may also be used as a male sexual device) and Sexual device 120 may include, as shown in FIG. 1 , lubrication receptacle/dispenser 130 with dispensing holes 132 . Second device 102 and sexual device 120 may also include electrical connections 142 that may be used to heat the lubrication contained within lubrication receptacle/dispenser 130 and/or may be used to operate massagers 150 and/or vibrate sexual device 120 . Lubrication receptacle/dispenser 130 may be used to apply lubrication to the inner surface of second device 104 . In addition, lubrication receptacle/dispenser 130 may also apply the gel on the outer surface of the sexual device 120 . The lubrication dispensed may reduce friction during masturbation. In addition, lubrication dispenser/receptacle 130 may be used to apply medication that needs to be thoroughly applied to male genitalia and/or inserted into female genitalia. The lubricant applied may be any type of medical lotion, oil, or any other suitable type of liquid or gel.
[0034] In an embodiment, lubrication dispenser/receptacle 130 may be dispensed automatically at a predetermined interval and/or may be coupled to activation button 162 that may apply lubrication on demand.
[0035] In an embodiment of the present invention, concealment of sexual device 120 may be achieved by inserting sexual device 120 into second device 104 and may be secured by threading, or the like, cap 124 over distal end 108 of second device 104 . In operation, sexual device 120 may be pulled out of second device 104 by unscrewing cap 124 and thereafter retrieving it for use. In an embodiment, sexual device 120 may be reversed in orientation from its concealment orientation and may be coupled to distal end 108 of second device 104 in order to increase its usable length.
[0036] In an embodiment of the present invention, second device 104 may include semen receptacle 140 . The semen accumulated in the semen receptacle 140 may be removed via semen evacuation tube 145 . In an embodiment of the present invention, the semen receptacle 140 may include a semen liner (not shown) that may include an environment and/or chemicals for keeping sperm alive for a specified period of time. In this embodiment, semen receptacle 140 may be utilized for accumulating sperm to be used later for artificial reproduction.
[0037] Sexual device 120 may telescopically elongate outwards from second device 104 . In this arrangement, sexual device 120 may be housed with end 126 facing in the direction of distal end 108 . In operation, cap 124 may be unscrewed from distal end 108 of second device 104 , and sexual device 120 would telescopically extend outward from second device 104 . Further, sexual device 120 may remain affixed to second device 104 .
[0038] As shown in FIG. 1 , second device 104 and sexual device 120 may include textured surface 152 and/or include nodules 157 on the inner surface of second device 104 and the outer surface of sexual device 120 respectively. For example, nodules 157 may increase the amount of pleasure during masturbation.
[0039] In an embodiment of the present invention, concealment of sexual device 120 may be achieved by inserting sexual device 120 into second device 104 and may be secured by threading, or the like, cap 124 over distal end 108 of second device 104 . In operation, sexual device 120 may be pulled out of second device 104 by unscrewing cap 124 and thereafter retrieving it for use.
[0040] In an embodiment, as shown in FIG. 2 , sexual device 120 may be reversed in orientation from its concealment orientation and may be coupled to distal end 108 of second device 104 in order to increase its usable length.
[0041] Referring to FIG. 2B , sexual device 120 may telescopically elongate outwards from second device 104 using telescoping means 122 . In this arrangement, sexual device 120 may be housed with end 126 facing in the direction of distal end 108 . In operation, cap 124 may be unscrewed from distal end 108 of second device 104 , and sexual device 120 would telescopically extend outward from second device 104 . Further, sexual device 120 may remain affixed to second device 104 .
[0042] As shown in FIG. 3 , second device 104 and sexual device 120 may include textured surface 152 on the outer surface of sexual device 120 . In another embodiment Second device 104 and the sexual device 120 may be tapered along its longitudinal axis for increasing the pleasure.
[0043] It will be understood that the foregoing is only illustrative of the principles of the invention and that various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention. Various aspects disclosed in the exemplary embodiments may be incorporated with aspects disclosed in other exemplary embodiments without departing from the scope of the invention.
[0044] The present invention can be practiced by other than the described embodiments, which are presented for purposes of illustration rather than of limitation and that the present invention is limited only by the claims that follow. | Human stimulation devices and an apparatus for concealing such stimulation devices are provided. A preferred embodiment of the present invention provides one or more human stimulation devices and includes an electrically operated first device, a second device that functions as a male stimulation device and a concealment device, and a third device that is functions as a second stimulation device. The second stimulation devices may be concealed within the second device and once the second stimulation device is concealed, the apparatus as a whole resembles the electronically operated first device. | 0 |
RELATED APPLICATIONS
[0001] This application claims the benefit of provisional U.S. Application Serial No. 60/392,748, entitled “Method and System for Efficiently Acquiring CDMA Based Overhead Channel Data Frames,” filed on Jun. 28, 2002, assigned to the assignee of the present application, and incorporated herein by reference in its entirety for all purposes.
BACKGROUND
[0002] 1. Field
[0003] The present invention generally relates to wireless communications networks. More particularly, the present invention relates to a system and method for synchronizing timing in application specific integrated circuits (ASICs) associated with wireless communication terminals.
[0004] 2. Related Art
[0005] Code division multiple access (CDMA) is one of several modulation techniques for facilitating communications in which a large number of system users are present. Although other techniques, such as time division multiple access (TDMA), frequency division multiple access (FDMA) and AM modulation schemes such as amplitude companded single sideband (ACSSB) are known, CDMA has significant advantages over these other modulation techniques.
[0006] The use of CDMA techniques in a multiple access communication system is disclosed in U.S. Pat. No. 4,901,307, entitled “Spread Spectrum Multiple Access Communication System Using Satellite or Terrestrial Repeaters” and U.S. Pat. No. 5,103,459, entitled “System and Method for Generating Signal Waveforms in a CDMA Cellular Telephone System”, both of which are assigned to the assignee of the present invention and are incorporated by reference. The method for providing CDMA mobile communications was standardized in the United States by the Telecommunications Industry Association in TIA/EIA/IS-95-A entitled “Mobile Station-Base Station Compatibility Standard for Dual-Mode Wideband Spread Spectrum Cellular System”, referred to herein as IS-95.
[0007] In the above patents, CDMA techniques are disclosed in which a large number of mobile station users, each having a transceiver, communicate through satellite repeaters or terrestrial base stations. The satellite repeaters are known as gateways and the terrestrial base stations are known as cell base stations or cell-sites. The gateways provide communication links for connecting a user terminal to other user terminals or users of other communications systems, such as a public telephone switching network. By using CDMA communications, the frequency spectrum can be reused multiple times thus permitting an increase in system user capacity. The use of CDMA techniques result in much higher spectral efficiency than can be achieved using other multiple access techniques.
[0008] In a typical CDMA communications systems, both the remote units and the base stations discriminate the simultaneously received signals from one another via modulation and demodulation of the transmitted data with high frequency pseudo-noise (PN) codes, orthogonal Walsh codes, or both. For example, in the forward link, i.e., base station to mobile station direction, IS-95 separates transmissions from the same base station by the use of different Walsh codes for each transmission, while the transmissions from different base stations are distinguished by the use of PN codes uniquely offset in phase. In the reverse link, i.e., mobile station to base station direction, different PN sequences are used to distinguish different channels.
[0009] The forward CDMA link includes a pilot channel, a synchronization (sync)-channel, several paging channels, and a larger number of traffic channels. The reverse link includes an access channel and a number of traffic channels. The pilot channel transmits a beacon signal, known as a pilot signal, and is used to alert mobile stations of the presence of a CDMA compliant base station. After a mobile station has successfully acquired the pilot signal, it can then receive and demodulate the sync-channel in order to achieve frame level synchronization and system time etc. This feature will be discussed in greater detail below. The paging channel is used by the base station to assign communication channels and to communicate with the mobile station when the mobile station has not been assigned to a traffic channel. Finally, the traffic channels, assigned to individual mobile stations, are used to carry user communications traffic such as speech and data.
[0010] To communicate: properly in a CDMA system, the state of the particular codes selected must be synchronized at the base station and the mobile station. Code level synchronization is achieved when the state of the codes at the mobile station system are the same as those in the base station, less some offset to account for any processing and transmission delay. In IS-95, this code level synchronization is facilitated by the transmission of the pilot signal from each base station which is comprised of the repeated transmission of the uniquely offset PN code (pilot PN code). In addition to facilitating synchronization at the pilot PN code level, the pilot channel also provides for identification of each base station relative to the other associated base stations using the base station's pilot channel phase offset.
[0011] After a mobile station achieves PN code level synchronization, as stated above, it can receive and demodulate the sync channel. The synch channel carries a repeating message that specifically identifies the base station, provides system level timing, and provides the absolute phase of the pilot signal.
SUMMARY
[0012] Consistent with the principles of the present invention as embodied and broadly described herein, an exemplary circuit includes a first communications device including at least first and second type communication paths. The first communications device is adapted to (i) receive first and second timing signals in the first type communication path and (ii) transmit data on the second type communication path. The data is transmitted in association with the received first timing signal. Next, the circuit includes a processor electrically coupled to the first communications device and configured to (i) receive the second timing signal and (ii) produce a timing word from the second timing signal. Finally, the circuit includes a second communications device including at least a first type communication path. The second communications device is coupled to the processor and adapted to receive the timing word therefrom and is configurable to receive the transmitted data and derive synchronization information therefrom. The derived synchronization information is related to the first timing signal. The second communications device also performs one or more operations in accordance with the received second timing signal and the derived synchronization information.
[0013] Features and advantages of the present invention include the ability to enhance the speed with which remotely located terminals achieve synchronization in a system where synchronization is based upon a message being repeatedly transmitted from a centralized unit to the remote terminals. By enhancing the speed of synchronization, the amount of time the remote terminal is out of service can be reduced. Additionally, the unit may operate in a lower power mode, thus facilitating a reduction in overall power consumption once synchronization has been achieved. The time savings achievable by this process amount to an average, for example, of approximately 300 ms. This in turn implies the time a mobile station is out of service due to a system loss can also be 300 ms less for each synchronization cycle. The net result is an overall savings of at least eight minutes of standby mobile phone time every hour, when the mobile phone is operating in a non-preferred system. In the non-preferred system, the total mobile phone standby time is increased by about 13%. If, for example, the mobile phone is operating in a system that experiences frequent system losses, the increase in standby time could be even higher.
BRIEF DESCRIPTION OF THE FIGURES
[0014] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention and, together with the description, explain the purpose, advantages, and principles of the invention. In the drawings:
[0015] [0015]FIG. 1 illustrates an exemplary wireless communication system;
[0016] [0016]FIG. 2 is a block diagram illustration of the mobile communications terminal 124 b shown in FIG. 1;
[0017] [0017]FIG. 3 a is an illustration of an exemplary data stream produced by the terminal of FIG. 2;
[0018] [0018]FIG. 3 b is an illustration of applying an exemplary synchronization timing scheme;
[0019] [0019]FIG. 4 is a block diagram representation of an exemplary message fragment;
[0020] [0020]FIG. 5 is an illustration of a conventional synch channel message;
[0021] [0021]FIG. 6 is an illustration of the message fields associated with the message of FIG. 5;
[0022] [0022]FIG. 7 is a more detailed illustration of the example of FIG. 3B; and
[0023] [0023]FIG. 8 is an exemplary method of practicing the present invention.
DETAILED DESCRIPTION
[0024] The following detailed description of the present invention refers to the accompanying drawings that illustrate exemplary embodiments consistent with this invention. Other inventions are possible, and modifications may be made to the embodiments from the spirit and scope of the invention. Therefore, the following detailed description is not meant to limit the invention. Rather, the scope of the invention is defined by the appended claims.
[0025] It would be apparent to one of skill in the art that the present invention, as described below, may be implemented in many different embodiments of hardware, software, firmware, and/or the entities illustrated in the figures. Any actual software code with specialized controlled hardware to implement the present invention is not limiting of the present invention. Thus, the operation and behavior of the present invention will be described with the understanding that modifications and variations of the embodiments are possible, given the level of detail presented herein.
[0026] Before describing the invention in detail, it is helpful to describe an example environment in which the invention may be implemented. The present invention is particularly useful in mobile communications environments. FIG. 1 illustrates such an environment.
[0027] [0027]FIG. 1 is a block diagram of an exemplary wireless communication system (WCS) 100 that includes a base station 112 , two satellites 116 a and 116 b, and two associated gateways (also referred to herein as hubs) 120 a and 120 b. These elements engage in wireless communications with user terminals 124 a, 124 b, and 124 c. Typically, base stations and satellites/gateways are components of distinct terrestrial and satellite based communication systems. However, these distinct systems may interoperate as an overall communications infrastructure.
[0028] Although FIG. 1 illustrates a single base station 112 , two satellites 116 , and two gateways 120 , any number of these elements may employed to achieve a desired communications capacity and geographic scope. For example, an exemplary implementation of WCS 100 includes 48 or more satellites, traveling in eight different orbital planes in Low Earth Orbit (LEO) to service a large number of user terminals 124 .
[0029] The terms base station and gateway are also sometimes used interchangeably, each being a fixed central communication station, with gateways, such as gateways 120 , being perceived in the art as highly specialized base stations that direct communications through satellite repeaters while base stations (also sometimes referred to as cell-sites), such as base station 112 , use terrestrial antennas to direct communications within surrounding geographical regions.
[0030] User terminals 124 each include a wireless communication device such as, but not limited to, a cellular telephone, a data transceiver, or a paging or position determination receiver. Furthermore each of user terminals 124 can be hand-held, vehicle-mounted or fixed. For example, FIG. 1 illustrates user terminal 124 a as a fixed telephone, user terminal 124 b as a hand-held portable device, and user terminal 124 c as a vehicle-mounted device.
[0031] User terminals 124 engage in wireless communications with other elements in WCS 100 through CDMA communications systems. However, the present invention may be employed in systems that employ other communications techniques, such as time division multiple access (TDMA), and frequency division multiple access (FDMA).
[0032] Generally, beams from a beam source, such as base station 112 or satellites 116 , cover different geographical areas in predefined patterns. Beams at different frequencies, also referred to as CDMA channels or ‘sub-beams’, can be directed to overlap the same region. It is also readily understood by those skilled in the art that beam coverage or service areas for multiple satellites, or antenna patterns for multiple base stations, might be designed to overlap completely or partially in a given region depending on the communication system design and the type of service being offered, and whether space diversity is being achieved.
[0033] [0033]FIG. 1 illustrates several exemplary signal paths. For example, communication links 130 a - c provide for the exchange of signals between base station 112 and user terminals 124 . Similarly, communications links 138 a - d provide for the exchange of signals between satellites 116 and user terminals 124 . Communications between satellites 116 and gateways 120 are facilitated by communications links 146 a - d.
[0034] User terminals 124 are capable of engaging in bi-directional communications with base station 112 and/or satellites 116 . As such, communications links 130 and 138 each include a forward link and a reverse link. A forward link conveys information signals to user terminals 124 . For terrestrial-based communications in WCS 100 , a forward link conveys information signals from base station 112 to a user terminal 124 across a link 130 . A satellite-based forward link in the context of WCS 100 conveys information from a gateway 120 to a satellite 116 across a link 146 and from the satellite 116 to a user terminal 124 across a link 138 . Thus, terrestrial-based forward links typically involve a single wireless connection, while satellite-based forward links typically involve two wireless connections.
[0035] In the context of WCS 100 , a reverse link conveys information signals from a user terminal 124 to either a base station 112 or a gateway 120 . Similar to forward links in WCS 100 , reverse links typically require a single wireless connection for terrestrial-based communications and two wireless connections for satellite-based communications. WCS 100 may feature different communications offerings across these forward links, such as low data rate (IDR) and high data rate (HDR) services. An exemplary LDR service provides forward links having data rates from 3 kilobits per second (kbps) to 9.6 kbps, while an exemplary HDR service supports data rates as high as 604 kbps.
[0036] HDR service may be bursty in nature. That is, traffic transferred across HDR links may suddenly begin and end in an unpredictable fashion. Thus, in one instant, an HDR link may be operating at zero kbps, and in the next moment operating at a very high data rate, such as 604 kbps.
[0037] As described above, WCS 100 performs wireless communications according to CDMA techniques. Thus, signals transmitted across the forward and reverse links of links 130 , 138 , and 146 convey signals that are encoded, spread, and channelized according to CDMA transmission standards. In addition, block interleaving is employed across these forward and reverse links. These blocks are transmitted in frames having a predetermined duration, such as 20 milliseconds.
[0038] Base station 112 , satellites 116 , and gateways 120 may adjust the power of the signals that they transmit across the forward links of WCS 100 . This power (referred to herein as forward link transmit power) may be varied according to user terminal 124 and according to time. This time varying feature may be employed on a frame-by-frame basis. Such power adjustments are performed to maintain forward link bit error rates (BER) within specific requirements, reduce interference, and conserve transmission power.
[0039] For example, gateway 120 a, through satellite 116 a, may transmit signals to user terminal 124 b, such as a mobile phone, at a different forward link transmission power than it does for user terminal 124 c. Additionally, gateway 120 a may vary the transmit power of each of the forward links to user terminals 124 b and 124 c for each successive frame.
[0040] [0040]FIG. 2 is a block diagram of the exemplary mobile phone 124 b shown in FIG. 1. The mobile phone 124 b includes an antenna 200 coupled to an antenna switch 202 . Also included is a receive path 204 with an input coupled to the antenna switch 202 and a transmit path 206 having an output also coupled to the antenna switch 202 . The antenna switch 202 switches the antenna 200 between input and output modes respectively associated with the receiver 204 and the transmitter 206 . The antenna 200 receives and forwards radio frequency signals to the receive path 204 in conventional manner. The mobile phone 124 b also includes a processor 208 comprising a CPU 210 and a memory 212 . The CPU 210 receives input signals via the receive path 204 and processes those signals in accordance with an appropriate signaling standard and instructions stored in the memory 212 .
[0041] Finally, a user interface 214 , which can include a display panel and/or a keyboard, is also provided. The CPU 210 provides an output signal along a reverse-link path 215 , to the transmit path 206 for transmission across a wireless communications link via the antenna 202 . As discussed above, in order for the mobile phone 124 b to obtain access to the communications network, it must first receive the pilot signal transmitted by the base station 112 . Next, it must receive and demodulate the associated system's synchronization channel. After the synchronization channel has been demodulated, the mobile phone 124 b can gain access to the synchronization message and other pertinent information required for system use.
[0042] In FIG. 3A, a data stream 300 , transmitted by the WCS 100 via the base station 112 , includes portions of a number of different synchronization messages transmitted at different times. A portion of a synchronization message 302 includes data frames labeled as (A 0 -A 9 ), a synchronization message 304 includes data frames labeled as (B 0 -B 9 ), a synchronization message 306 includes data frames labeled as (C 0 -C 9 ), and a portion of a synchronization message 308 includes data frames labeled as (D 0 -D 3 ). The synchronization message 304 includes a starting point 310 at which the mobile phone 124 b, and thus the processor 208 , begins to receive the data stream 300 . Additionally, the synchronization message 306 includes a start-of-message bit indicating a start of the message 306 within its associated data frame 311 . Although the present invention is described with reference to an exemplary synchronization channel and associated synchronization message, the present invention is not limited to such a configuration. The present invention may be practiced with regard to any communications channel or process that includes receiving periodic messages that include data frames containing one or more constant fields.
[0043] When the mobile phone 124 b is initially powered-up, its processor 208 must be synchronized with the data frame structure of the WCS 100 . Since its initially unsynchronized, the first frame the processor 208 receives will not necessarily be the first frame of any of the messages 302 , 304 , 306 , and 308 in the data stream 300 . Using conventional approaches, processors typically examine successively received frames until a start-of-a message (SOM) indication is received, such as the SOM indication within the frame 311 of the synchronization message 306 . However, if the first data frame received by the processor was not at the beginning of a message, as in the case of the data frame 310 of the synchronization message 304 , synchronization would not occur at that time. Subsequently, if the first data frame the processor 208 receives is the data frame 310 , it will search through the data stream 300 to find an SOM bit within the data frame 311 .
[0044] After locating the SOM bit, the processor 208 must then receive all of the subsequent data frames (C 0 -C 9 ) associated with the synchronization message 306 . After receiving all of the data frames (C 0 -C 9 ), the processor 208 can properly read the associated data fields, decode the message, and subsequently obtain synchronization. That is, the subsequent frames must be accumulated until the entire message 306 has been received.
[0045] If there were (N) frames in a message, then in an error-free environment, between N and (N-1)+N frames must be received in order to assemble a complete message. This results in an average of (3N-1)/2 frames to receive the message. Since (N) frames must be received for a complete message, this approach has an average penalty of (N-1)/2 frames. Therefore, the requirement to accumulate subsequent frames until the entire message has been received, is somewhat inefficient and time-consuming.
[0046] The present invention, however, eliminates the need to collect all of the frames from an entire message before synchronization can be achieved. Alternatively, the present invention facilitates a more efficient process of combining message fragments from successive messages to hasten synchronization. Here, the processor 208 of the mobile phone 124 b begins receiving frames in the manner discussed above. As shown in FIG. 3A, after (m) frames of the data stream 300 have been collected, the frame 311 containing the SOM bit will be received. Also as shown in FIG. 3A, a complete message requires the collection of a total of (N) frames.
[0047] In the present invention, unlike the conventional techniques discussed above, the total number of required frames (N) can be represented by (m) frames from an initial message, plus (N-m) frames from a next message. That is, all of the frames need not occur in the same message, but can be derived from different message fragments, as represented by (P). For purposes of discussion herein, the initial message ( 304 ) will be referred to as the first message fragment and the next message ( 306 ) will be referred to as the second message fragment.
[0048] From the first and the second message fragments, it will be possible to synthetically construct an entire message, such as an inferred, or new, synch channel message 312 shown in FIG. 3B. As shown in FIG. 3B, if error-checking information is at the end of a message, then the frames from the second message fragment, shown as 306 a will be moved into the first message fragment 304 a. In other words, the frames shown as (N-m) of the message 306 in FIG. 3A will be moved to a beginning portion of the new synch channel message 312 . Similarly, an end portion shown as (m) of the synch channel message 304 , also called the “previous synch channel message,” will be moved to an end portion of the new synch channel message 312 . Some data fields may require conversion before being moved, or copied, into other frames. This process is discussed in greater detail below. An exemplary construction process is illustrated in FIG. 4.
[0049] In FIG. 4, a data register 400 is included in the processor 208 and is configured to receive a portion of the data stream 300 as time progresses along a timeline (t). In FIG. 4, the portion (P) of the data stream 300 , shown in FIG. 3A, is stored in the data register 400 . In order to construct the new synch channel message 312 , the first and second message fragments are combined in the register 400 . Next, a data register 404 includes the message fragment 304 a, which is formed of the last eight frames from the message 304 . Similarly, a register 406 includes the fragment 306 a, which is formed of the first two frames from the message 306 .
[0050] In order to combine the message fragments 304 a and 306 a, either the fragment 304 a must be moved from the register 404 and appended to the contents of the register 406 or the fragment 306 a must be removed from register 406 and appended to the contents of the register 404 . As a solution, the inventors of the present invention have discovered that if error-checking information is contained at the end of any first message fragment, such as the fragment 304 a, then the frames from a successive synch channel message fragment, such as the fragment 306 a, should be moved into the first message fragment. In IS-95-A, CDMA2000, and W-CDMA, error checking is traditionally performed at the end of the message. Therefore, the data frames from the message fragment 306 a are added to the beginning of the first message fragment 304 a.
[0051] A resulting new synch channel message 312 is therefore formed in a data register 408 by prepending the converted message fragment 306 a to the message fragment 304 a. The data register 408 includes data frames C′ 0 and C′ 1 , representative of modifications to the data frames C 0 and C 1 , respectively. If, on the other hand, the error checking information had been contained at the start of the message, the converted message fragment 304 a would have been appended to the fragment 306 a. A detailed view of a conventional message and frame structure is shown in FIG. 5.
[0052] In FIG. 5, a conventional synchronization message 500 is shown and includes three superframes 501 formed from nine individual frames 502 . Each of the individual frames 502 includes an SOM bit 503 within its frame body 504 . As stated above, and shown in relation to FIG. 3A, the message 306 includes an SOM bit at the beginning of the frame 311 . During operation of the present invention, an incoming data stream, such as the exemplary data stream 300 , is analyzed. From this analysis, a complete message is constructed from the partially received messages contingent in-part on the location of the SOM bit. Each message also includes a number of predetermined data fields 506 that provide specific information for use by the mobile phone 124 b in acquiring, achieving synchronization, and maintaining communication within the WCS 100 . Each of the data fields 506 includes a specific data field value. The data field value is ultimately determinative of the ease at which frames can be combined to form complete messages.
[0053] Data frames including constant data field values may be copied directly from one message to the other without further manipulation. As shown in FIG. 5, many of the data field values are indicated as being constant. Although constant fields may be copied directly from one message to the other, non-constant fields require value adjustments to determine the required value for the field in the previous or next message, depending on the direction the associated frames are being moved. Once frames from different messages are combined to form a complete message, an error-checking algorithm will then be run on the new synthesized message to verify that it is indeed a valid message. Although many of the field values are constant, several of the field values are indicated as being variable and consequently require processing of varying degrees of complexity before they can be copied to another message.
[0054] As illustrated in FIG. 5, some message fields are variable and require complex processing before copying, while others are variable but are relatively simple to process. Even further, some field values, such as the cyclic redundancy check (CRC), are variable and require extremely complex processing before they can be copied from one message to another. The CRC, for example, is varied, not in a simple fashion, but in a complex pseudo-random manner. FIG. 6 provides an even greater detailed illustration of the particular message fields 506 associated with the sync channel message data frames.
[0055] A significant benefit of the present invention is that it takes exactly (N) frames to receive a message of (N) frame length, regardless of the point in the message that frame reception began. Thus, the average penalty of the present technique is zero, which is an improvement of (N-1)/2 frames over the conventional approaches. The situation becomes even more complex when a non-constant message field spans a message frame boundary, such as the CRC and long-code state field values shown in FIG. 5. As shown, each of these variable field values extends across the boundaries of the frames 502 . If the process for adjusting the field value is a simple operation, it may be possible to adjust the value despite part of the field being contained in more than one frame. An exemplary adjustment technique is discussed below.
[0056] Certain fields, although non-constant in value, may increase by a constant value each successive message. One such field is system time, shown in FIG. 5 as SYS_TIME. Assume, for purposes of illustration, that the first message fragment contains the least significant bits of the SYS_TIME field, and the second message fragment contains the most significant bits. To determine the field's value in the second message, the constant value should be added to the least significant bits from the first message, ignoring any overflow into the most significant bits. The most significant bits of the result should be set to the most significant bits from the second message fragment. To determine the field's value in the first message, the constant value may be subtracted from the field value in the second message, as shown in Equations (A)-(C) below:
Eq. (A):
xxx 789 + 1234 345 YYY
[0057] from first message fragment
[0058] increase in value from one message to the next
[0059] from second fragment
Eq. (B):
789 + 1234 ?? ?023
[0060] thus YYY=023, and the second message's field value must be 345023
Eq. (C):
345023 - 1234 343789
[0061] the first message's field value must be 343789
[0062] If, on the other hand, the operation for adjusting the field value from one message to the next is not a simple operation, and the field crosses one or message frame boundaries, it may be simpler to wait until all of the bits in the field have been accumulated. This invention assumes, therefore, that there are constant fields in the message. These fields do not have to be truly constant, but merely infrequently changing. If a constant field's value changes from one message to the next, the error-detection procedure will determine that the synthesized message is not a valid message. In this case, the additional message frames will be required, and the process will repeat until a valid message can be synthesized or a complete message is received. In other words, the average penalty for changing an otherwise constant field in the message is the same as the original method stated above. Therefore, use of the invention does not result in any greater degradation, even during a worst-case scenario than using traditional methods.
[0063] Of the data fields shown in FIG. 6, only LC_STATE, SYS_TIME, and CRC change with each successive synch channel message. The SYS_TIIME and LC_STATE fields change in a predictable fashion from one synch channel message to the next. For example, the SYS_TIME field, which is in units of 80 milliseconds (ms), is increased by 3 each message, corresponding to a total of 240 ms. The CRC field, however, does not change in any easily determined fashion. The remaining fields are effectively constant. For example, the DAYLT field will only change twice in over 100 million synch channel messages.
[0064] If the synchronization channel decoding starts in the middle of a synch channel message, the synch channel frame's SOM bits will be zero because only the frame depicting the start of the message has its bit set. Eventually, the synch channel message will end, and the next one will begin. This is signaled by a synch channel frame with its SOM bit set to 1. At this point, the MSG_LENGTH field can be examined to determine the length of the synch channel message. The frames immediately before the frame with the SOM bit set to 1 may be pure padding frames, containing no useable information, and may be ignored. The synch channel message length can be expressed in the following manner:
in bytes: B = MSG_LENGTH in frames: F = [MSG_LENGTH * 8/31] in superframes: SF = [MSG_LENGTH * 8/93]
[0065] The frames immediately before the frame with the SOM bit set to one may be “pure padding” frames containing no useful information.
[0066] “Pure padding” frames at end of Sync Channel Message Capsule:
[0067] in frames: PF=3*SF-F
[0068] After “F” frames have been received on the sync channel, ignoring any pure padding frames, the end of one sync channel message and the beginning of the next will have been received. From these, a complete sync channel message may be constructed as shown in the example 700 of FIG. 7.
[0069] The constant fields from the next synch channel message fragment can be copied directly to the start of the previous synch channel message. The non-constant fields, SYS_TIME and LC_STATE, will need to be converted as they are copied. The SYS_TIME field will need to be decreased by a predetermined amount, the number of superframes in the synch channel message. The LC_STATE field will need to be backed up by about 3× SF PN rolls (3*SF*32768 steps). At this point, the CRC for the inferred synch channel message can be computed. If the CRC check passes, then the message can be assumed to be correct. If the CRC fails, then bit errors are present, or one or more of the constant fields must have changed. Subsequent synch channel frames can overwrite the previous frames until either the CRC of the inferred message passes or enough frames have been collected to complete the next synch channel message.
[0070] If all of the SYS_TIME field bits are from the next synch channel message fragment, then computing what the value of the field would have been in the previous message is straightforward. If some of the least significant bits are from the previous message, and the most significant bits are from the next message, then conversion is more involved but still possible, as discussed above.
[0071] If, for example, all of the LC_STATE field bits are from the next synch channel message fragment, then the LC_STATE for the previous message can be computed by a polynomial division by 3*SF*32768. Alternately, due to the cyclical nature of the long code, this can also be computed by an advance (polynomial multiplication) of (2 42 −1)−(3*SF*32768). If all the LC_STATE bits are not contained in either message fragment, computation of the required long code state will be more difficult. In this case, more synch channel frames must be collected until all LC_STATE bits are from the same message fragment.
[0072] Conversion of the CRC bits from the next synch channel message fragment to the previous synch channel message fragment is not possible. However, when all the CRC bits are collected from the next synch channel message fragment, this is no longer a message fragment, but rather a complete message and can be processed as such.
[0073] [0073]FIG. 8 provides a detailed illustration of an exemplary method of practicing the present invention. In FIG. 8, a flowchart 800 is provided to present a detailed illustration of an exemplary method of practicing the present invention. In block 802 , a user begins the process by activating the mobile phone 124 b. In a block 804 , data frames, transmitted via synchronization messages associated with the WCS 100 , are collected and stored in the register 400 of the processor 208 , as illustrated in FIGS. 2 and 4.
[0074] Next, in block 806 , the processor 208 determines whether a first message frame, such as the first frame 311 shown in FIG. 3A, has been collected. If a first frame has been collected, as evidenced by inspection of the SOM bit, then the processor 208 computes the message length, as depicted in block 808 . For example, in FIG. 3A, the message length is shown to be 10 frames. If on the other hand a first frame has not been collected, the processor 208 continues to collect and store frames as shown in block 804 . After the message length (N) has been computed, the total number of received frames (P) is determined in block 810 .
[0075] Next, the processor 208 determines whether (N) frames have been collected and stored as depicted in block 812 . If (N) frames have not been collected and stored, the processor 208 again collects and stores additional frames, as shown in block 814 , and the process returns to block 810 . If (N) frames have been collected, the processor 208 determines whether the (N) collected frames form a complete next message as depicted in block 816 . If a complete next message has been formed, the processor 208 determines whether the CRC passes as indicated in block 818 . If the CRC passes, the process is completed, the next message is formed and may be decoded to facilitate synchronization. If on the other hand however, the number of collected (N) frames do not all belong to the next message, as illustrated in the example of FIG. 4, the collected next frames are transferred and converted into the previous frames described in block 820 of FIG. 7.
[0076] Once the frames have been transferred to the previous message, by mere copying or copying and conversion, the processor 208 determines whether the CRC of the previous message has passed, as shown in block 822 . If the CRC passes, the field values are adjusted in accordance with present time values as described above and as illustrated in block 824 . The process then finishes with formation of a next, or new, message as stored in the register 408 of FIG. 4. If the previous message CRC 822 does not pass, then the processor 208 continues to collect and store data frames.
CONCLUSION
[0077] By accelerating the synchronization process, the amount of time a remote unit, such as the mobile phone 124 b is out of service, is reduced. Additionally, mobile phone 124 b can operate in a lower power mode once synchronization has been achieved and power savings can be realized. Thus, by using the present invention, the latency created when the decoding of the sync channel message does not begin at the start of the message can be reduced. The technique of the present invention therefore provides a savings of about 300 milliseconds for each synchronization cycle.
[0078] The foregoing description of the preferred embodiments provides an illustration and description, but is not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications and variations are possible consistent with the above teachings, or may be acquired from practice of the invention. | Provided is a system and method for constructing a data message in a communications device including a processor configured to process sequentially transmitted messages. Each of the messages requires a predetermined number of data frames. The technique of the instant invention includes receiving portions of at least two of the transmitted messages in the processor. Each of the at least two received portions includes a subset of the predetermined number of data frames and excludes a remainder of the predetermined number of data frames. The subset of one of the received portions substantially matches the remainder of the other portion. Next, a determination is made as to whether a total number of the received subsets equals the predetermined number. Finally, a synthesized messaged is produced when the total number of the subsets is at least equal to the predetermined number. The synthesized message is formed of a combination of the subsets from each of the received portions. | 7 |
TECHNICAL FIELD
This invention relates to the art of demand controllers wherein operation of one electrical device limits the power available to another electrical device.
BACKGROUND ART
With the cost of constructing an electric power plant increasing, it has become common to charge a customer for the peak demand required by the customer in addition to charging for the total amount of power consumed. Thus, a customer who allows all of his electrical equipment to operate simultaneously may pay a higher utility bill than the customer who spreads out his usage to operate the equipment at different times.
It has been common to apply demand charges to commercial customers, but is has only recently become common to apply demand charges to residential customers also. This means that the residential consumer who operates the stove, washing machine, clothes dryer and water heater simultaneously may be forced to pay a very high demand charge, while the consumer who is attentive enough to not run these appliances simultaneously will pay a lower demand charge. Of course, both of these customers may pay an equal charge for the power actually consumed.
While it is evident that a consumer may lower his demand charge by being attentive to the appliances in use, such is oftentimes difficult to do. Therefore, automatic demand controllers have been proposed to measure the power consumed by major electrical devices and to limit power available to some of these devices so as to maintain the peak demand below a predetermined level.
One such automatic demand controlling device is disclosed by the U.S. Pat. No. (2,843,759) to Roots. This patent teaches a system primarily designed for an industrial environment, and includes a power sensitive means in series with an electrical device to measure the power consumed by the device. The power sensitive means for one device is connected to a switch in series with a second device to control the power available to the second device. Each switch controls only one load, so that if one load is out of operation, for example because of its being repaired, other loads will not be controlled.
A second demand controller is shown in the U.S. Pat. No. (2,469,645) to Harper. This controller operates by integrating the power consumed by a load and comparing that with the maximum power which may be consumed in a predetermined time interval. When the electrical load device is consuming too much power, the controller will begin to interrupt the power available to that device.
Another controller is shown by the patent to Briscoe, et al. U.S. Pat. No. (4,141,407). This device simply interrupts the power to a group of load devices to ensure that the power consumed by all of the devices is below a predetermined level.
A device taught by Breitmeier U.S. Pat. No. (3,858,110) merely limits the power to a load device, and does not turn off one load device in favor of another.
STATEMENT OF THE INVENTION
The prior art does not provide a demand controller suitable for use by the typical residential customer. Prior devices must be wired into individual circuits, and the operations of the devices are unduly complex. Furthermore, prior devices do not facilitate the use of a time clock to allow the controller to operate only when the peak demand rates are in effect.
Applicant's invention is a demand controller particularly adapted for use by a residential customer. The inventive demand controller is self-contained, and it may be easily installed to cooperate with existing electrical service by any electrician.
Applicant's demand controller utilizes a plurality of current detectors to sense the operation of selected electrical applicances. The applicances are placed in a hierarchy so that when the most important appliance is turned on, the other major appliances are turned off. When an appliance of lesser importance is turned on, appliances below it in the hierarchy are turned off, but appliances which are above it are still available for use. Applicant's controller is preferably arranged so that an electric range is at the top of the hierarchy, followed by the electric dryer, the air conditioner, and the water heater.
According to the preferred embodiment of Applicant's controller, the water heater will be turned off whenever the range, the clothes dryer, or the air conditioner is operating. This has been shown to be effective because the water heater is typically well-insulated and can maintain the temperature of the water over a long period of time without electric power. Operation of the air conditioner will switch off the water heater, but operation of the air conditioner is subject to operation of the range or the clothes dryer. If either of these appliances is in operation, the air conditioner and the hot water heater will both be switched off. Experience has shown that the temperature of the house will not increase dramatically in the period of time taken to dry a load of clothes or to operate the range for an average period. The range draws the most amount of power, and it is at the top of the hierarchy. All other appliances operate subject to the operation of the range.
Applicant's controller employs a series of magnetic contactors to connect the appliances below the appliance at the top of the hierarchy to a source of electrical power. Each of the contactors is controlled by a current relay, and each of the current relays is controlled by one of the current sensors. Thus, when an appliance is operating, a current sensor detects that operation and supplies a voltage to a current relay. The current relays have normally closed contacts so that if no voltage is applied by the current sensor, the current relay supplies power to a magnetic contactor and the appliance controlled by that contactor receives electrical power. When the current sensor detects that an appliance is in operation, the contacts of the respective current relay are opened and the contacts of the magnetic contactor open also because of the absence of activating current from the relay. When the magnetic contactor opens, the appliance controlled by that contactor does not receive electrical power and it thus does not operate. Each magnetic contactor also operates an auxilliary switch placed in series with the current relay which controls the magnetic contactor having a lower position in the hierarchy. This auxilliary switch acts to prevent power from being supplied to the magnetic contactor for the lower appliance, so that when a given magnetic contactor is opened, all lower magnetic contactors are also opened.
A clock is operated from electric power independent of the power applied to the appliances. The clock supplies current to a timing relay during pre-selected periods of the day. When the timing relay is activated, power is supplied to each of the magnetic contactors so that all appliances are operable regardless of the amount of power being consumed.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows the installation of the main controller with a conventional circuit breaker or fuse panel.
FIG. 2 shows the circuit diagram of the inventive demand controller.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows the demand controller of the invention 2 installed on a wall 4 adjacent a pre-existing circuit breaker or fuse panel 6. A conduit 8 may be installed to protect the electrical wires which run between the controller 2 and the circuit breaker or fuse panel 6.
FIG. 2 shows the schematic diagram of the demand controller 2. Located at the top of the main controller are a first terminal block 10 and a second terminal block 12. The first terminal block is larger and thus has a capacity for carrying higher current than does the second terminal block 12. These terminal blocks are alternatively of equal size. The upper row of each terminal block receives wires from the circuit breaker or fuse panel 6. In the terminal block 10, terminals 14, 15 and 16 are adapted to receive three wires from a circuit breaker or fuse in the circuit breaker panel supplying 220 volt power, for example, to the range. Three wires connected to terminals 14', 15' and 16' would return to the circuit breaker panel to be connected to the wires supplying the range. Thus, the terminal block 10 is preferably "downstream" of the circuit breaker or fuse supplying, for example, the range and may be connected by a series of six wires communicating with the circuit breaker and fuse panel 6. Terminals on the other side of the terminal block 10 facing terminals 14-16 and 14'-16' are connected to the circuitry of the demand controller.
Terminal block 12 is connected in the same manner as the terminal block 10 and contains terminals 17 through 27 and 17' through 25'. The terminals 17 through 25 and 17' through 25' supply and control three additional appliances while terminals 26 and 27 supply power to the demand controller itself as will be described below.
As may be seen from an inspection of terminal block 10, terminal 15 is connected directly to terminal 15' and this represents the neutral terminal. Terminal 14 is connected directly to terminal 14' and terminal 16 is connected to terminal 16' by way of a current sensor 28. A conductor 30 extends from terminal 16 to current sensor 28 and has a section 32 in which the conductor 30 is coiled around the current sensor 28 and it is then connected to terminal 16'. It will thus be seen that when the appliance draws current from terminals 14', 15' and 16' the current sensor 28 will produce a voltage on conductors 34 and 36, for example, by induction.
Thus, the appliance which is connected to the first terminal block 10 always has electric power available and is not controlled by a switch. This appliance is at the top of the control hierarchy.
The appliance which is connected to the terminals 17, 18, 19 and 17', 18' and 19' will operate only if the appliance connected to terminals 14, 15 and 16 is not operating. The manner in which the operation of one appliance controls the operation of another appliance will now be described.
Terminals 17 and 19 are connected to one side of a magnetic contactor 42 by conductors 38, 40. The other side of the magnetic contactor 42 is connected to terminals 17' and 19' by conductors 44 and 46. Conductor 46 has a coiled section 48 which cooperates with a second current sensor 50 as will be described below. As described above with respect to terminal block 10, the neutral terminals are connected together directly.
Magnetic contactor 42 has interior switches 52 which are activated by coil 54.
Relay 56 is activated by the voltage between conductors 34 and 36 in response to power drawn by the appliance connected to terminal block 10. This relay has an internal switch 58 which is operated by the coil 60. Switch 58 is normally closed and draws power from conductor 62 through a conductor 64. The other side of the relay 56 is connected to one side of the magnetic contactor coil 54 by a conductor 66. The other side of the magnetic contactor coil is connected to terminal 27 by conductor 68 which is connected to conductor 70.
It will thus be seen that the appliance connected to terminals 17 through 19 and 17' through 19' will receive power when the switch 58 in relay 56 is closed, thus supplying power to the magnetic contactor 42 to close the switches 52. Since the switch 58 in relay 56 is normally closed, the magnetic contactor is normally activated. When the current sensor 28 senses current in conductor 30, relay 56 is activated to open switch 58 to thereby open switches 52 in the magnetic contactor 42 to thereby prevent power from being drawn by the appliance connected to terminals 17 through 19 and 17' through 19'.
Subsequent relays operate in a manner described with respect to the first relay and have been given similar reference numerals with one receiving primed reference numerals and another receiving double primed numerals.
Subsequent magnetic contactors also operate in a manner identical to that of magnetic contactor 42 and also have reference numerals having respective primed, and double primed numbers corresponding to those of contactor 42.
Attached to magnetic contactor 42 is an auxilliary contactor 72 having a switch which operates in conjunction with switches 52. Auxilliary contactor 72 is connected to relay 56' by a conductor 66' and is thus in series with that relay. It will thus be seen that when the magnetic contactor 42 is not activated, the auxilliary relay 72 is open, thus preventing current from conductor 62 from reaching magnetic contactor 42'. Magnetic contactor 42' similarly has an auxilliary contactor 72' which is in series with the output from the relay 56".
The appliance which is connected to terminals 20 through 22 and 20' through 22' operates only when magnetic contactor 42' is activated. Conductor 46' has coiled section 48' which interacts with current sensor 74 to control magnetic contactor 42" in the manner described above with respect to control of magnetic contactor 42.
It will be seen that the conductors 46" and 44" connect magnetic contactor 42" directly to output terminals 25' and 23' respectively. There is no need for these conductors to interact with a current sensor because in the embodiment shown in FIG. 2 there is no appliance in the hierarchy below the appliance connected to terminals 23 through 25 and 23' through 25'. If there were other appliances, it is clear that conductor 46" would cooperate with a fourth current sensor in the same manner as described with respect to the other magnetic contactors 42 and 42'.
The operation of the demand control circuit may now be described. Terminals 14 through 16 are preferably reserved for an electric range, terminals 17 through 19 for an electric clothes dryer, terminals 20 through 22 for a central air conditioning unit, and terminals 23 through 25 for an electric water heater. When there is no current being drawn by any of the appliances, switches 58, 58' and 58" in the relays will be in their normally closed positions. Thus, the magnetic contactors 42, 42' and 42" will be activated so that the switches 52, 52' and 52" will be closed. Therefore, all of the appliances will have power available. If the range were to be turned on, the current passing through conductor 30 would produce a voltage at conductors 34 and 36. This voltage would activate relay 56 to open switch 58 to thereby deactive magnetic contactor 42. The auxilliary relay 72 operates in conjunction with the magnetic contactor 42 and its internal switch would thereby be opened thus deactivating magnetic contactor 42' regardless of the condition of relay 56'. When magnetic contactor 42' is deactivated, auxilliary contactor 72' is also deactivated and the magnetic contactor 42" ceases to receive power regardless of the condition of relay 56". It may thus be seen that when the appliance connected to terminals 14 through 16 is drawing current, all of the other appliances are turned off.
In a similar manner, if the appliance connected to terminals 14 through 16 were turned off, but the appliance connected to terminals 17 through 19 were turned on, a current would be produced in conductor 46 and a voltage would be generated at conductors 34' and 36'. The relay 56' would therefore be activated to open switch 58' to deactivate magnetic contactor 42', auxilliary contactor 72' and magnetic contactor 42".
The above operation has been described for the situation where the demand controller is operated during the period of the day when peak demand rates are in effect. The invention also includes a time clock 76 which prevents the demand controller from operating during non-peak periods. The clock 76 is connected to terminal 27 by conductor 70 and is connected to terminal 26 by conductor 78 which is connected to conductor 62. Conductor 78 is also connected to one side of a time clock relay 80. This relay is preferably a triple-pole switch. Time clock 76 closes a switch 82 during certain pre-selected periods of the day to supply power to time clock relay 80 through conductor 84. The time clock relay is also connected to terminal 27 by conductor 68. When the switch 82 is closed, the switches in the relay 80 close to supply power to each of the magnetic contactors through conductors 86, 86' and 86". By this action, the operation of the relays 56, 56' and 56" is overridden, and each of the magnetic contactors 42, 42' and 42" is activated to supply current to their respective appliances. Thus, during non-peak rate periods, time clock 76 will activate switch 82 to prevent the controller from disconnecting any appliance.
If desired, a thermostat may be used in addition to the time clock. When the outside temperature reaches a pre-determined level, the thermostat would activate relay 80, or a similar relay, to prevent the controller from disconnecting any appliance.
It may thus be seen that an easily connected and effective demand controller has been described. This controller is capable of being attached to an existing household circuit in a simple manner and is constructed of parts which are readily available. | A demand controller uses a sensor to detect the operation of an electric load. The sensor operates a relay which supplies power to a magnetic contactor. The magnetic contactor controls power available to a second electric load so that the total amount of power consumed is held below a predetermined maximum. An auxillary switch operates in conjunction with the magnetic contactor to control power available to other loads. A hierarchy is established so that the most important load always has power available, and loads of lesser importance are controlled. | 8 |
FIELD OF THE INVENTION
This invention relates to the use of a high-level language to specify the circuitry of an integrated circuit device, and particularly to configure a programmable integrated circuit device such as a field-programmable gate array (FPGA) or other type of programmable logic devices (PLD).
BACKGROUND OF THE INVENTION
Early programmable devices were one-time configurable. For example, configuration may have been achieved by “blowing”—i.e., opening—fusible links. Alternatively, the configuration may have been stored in a programmable read-only memory. Those devices generally provided the user with the ability to configure the devices for “sum-of-products” (or “P-TERM”) logic operations. Later, such programmable logic devices incorporating erasable programmable read-only memory (EPROM) for configuration became available, allowing the devices to be reconfigured.
Still later, programmable devices incorporating static random access memory (SRAM) elements for configuration became available. These devices, which also can be reconfigured, store their configuration in a nonvolatile memory such as an EPROM, from which the configuration is loaded into the SRAM elements when the device is powered up. These devices generally provide the user with the ability to configure the devices for look-up-table-type logic operations.
At some point, such devices began to be provided with embedded blocks of random access memory that could be configured by the user to act as random access memory, read-only memory, or logic (such as P-TERM logic). Moreover, as programmable devices have become larger, it has become more common to add dedicated circuits on the programmable devices for various commonly-used functions. Such dedicated circuits could include phase-locked loops or delay-locked loops for clock generation, as well as various circuits for various mathematical operations such as addition or multiplication. This spares users from having to create equivalent circuits by configuring the available general-purpose programmable logic.
While it may have been possible to configure the earliest programmable logic devices manually, simply by determining mentally where various elements should be laid out, it was common even in connection with such earlier devices to provide programming software that allowed a user to lay out logic as desired and then translate that logic into a configuration for the programmable device. With current larger devices, including those with the aforementioned dedicated circuitry, it would be impractical to attempt to lay out the logic without such software. Such software also now commonly includes pre-defined functions, commonly referred to as “cores,” for configuring certain commonly-used structures, and particularly for configuring circuits for mathematical operations incorporating the aforementioned dedicated circuits. For example, cores may be provided for various trigonometric or algebraic functions.
Although available programming software allows users to implement almost any desired logic design within the capabilities of the device being programmed, most such software requires knowledge of hardware description languages such as VHDL or Verilog. However, many potential users of programmable devices are not well-versed in hardware description languages and may prefer to program devices using a higher-level programming language. But if the underlying logic to be implemented includes flow control elements, the implementation of that logic may be inefficient, particularly if the device is programmed using a high-level language.
SUMMARY OF THE INVENTION
One high-level programming language that may be adopted for specifying circuitry of an integrated circuit device, such as for configuring a programmable device, is OpenCL (Open Computing Language), although use of other high-level languages, and particularly other high-level synthesis languages, including C, C++, Fortran, C#, F#, BlueSpec and Matlab, also is within the scope of this invention.
In OpenCL, computation is performed using a combination of a host and kernels, where the host is responsible for input/output (I/O) and setup tasks, and kernels perform computation on independent inputs. Where there is explicit declaration of a kernel, and each set of elements to be processed is known to be independent, each kernel can be implemented as a high-performance hardware circuit. Based on the amount of space available on a programmable device such as an FPGA, the kernel may be replicated to improve performance of an application.
A kernel compiler converts a kernel into a hardware circuit, implementing an application from an OpenCL description, through hardware generation, system integration, and interfacing with a host computer. The compiler may be based on an open-source Low-Level Virtual Machine compiler extended to enable compilation of OpenCL applications. The compiler parses, analyzes, optimizes and implements an OpenCL kernel as a high-performance pipelined circuit, suitable for implementation on programmable device such as an FPGA.
In one variant, that circuit is input to the programming tools appropriate for the particular programmable device, which generates a configuration bitstream to program the device with that circuit. In another variant, the device also has an embedded hard processor or may be configured with an embedded soft processor, to run OpenCL (or other high-level) code, or an external processor may be used. The OpenCL or other high-level code can be run by executing the host program on the embedded or external processor. The system may then be compiled in conjunction with the aforementioned programming tools so that, when executed on the embedded or external processor, it instantiates the circuit equivalent of the kernel.
As disclosed herein, conditional flow control branches in the logic to be implemented in the circuit are converted into predicated instructions. The predicated instructions may be optimized to enhance the reduction of the resulting hardware size and latency, and to increase throughput.
In accordance with the present invention there is provided a method of programming or configuring an integrated circuit device using a high-level language. The method includes parsing a logic flow to be embodied in the integrated circuit device to identify branching control flow, converting the branching control flow into predicated instructions, incorporating the predicated instructions into a high-level language representation of a configuration of resources of the integrated circuit device, and compiling the high-level language representation to configure said integrated circuit device.
A machine-readable data storage medium encoded with instructions to perform the method also is provided, as is a programmable device configured according to the method.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features of the invention, its nature and various advantages will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:
FIG. 1 shows a control-data flow graph used in methods including methods according to embodiments of the invention;
FIG. 2 shows an example of a feed-forward logic pipeline;
FIG. 3 shows an example of a branched logic pipeline with flow control;
FIG. 4 shows an example of a logic flow including loops;
FIG. 5 shows how the logic flow of FIG. 4 may be redefined to work with embodiments of the invention;
FIG. 6 shows a method, which may be used with embodiments of the invention, for using a high-level language to configure a programmable device;
FIG. 7 is a cross-sectional view of a magnetic data storage medium encoded with a set of machine-executable instructions for performing the method according to the present invention;
FIG. 8 is a cross-sectional view of an optically readable data storage medium encoded with a set of machine executable instructions for performing the method according to the present invention; and
FIG. 9 is a simplified block diagram of an illustrative system employing a programmable logic device incorporating the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In OpenCL, an application is executed in two parts—a host and a kernel. The host is a program responsible for processing I/O requests and setting up data for parallel processing. When the host is ready to process data, it can launch a set of threads on a kernel, which represents a unit of computation to be performed by each thread.
Each thread executes a kernel computation by loading data from memory as specified by the host, processing those data, and then storing the results back in memory to be read by the user, or by the user's application. In OpenCL terminology, a kernel and the data on which it is executing are considered a thread. Results may be computed for a group of threads at one time. Threads may be grouped into workgroups, which allow data to be shared between the threads in a workgroup. Normally, no constraints are placed on the order of execution of threads in a workgroup.
For the purposes of data storage and processing, each kernel may have access to more than one type of memory—e.g., global memory shared by all threads, local memory shared by threads in the same workgroup, and private memory used only by a single thread.
Execution of an OpenCL application may occur partially in the host program and partially by executing one or more kernels. For example, in vector addition, the data arrays representing the vectors may be set up using the host program, while the actual addition may be performed using one or more kernels. The communication between these two parts of the application may facilitated by a set of OpenCL functions in the host program. These functions define an interface between the host and the kernel, allowing the host program to control what data is processed and when that processing begins, and to detect when the processing has been completed.
A programmable device such as an FPGA may be programmed using a high-level language such as OpenCL by starting with a set of kernels and a host program. The kernels are compiled into hardware circuit representations using a Low-Level Virtual Machine (LLVM) compiler that may be extended for this purpose. The compilation process begins with a high-level parser, such as a C-language parser, which produces an intermediate representation for each kernel. The intermediate representation may be in the form of instructions and dependencies between them. This representation may then be optimized to a target programmable device.
An optimized LLVM intermediate representation is then converted into a hardware-oriented data structure, such as a Control-Data Flow Graph (CDFG) ( FIG. 1 ). This data structure represents the kernel at a low level, and contains information about its area and maximum clock frequency. The CDFG can then be optimized to improve area and performance of the system, prior to RTL generation which produces a Verilog HDL description of each kernel.
The compiled kernels are then instantiated in a system that preferably contains an interface to the host as well as a memory interface. The host interface allows the host program to access each kernel. This permits setting workspace parameters and kernel arguments remotely. The memory serves as global memory space for an OpenCL kernel. This memory can be accessed via the host interface, allowing the host program to set data for kernels to process and retrieve computation results. Finally, the host program may be compiled using a regular compiler for the high-level language in which it is written (e.g., C++).
To compile kernels into a hardware circuit, each kernel is implemented from basic block modules. Each basic block module comprises an input and an output interface with which it talks to other basic blocks, and implements an instruction such as load, add, subtract, store, etc.
The next step in implementing each kernel as a hardware circuit is to convert each basic block module into a hardware module. Each basic block module is responsible for handling the operations inside of it. To function properly, a basic block module also should to be able to exchange information with other basic blocks. Determining what data each basic block requires and produces may be accomplished using Live-Variable Analysis.
Once each basic block is analyzed, a Control-Data Flow Graph (CDFG) ( FIG. 1 ) can be created to represent the operation of that basic block module, showing how that basic block module takes inputs either from kernel arguments or another basic block, based on the results of the Live-Variable Analysis. Each basic block, once instantiated, processes the data according to the instructions contained within the block and produces output that can be read by other basic blocks, or directly by a user.
Once each basic block module has been represented as a CDFG, operations inside the block can be scheduled. Each node may be allocated a set of registers and clock cycles that it requires to complete an operation. For example, an AND operation may require no registers, but a floating-point addition may require at least seven clock cycles and corresponding registers. Once each basic block is scheduled, pipelining registers may be inserted to balance the latency of each path through the CDFG. This allows many threads to be processed.
Once each kernel has been described as a hardware circuit, a design may be created including the kernels as well as memories and an interface to the host platform. To prevent pipeline overload, the number of threads allowed in a workgroup, and the number of workgroups allowed simultaneously in a kernel, may be limited.
Embodiments of the invention may be described with reference to FIGS. 2-6 .
FIG. 2 shows a feed-forward pipeline 200 with three blocks 201 . Each block 201 could be a load-store unit (i.e., an instruction, or the corresponding hardware implementation of that instruction, that reads or writes a single value from or to a specified address in memory) or a basic computation unit (e.g., addition or multiplication). Data flow from the entry of the pipeline to the exit without diverging or repeating. Thus, each datum is processed once by each block 201 of pipeline 200 . Different blocks 201 of pipeline 200 may take different amounts of time to process the data.
To avoid bottlenecks, pipeline 200 may be implemented as a stall signal network, in which each block 201 has a “valid” signal 211 input from the preceding block 201 —indicating that the preceding block 201 has completed its computations, and that the data 202 input to the current block 201 are therefore ready to be processed, and a “stall” signal 221 output to the preceding block 201 —indicating to preceding block 101 that current block 201 is busy and cannot accept any data. The valid/stall signals 211 , 221 allow pipeline 200 to take as much data as it can process and no more.
Consider, however, the following logic:
N=j*j if (N>3)
res=N*2 out[i]=res
else
res=sin(N) out[i]=0 out[i+1]=res
endif
Depending on how N compares to 3, a different value of res will be calculated and stored in a different location.
FIG. 3 shows how pipeline 200 may be modified to support the control flow described by the if-statements in the logic described in the previous paragraph. In modified pipeline 300 , the first block 301 performs the N=j×j computation, and feeds the result to branch node 302 , which selects one of paths 310 , 320 , depending on the value of N. One of the blocks 301 in path 310 may, e.g., be a multiplier to compute N×2, while one of blocks 301 in path 320 may, e.g., be a DSP block to compute sin(N). The two paths 310 , 320 , each of which is similar to path 200 , merge at merge node 303 , which gathers multiple data, valid, and stall signals to be presented to node 304 .
The branch and merge nodes 302 , 303 are undesirable because they consume relatively large amounts of hardware area. In addition, the computation flows through either path 310 or path 320 , but never through both paths, so one path is always idle. Moreover, if there are blocks in both paths that perform essentially the same function, then because the two copies of the block will never be used at the same time (because one path is always idle), replication of that block in both paths is a further waste of hardware area.
If the logic described above is implemented instead replacing each flow control condition with a predicated instruction—i.e., an instruction that does not do anything if its predicate (a Boolean argument) is false—then the logic may look like this:
N=j*j cond=(N>3) res1=N*2 res2=sin(N) value=if (cond) res1, else 0 out[i]=value out[i+1]=res2 if not cond
Such logic can be implemented in a feed-forward path such as path 200 , and achieves the same result as (i.e., the same values in the out [ ] array), but without the explicit control flow branches of, the previous logic.
The variable res1 is output only if the condition is met, while the variable res2 is output only if the condition is not met. Nevertheless, both res1 and res2 are always calculated, even though only one of them will be needed. There is no harm in letting an element execute even if its controlling condition is false, as long as the execution or its effects are not observable outside the circuit. The savings in area and execution speed resulting from elimination of the flow control nodes more than makes up for the resources consumed by executing the unused elements.
In addition, the feed-forward logic has only two load-store units (i.e., assignments to the output array out [ ]), whereas the branching logic has three load-store units. Load-store units are relatively large, so reducing their number is advantageous. The reduction in the number of load-store units is an example of instruction sharing.
An instruction that appears in two mutually exclusive branches can be shared by both branches. In the example above, the load-store unit out[i] is shared by selecting the value being stored based on the condition cond. The sharing is worth doing if the size of the selection instruction is smaller than the size of the instruction considered for sharing, which is almost always the case.
The more complicated the instruction is, and the greater the number of branches among which the instruction can be shared, the more worthwhile instruction sharing will be. The example below, which shows sharing of an instruction among three branches, also shows how to convert branches to conditions for predicated instructions.
Consider the following logic:
if (a)
if(b and c)
X
else if (b)
Y
endif
else
V
endif Z if (c)
if (b and not a)
W
endif
endif
in which each block of logic V, W, X, Y, Z includes a load-store unit. Translating the if-else flow control statements, the predicates for each block are:
Block X: a and b and c Block Y: a and b and not c Block V: not a Block Z: true Block W: b and c and not a
Therefore, all the branches in the code above can be removed and the code re-written in predicated form as follows:
X if (a & b & c) Y if (a & b & !c) V if (!a) Z if (true) W if (!a & b & c)
The next step is to push the predication down from the blocks to the individual instructions within each block. For most instructions, the predicate can be ignored (because, as noted above, if unnecessary execution of the instruction has no effect on the outside world, it can be allowed to proceed). Instructions for which the predicate cannot be ignored are:
1. Any instruction whose effect is observable to the outside world (such as a load-store unit). Such instructions should be predicated. 2. Any instruction whose implementation requires a large area. Maintaining a predicate on such an instruction may allow instruction sharing if two or more uses of the instruction exist with mutually exclusive predicates.
The size of a hardware implementation can be decreased if the predicate conditions can be simplified. For example, assume in the most recent example above that logic blocks X, Y, and V all contain the same load-storage unit. Those three load-storage units can be merged into a single load-storage unit that will be active if block X is active OR block Y is active OR block V is active. Combining the predicates for X, Y and V yields:
(a & b & c)|(a & b & !c)|(!a)
This can be simplified further to:
!a|b
which minimizes the hardware even further.
One way to simplify Boolean equations is use Binary Decision Diagrams (BDDs). Each predicate (which is a Boolean expression) can be expressed as a BDD, and then standard BDD transformations may be applied to the BDD. Finally, the BDD may be converted back to a Boolean expression.
If the high-level code does not have any loops, the branch removal techniques described above will remove all branches. That technique will also remove branches inside a single loop, if the loop has one entry and one exit point. However, if the high-level code has branches that go from inside to outside of a loop, as shown in FIG. 4 , that technique would not be effective to remove those branches.
In logic 400 of FIG. 4 , blocks A ( 401 ), B ( 402 ), C ( 403 ) and D ( 404 ) form a loop 410 . However, each of blocks A ( 401 ) , B ( 402 ) , C ( 403 ) includes a respective condition 411 , 412 , 413 to allow early exit from loop 410 (i.e., exit without going through block D ( 404 )) to block E ( 405 ). Block D ( 404 ) also contains an exit condition 414 that causes exit to block E ( 405 ).
To use the technique above to remove branches from logic 400 , logic 400 first may be converted to logic 500 of FIG. 5 , in which the flow from each of blocks A ( 401 ), B ( 402 ) and C ( 403 ) is always to the respective next block B ( 402 ), C ( 403 ) and D ( 404 ). Such control flow conversion can be achieved by using the respective early exit condition 411 / 412 / 413 as the predicate for instructions in the following block B ( 402 ), C ( 403 ) and D ( 404 ). For example, say control flow from block A ( 401 ) goes to block E ( 405 ) (early exit condition 411 ), if condition K is true. Instead, block A ( 401 ) can be controlled to flow to block B ( 402 ), then block C ( 403 ) then block D ( 404 ) at all times, but the instructions in all following blocks B ( 402 ), C ( 403 ) and D ( 404 ) are predicated to execute only if condition K is false, and block D ( 404 ) also contains an instruction to go to block E ( 405 ) if condition K is true. Additional similar predicate conditions can be included in the instructions of blocks C ( 403 ) and D ( 404 ) relative to the exit conditions 412 / 413 of blocks B ( 402 ) and C ( 403 ). Indeed, once such a control structure has been established, blocks A ( 401 ) through D ( 404 ) can be collapsed down into a single block (not shown) looping back on itself or exiting to block E ( 405 ). Thus, use of predicated instructions simplifies loops in the code to a loop in a single basic block.
Once the predicated code has been derived, and simplified to the extent desired, known techniques can be used to configure a programmable device. For example, the code can be incorporated in an OpenCL kernel which is converted in method 600 , diagrammed in FIG. 6 , into a configuration bitstream for a programmable device.
Method 600 starts with a kernel file (kernel.cl) 611 . Parser front end 621 derives unoptimized intermediate representation 631 from kernel file 611 , which is converted by optimizer 641 to an optimized intermediate representation 651 . The optimization process includes compiler techniques to make the code more efficient, such as, e.g., loop unrolling, memory-to-register conversion, dead code elimination, etc. A Register Timing Language (RTL) 661 generator converts optimized intermediate representation 651 into a hardware description language representation 671 , which may be written in any hardware description language such as Verilog (shown) or VHDL.
Hardware description language representation(s) 671 of the kernel(s) are compiled into a programmable device configuration by appropriate software 603 . For example, for FPGA devices available from Altera Corporation, of San Jose, Calif., software 603 might be the QUARTUS® II software provided by Altera.
Although some or all of the various functions in method 600 may be executed by special-purpose hardware circuits dedicated to those functions, most or all of those functions would more commonly be performed by a processor. As previously noted, the device being configured could be a fixed-logic device or a programmable device. In the case of fixed-logic device, the processor would necessarily be external to the device, as the device will not yet have been formed. In the case of a programmable device, as previously noted, the processor could be external to the device being configured, or could be embedded in the device, and if the processor is embedded, it could be a “hard” processor or a “soft” processor. If the embedded processor is a “soft” processor, it also may be configured using software 603 . If the embedded processor is a “hard” processor, software 603 may configure appropriate connections to the hard processor.
Thus it is seen that a method for configuring a fixed or programmable integrated circuit device using a high-level synthesis language, while reducing the resources consumed, particularly on a programmable device, has been provided.
Instructions for carrying out a method according to this invention for configuring an integrated circuit device may be encoded on a non-transitory machine-readable memory medium (e.g., a magnetic disk, a nonvolatile RAM, or an optical disk such as a CD-ROM or DVD-ROM), to be executed by a suitable computer or similar device to implement the method of the invention for programming or configuring PLDs or other devices with a configuration described by a high-level synthesis language as described above. For example, a personal computer may be equipped with an interface to which a PLD can be connected, and the personal computer can be used by a user to program the PLD using suitable software tools as described above.
FIG. 7 presents a cross section of a magnetic data storage medium 1200 which can be encoded with a machine executable program that can be carried out by systems such as the aforementioned personal computer, or other computer or similar device. Medium 1200 can be a floppy diskette or hard disk, or magnetic tape, having a suitable substrate 1201 , which may be conventional, and a suitable coating 1202 , which may be conventional, on one or both sides, containing magnetic domains (not visible) whose polarity or orientation can be altered magnetically. Except in the case where it is magnetic tape, medium 1200 may also have an opening (not shown) for receiving the spindle of a disk drive or other data storage device.
The magnetic domains of coating 1202 of medium 1200 are polarized or oriented so as to encode, in manner which may be conventional, a machine-executable program, for execution by a programming system such as a personal computer or other computer or similar system, having a socket or peripheral attachment into which the PLD to be programmed may be inserted, to configure appropriate portions of the PLD, including its specialized processing blocks, if any, in accordance with the invention.
FIG. 8 shows a cross section of an optically-readable data storage medium 1210 which also can be encoded with such a machine-executable program, which can be carried out by systems such as the aforementioned personal computer, or other computer or similar device. Medium 1210 can be a conventional compact disk read-only memory (CD-ROM) or digital video disk read-only memory (DVD-ROM) or a rewriteable medium such as a CD-R, CD-RW, DVD-R, DVD-RW, DVD+R, DVD+RW, or DVD-RAM or a magneto-optical disk which is optically readable and magneto-optically rewriteable. Medium 1210 preferably has a suitable substrate 1211 , which may be conventional, and a suitable coating 1212 , which may be conventional, usually on one or both sides of substrate 1211 .
In the case of a CD-based or DVD-based medium, as is well known, coating 1212 is reflective and is impressed with a plurality of pits 1213 , arranged on one or more layers, to encode the machine-executable program. The arrangement of pits is read by reflecting laser light off the surface of coating 1212 . A protective coating 1214 , which preferably is substantially transparent, is provided on top of coating 1212 .
In the case of magneto-optical disk, as is well known, coating 1212 has no pits 1213 , but has a plurality of magnetic domains whose polarity or orientation can be changed magnetically when heated above a certain temperature, as by a laser (not shown). The orientation of the domains can be read by measuring the polarization of laser light reflected from coating 1212 . The arrangement of the domains encodes the program as described above.
A PLD 140 programmed according to the present invention may be used in many kinds of electronic devices. One possible use is in a data processing system 1400 shown in FIG. 9 . Data processing system 1400 may include one or more of the following components: a processor 1401 ; memory 1402 ; I/O circuitry 1403 ; and peripheral devices 1404 . These components are coupled together by a system bus 1405 and are populated on a circuit board 1406 which is contained in an end-user system 1407 .
System 1400 can be used in a wide variety of applications, such as computer networking, data networking, instrumentation, video processing, digital signal processing, or any other application where the advantage of using programmable or reprogrammable logic is desirable. PLD 140 can be used to perform a variety of different logic functions. For example, PLD 140 can be configured as a processor or controller that works in cooperation with processor 1401 . PLD 140 may also be used as an arbiter for arbitrating access to a shared resources in system 1400 . In yet another example, PLD 140 can be configured as an interface between processor 1401 and one of the other components in system 1400 . It should be noted that system 1400 is only exemplary, and that the true scope and spirit of the invention should be indicated by the following claims.
Various technologies can be used to implement PLDs 140 as described above and incorporating this invention.
It will be understood that the foregoing is only illustrative of the principles of the invention, and that various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention. For example, the various elements of this invention can be provided on a PLD in any desired number and/or arrangement. One skilled in the art will appreciate that the present invention can be practiced by other than the described embodiments, which are presented for purposes of illustration and not of limitation, and the present invention is limited only by the claims that follow. | A method of programming or configuring an integrated circuit device using a high-level language includes parsing a logic flow to be embodied in the integrated circuit device to identify branching control flow, converting the branching control flow into predicated instructions, incorporating the predicated instructions into a high-level language representation of a configuration of resources of the integrated circuit device, and compiling the high-level language representation to configure said integrated circuit device. The high-level language representation can be executed to generate a configuration bitstream for the programmable integrated circuit device, or can be run on a processor on the programmable integrated circuit device to instantiate the configuration. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to a series of dihydropyrazolopyrroles which are selective inhibitors of phosphodiesterase (PDE) type IV or the production of tumor necrosis factor (TNF), and as such are useful in the treatment of, respectively, inflammatory and other diseases; and AIDS, septic shock and other diseases involving the production of TNF.
This invention also relates to a method of using such compounds in the treatment of the above diseases in mammals, especially humans, and to pharmaceutical compositions containing such compounds.
Since the recognition that cyclic adenosine phosphate (AMP) is an intracellular second messenger, E. W. Sutherland, and T. W. Rall, Pharmacol. Rev., 12, 265, (1960), inhibition of the phosphodiesterases has been a target for modulation and, accordingly, therapeutic intervention in a range of disease processes. More recently, distinct classes of PDE have been recognized, J. A. Beavo et al., TIPS, 11, 150, (1990), and their selective inhibition has led to improved drug therapy, C. D. Nicholson, M. S. hahid, TIPS, 12, 19, (1991 ). More particularly, it has been recognized that inhibition of PDE type IV can lead to inhibition of inflammatory mediator release, M. W. Verghese et al., J. Mol. Cell Cardiol., 12 (Suppl. II), S 61, (1989) and airway smooth muscle relaxation (T. J. Torphy in "Directions for New Anti-Asthma Drugs," eds S. R. O'Donnell and C. G. A. Persson, 1988, 37 Birkhauser-Verlag). Thus, compounds that inhibit PDE type IV, but which have poor activity against other PDE types, would inhibit the release of inflammatory mediators and relax airway smooth muscle without causing cardiovascular effects or antiplatelet effects.
TNF is recognized to be involved in many infectious and auto-immune diseases, W. Friers, FEBS Letters, 285, 199, (1991). Furthermore, it has been shown that TNF is the prime mediator of the inflammatory response seen in sepsis and septic shock, C. E. Spooner et al., Clinical Immunology and Immunopathology, 62, S11, (1992).
SUMMARY OF THE INVENTION
The present invention relates to compounds of the formula ##STR2## and the pharmaceutically acceptable salts thereof; wherein X is oxygen or two hydrogens; R 1 is hydrogen, C 1 -C 7 alkyl, C 2 -C 3 alkenyl, phenyl, C 3 -C 5 cycloalkyl or methylene(C 3 -C 5 cycloalkyl) wherein each alkyl, phenyl or alkenyl group may be substituted with one or two methyl, ethyl or trifluoromethyl, or up to three halogens; R 2 and R 3 are each independently selected from the group consisting of hydrogen; C 1 -C 14 alkyl; (C-C 7 alkoxy)(C 1 -C 7 alkyl)--; C 2 -C 14 alkenyl; --(CH 2 ) n (C 3 -C 5 cycloakyl) wherein n is 0, 1 or 2; a (CH 2 ) n (C 4 -C 7 heterocyclic group) wherein n is 0, 1 or 2, containing as the heteroatom one of oxygen, sulphur, sulphonyl or NR 5 wherein R 5 is hydrogen, or C 1 -C 4 alkyl; or a group of the formula ##STR3## wherein a is an integer from 1 to 4; b and c are 0 or 1; R 6 is hydrogen, hydroxy, C 1 -C 5 alkyl, C 2 -C 5 alkenyl, C 1 -C 5 alkoxy, C 3 -C 6 cycloalkoxy, halogen, trifluoromethyl, nitro, CO 2 R 7 , CONR 7 R 8 , NR 7 R 8 , or SO 2 NR 7 R 8 wherein R 7 and R 8 are each independently hydrogen or C 1 -C 4 alkyl; Z is oxygen, sulphur, sulphonyl or NR 9 wherein R 9 is hydrogen or C 1 -C 4 alkyl; and Y is C 1 -C 5 alkylene or C 2 -C 6 alkenylene which may be substituted with one or two C 1 -C 7 alkyl or C 3 -C 7 cycloakyl; wherein each of said alkyl, alkenyl, cycloalkyl, alkoxyalkyl or heterocyclic group may be substituted with one to fourteen substituents R 10 selected from the group consisting of methyl, ethyl, trifluoromethyl and halogen; and R 4 is hydrogen, C 1 -C 7 alkyl, phenyl, C 3 -C 5 cycloalkyl, or methylene (C 3 -C 5 cycloalkyl) wherein each alkyl or phenyl group may be substituted with one or two methyl, ethyl or trifluoromethyl, or up to three halogens.
More specific compounds of the invention are those wherein X is oxygen, those wherein R 1 is C 1 -C 7 alkyl, those wherein R 4 is hydrogen, those wherein R 3 is C 1 -C 6 alkyl; phenyl substituted by one or two halogen; cyclopentyl, or methylenecyclopropyl; and those wherein R 2 is hydrogen, C 1 -C 6 alkyl, or phenyl which may be substituted by C 1 -C 5 alkyl, C 1 -C 5 alkoxy or COOH.
Other more specific compounds of the invention are those wherein X is oxygen, R 1 is C 1 -C 7 alkyl, R 4 is hydrogen, R 3 is C 1 -C 6 alkyl; phenyl substituted by one or two halogen; cyclopentyl, or methylenecyclopropyl, and R 2 is hydrogen, C 1 -C 6 alkyl or phenyl which may be substituted with C 1 -C 5 alkyl, C 1 -C 5 alkoxy or COOH.
The present invention further relates to a pharmaceutical composition for the inhibition of phosphodiesterase (PDE) type IV and the production of tumor necrosis factor (TNF) comprising a pharmaceutically effective amount of a compound according to formula I or a pharmaceutically acceptable salt thereof, and a pharmaceutically acceptable carrier.
The present invention further relates to a method for the inhibition of phosphodiesterase (PDE) type IV and the production of tumor necrosis factor (TNF) by administering to a patient an effective amount of a compound according to formula I or a pharmaceutically acceptable salt thereof.
The present invention further relates to a method of treating an inflammatory condition in mammals by administering to said mammal an antiinflammatory amount of a compound of the formula I or a pharmaceutically acceptable salt thereof.
According to the invention, an inflammatory condition includes asthma, arthritis, bronchitis, chronic obstructive airways disease, psoriasis, allergic rhinitis, and dermatitis.
The present invention further relates to a pharmaceutical composition for the treatment of AIDS, septic shock and other diseases involving the production of TNF comprising a pharmaceutically effective amount of a compound according to formula I or a pharmaceutically acceptable salts thereof together with a pharmaceutically acceptable carrier.
This invention further relates to a method of treating or preventing an inflammatory condition, or AIDS, septic shock and other diseases involving the production of TNF by administering to a patient an effective amount of a compound according to formula I or a pharmaceutically acceptable salt thereof.
DETAILED DESCRIPTION OF THE INVENTION
The term "halogen", as used herein, includes chloro, fluoro and bromo.
Unless indicated otherwise, the alkyl, alkoxy and alkenyl groups referred to herein may be straight chain or if comprising three or more carbons may be straight chained or branched.
R 1 , R 2 , R 3 and R 4 , as used herein are as defined above with reference to formula I, unless otherwise indicated.
The compounds of the invention of formula I may be prepared as depicted in Scheme 1. ##STR4##
The ethyl 2,4-dioxoalkanoate of formula II is converted to the corresponding N-(R 2 )-2,5-dihydropyrrole compound III by subjecting II to the conditions of a Mannich reaction using compounds of the formulae R 2 NH 2 , and R 4 C(O)H, and concentrated hydrogen chloride in alcohol. The mixture is heated to reflux for 2 to about 6 hours, preferably about 3 hours.
The compound of formula Ill is converted to 4,6-dihydro-1H-pyrazolo[3,4c]pyrrole compound IV by reacting III with a hydrazine hydrochloride of the formula R 3 HNNH 2 .HCl and a sodium C 1 -C 6 alkoxide in an anhydrous polar protic solvent. The preferred sodium alkoxide is sodium methoxide and the preferred anhydrous polar solvent is anhydrous ethanol. The reaction mixture is heated to reflux for about 9 hours to about 20 hours, preferably about 16 hours.
The compound of formula IV is converted to the corresponding compound of formula V by reacting IV with a reducing agent, preferably lithium aluminum hydride, in a non-polar aprotic solvent, preferably ether. The majority of the solvent is removed by distillation, and the remaining mixture is diluted with a higher boiling non-polar aprotic solvent, preferably toluene. The reaction is heated to reflux for about 12 hours to about 24 hours, preferably 24 hours.
The compounds of formula IV wherein R 4 is hydrogen may alternatively be prepared as depicted in Scheme 2. ##STR5##
The compound II is subjected to the conditions of a Mannich reaction using dimethylmethylene ammonium chloride in a non-polar aprotic solvent, preferably acetonitrile. The mixture is cooled to about -40° C. and treated with ammonia gas for about 5 minutes and is slowly warmed to about 5° C. over about 1 hour before treating with concentrated ammonium hydroxide. The compound VI so formed is reacted as described above for the conversion of compound III to compound IV. The compound of formula VII so formed is converted to compound IV by reaction with a base, such as sodium hydride, in a polar aprotic solvent such as tetrahydrofuran or dimethylformamide. The reaction is generally conducted at reflux for about 30 minutes to about one hour, preferably about 45 minutes. The mixture is then cooled to ambient temperature and treated with the appropriate R 3 -- halide at ambient temperature. The mixture is stirred at reflux for about 1 hour to 24 hours, preferably about 16 hours.
Pharmaceutically acceptable acid addition salts of the compounds of this invention include, but are not limited to, those formed with HCl, HBr, HNO 3 , H 2 SO 4 , H 3 PO 4 , CH 3 SO 3 H, p-CH 3 C 6 H 4 SO 3 H, CH 3 CO 2 H, gluconic acid, tartaric acid, maleic and succinic acid. Pharmaceutically acceptable cationic salts of the compounds of this invention of formula I wherein R 6 is CO 2 R 7 and R 7 is hydrogen include, but are not limited to, those of sodium, potassium, calcium, magnesium, ammonium, N,N'-dibenzylethylenediamine, N-methylglucamine (meglumine), ethanolamine and diethanolamine.
For administration to humans in the curative or prophylactic treatment of inflammatory diseases, oral dosages of a compound of formula I or the pharmaceutically acceptable salts thereof (the active compounds) are generally in the range of from 0.1-100 mg daily for an average adult patient (70 kg). Thus for a typical adult patient, individual tablets or capsules contain from 0.1 to 50 mg of active compound, in a suitable pharmaceutically acceptable vehicle or carrier. Dosages for intravenous administration are typically within the range of 0.1 to 10 mg per single dose as required. For intranasal or inhaler administration, the dosage is generally formulated as a 0.1 to 1% (w/v) solution. In practice the physician will determine the actual dosage which will be most suitable for an individual patient and it will vary with the age, weight and response of the particular patient. The above dosages are exemplary of the average case but there can, of course, be individual instances where higher or lower dosage ranges are merited, and all such dosages are within the scope of this invention,
For administration to humans for the inhibition of TNF, a variety of conventional routes may be used including orally, parenterally and optically. In general, the active compound will be administered orally or parenterally at dosages between about 0.1 and 25 mg/kg body weight of the subject to be treated per day, preferably from about 0.3 to 5 mg/kg. However, some variation in dosage will necessarily occur depending on the condition of the subject being treated. The person responsible for administration will, in any event, determine the appropriate dose for the individual subject.
For human use, the active compounds of the present invention can be administered alone, but will generally be administered in an admixture with a pharmaceutical diluent or carrier selected with regard to the intended route of administration and standard pharmaceutical practice. For example, they may be administered orally in the form of tablets containing such excipients as starch or lactose, or in capsules or ovales either alone or in admixture with excipients, or in the form of elixirs or suspensions containing flavoring or coloring agents. They may be injected parenterally; for example, intravenously, intramuscularly or subcutaneously. For parenteral administration, they are best used in the form of a sterile aqueous solution which may contain other substance; for example, enough salts or glucose to make the solution isotonic.
Additionally, the active compounds may be administered topically when treating inflammatory conditions of the skin and this may be done by way of creams, jellies, gels, pastes, and ointments, in accordance with standard pharmaceutical practice.
The ability of the compounds of formula I or the pharmaceutically acceptable salts thereof to inhibit PDE IV may be determined by the following assay.
Thirty to forty grams of human lung tissue is placed in 50 ml of pH 7.4 Tris/phenylmethylsulfonyl fluoride (PMSF)/sucrose buffer and homogenized using a Tekmar Tissumizer® (Tekmar Co., 7143 Kemper Road, Cincinnati, Ohio 45249) at full speed for 30 seconds. The homogenate is centrifuged at 48,000×g for 70 minutes at 4° C. The supernatant is filtered twice through a 0.22 μm filter and applied to a Mono-Q FPLC column (Pharmacia LKB Biotechnology, 800 Centennial Avenue, Piscataway, N.J. 08854) pre-equilibrated with pH 7.4 Tris/PMSF Buffer. A flow rate of 1 ml/minute is used to apply the sample to the column, followed by a 2 ml/minute flow rate for subsequent washing and elution. Sample is eluted using an increasing, step-wise NaCl gradient in the pH 7.4 Tris/PMSF buffer. Eight ml fractions are collected. Fractions are assayed for specific PDE IV activity determined by [ 3 H]cAMP hydrolysis and the ability of a known PDE IV inhibitor (e.g. rolipram) to inhibit that hydrolysis. Appropriate fractions are pooled, diluted with ethylene glycol (2 ml ethylene glycol/5 ml of enzyme prep) and stored at -20° C. until use.
Compounds are dissolved in dimethylsulfoxide (DMSO) at a concentration of 10 mM and diluted 1:25 in water (400 μM compound, 4% DMSO). Further serial dilutions are made in 4% DMSO to achieve desired concentrations. The final DMSO concentration in the assay tube is 1%. In duplicate the following are added, in order, to a 12×75 mm glass tube (all concentrations are given as the final concentrations in the assay tube).
i) 25 μl compound or DMSO (1%, for control and blank)
ii) 25 μl pH 7.5 Tris buffer
iii) [ 3 H]cAMP (1 μM)
iv) 25 μl PDE IV enzyme (for blank, enzyme is preincubated in boiling water for 5 minutes)
The reaction tubes are shaken and placed in a water bath (37° C.) for 20 minutes, at which time the reaction is stopped by placing the tubes in a boiling water bath for 4 minutes. Washing buffer (0.5 ml, 0.1M 4-(2-hydroxyethyl)-1-piperazine-ethanesulfonic acid (HEPES)/0.1M naci, pH 8.5) is added to each tube on an ice bath. The contents of each tube are filed to an AFF-Gel 601 column (Biorad Laboratories, P.O. Box 1229, 85A Marcus Drive, Melvile, N.Y. 11747) (boronate affinity gel, 1 ml bed volume) previously equilibrated with washing buffer. [ 3 H]cAMP is washed with 2×6 ml washing buffer, and [ 3 H]5'AMP is then eluted with 4 ml of 0.25M acetic acid. After vortexing, 1 ml of the elution is added to 3 ml scintillation fluid in a suitable vial, vortexed and counted for [ 3 H]. ##EQU1## IC 50 is defined as that concentration of compound which inhibits 50% of specific hydrolysis of [ 3 H]cAMP to [ 3 H]5'AMP.
The ability of the compounds I or the pharmaceutically acceptable salts thereof to inhibit the production TNF and, consequently, demonstrate their effectiveness for treating disease involving the production of TNF is shown by the following in vitro assay:
Peripheral blood (100 mls) from human volunteers is collected in ethylenediaminetetraacetic acid (EDTA). Mononuclear cells are isolated by FICOLL,/Hypaque and washed three times in incomplete HBSS. Cells are resuspended in a final concentration of 1×10 6 cells per ml in pre-warmed RPMI (containing 5% FCS, glutamine, pen/step and nystatin). Monocytes are plated as 1×10 6 cells in 1.0 ml in 24-well plates. The cells are incubated at 37° C. (5% carbon dioxide) and allowed to adhere to the plates for 2 hours, after which time non-adherent cells are removed by gentle washing. Test compounds (10 μl) are then added to the cells at 3-4 concentrations each and incubated for 1 hour. LPS (10 μl) is added to appropriate wells. Plates are incubated overnight (18 hrs) at 37° C. At the end of the incubation period TNF was analyzed by a sandwich ELISA (R&D Quantikine Kit). IC 50 determinations are made for each compound based on linear regression analysis.
The following Examples illustrate the invention.
EXAMPLE 1
1-(4-Fluorophenyl)-3-isopropyl-6-oxo-5-phenyl-4,6-dihydro-1H-pyrazolo[3,4-c]pyrrole
A mixture of 3-hydroxy-4-isobutyryl-2-oxo-1-phenyl-2,5-dihydropyrrole (0.350 g, 1.43 mmole), 4-fluorophenylhydrazine hydrochloride (0.245 g, 1.50 mmole) and sodium methoxide (39 mg, 0.72 mmole) in ethanol (10 ml) was heated to reflux. After 16 hours the solvent was removed by rotory evaporation under reduced pressure, and the crude residue was chromatographed on a silica column using 1:3 ethyl acetate/hexane as eluent to give 210 mg of the title compound along with 80 mg of the 2-(4-fluorophenyl)-3-isopropyl-6-oxo-5-phenyl-4,6-dihydro-2H-pyrazolo[3,4-c]pyrrole regioisomer (M.P. 223°-224° C.). The title compound was recrystallized from ether to give a pale yellow solid. M.P. 150°-151° C.; 1 H NMR (250 Mhz, CDCl 3 ) δ 1.38 (d, J=7.0 Hz, 6H), 3.18 (heptet, J=7.0 Hz, 1H), 4.78 (s, 2H), 7.15 (dd, J=8.3, 9.1 Hz, 2H), 7.21 (m, 1H), 7.43 (t, J=7.9 Hz, 2H), 7.74 (d, J=7.8 Hz, 2H), 8.20 (dd, J=4.8, 9.1 Hz, 2H); MS m/z (M + ) 336.
EXAMPLES 2-18
Reaction of the appropriate hydrazine hydrochloride with the requisite 4-acyl-3-hydroxy-2-oxo-2,5-dihydropyrrole, analogous to the procedure of Example 1, afforded the following compounds of formula I wherein R 1 , R 2 and R 3 are as defined below and R 4 is hydrogen.
______________________________________ Mass Spectra Mass or Spectra or Analysis Analysis (found) (calcd.) % C, m.p. % C, % H, % H,Ex R.sup.1 R.sup.2 R.sup.3 (°C.) % N % N______________________________________2 iso- 4- 4-fluoro- 140- 69.03, 69.21, propyl methoxy- phenyl 142 5.52, 5.36, phenyl 11.49 10.71 MW 365.4 MS m/z 3663 iso- 4- cyclo- 94-96 70.77, 70.86, propyl methoxy- pentyl 7.42, 7.35, phenyl 12.38 11.00 MW 339.4 MS m/z 3404 ethyl phenyl 4-fluoro- 121- 71.01, 70.88, phenyl 122 5.02, 5.10, 13.08 12.59 MW 321.4 MS m/z 3225 methyl phenyl 4-fluoro- 176- 70.35, 70.11, phenyl 177 4.59, 4.54, 13.67 13.436 ethyl phenyl cyclo- oil 73.19, 72.83, pentyl 7.17, 7.56, 14.22 13.39 MW 295.4 Ms m/z 2967 iso- phenyl cyclo- oil MW 309.4 MS m/z propyl pentyl 3108 iso- 3-methyl- cyclo- 96-97 MW 323.4 MS m/z propyl phenyl pentyl 3249 iso- 3-methyl- 4-fluoro- 122- MW 349.4 MS m/z propyl phenyl phenyl 125 35010 methyl 3-benzoic 4-fluoro- 281- 64.96, 63.95, acid phenyl 282 4.02, 4.05, 11.96 11.5111 methyl 4-benzoic 4-fluoro- 323- 64.96, 64.56, acid phenyl 325 4.02, 4.30, 11.96 11.7512 ethyl phenyl methyl 56-57 69.69, 69.80, 6.27, 6.06, 17.41 17.4113 ethyl phenyl tert-butyl 111.0 72.06, 71.68, (sharp) 7.47, 716, 14.83 14.7814 ethyl phenyl 4- 95- 96 72.05, 71.91, methoxy- 5.74, 5.48, phenyl 12.60 12.7715 ethyl phenyl meth- 95-96 72.57, 72.21, ylene 6.81, 6.56, cyclo- 14.94 14.85 propyl16 methyl H 3,4- 241- 51.09, 51.01, dichloro- 242 3.22, 3.11, phenyl 14.89 15.1117 ethyl H 4-fluoro- 188- MW 245.3 MS m/z phenyl 189 24618 ethyl H cyclo- 98-99 65.73, 65.45, pentyl 7.81, 7.76, 19.16 19.14______________________________________
EXAMPLE 19
1-Cyclopentyl-3-ethyl-5-phenyl-4,6-dihydro-1H -pyrazolo[3,4-c]pyrrole
To a stirred solution of 1-cyclopentyl-3-ethyl-6-oxo-5-phenyl-4,6-dihydro-1H-pyrazolo[3,4-c]pyrrole (0.17 g, 0.58 mmole) in anhydrous ether (15 ml) was added lithium aluminum hydride (0.17 g, 4.6 mmole). The majority of the ether (12-13 ml) was then removed by distillation, and the remaining mixture diluted with toluene (25 ml) and heated to reflux over 24 hours. The mixture was cooled to 0° C. and cautiously treated with ice. The resulting mixture was filtered through celite, dried over sodium sulfate, filtered and concentrated under reduced pressure. The crude residue was chromatographed on a silica column using 1:9 ethyl acetate/hexane as eluent to give 100 mg of a colorless oil. 1 H NMR (250 MHz, CDCl 3 ) δ 1.26 (t, J=7.6 Hz, 3H), 1.65-2.25 (m, 8H), 2.67 (q, J=7.6 Hz, 2H), 4.35 (s, 2H), 4.45 (s, 2H), 4.53 (pentet, J=7.5 Hz, 1H), 6.61 (d, J=8.1 Hz, 2H), 6.74 (t, J=7.4 Hz, 1H), 7.29 (dd, J=7.5 and 8.4 Hz, 2H); MS m/z 282.
EXAMPLE 20
1-(3,4-Dichlorophenyl)-3-methyl-5-methylenecyclopropyl-6-oxo-4,6-dihydro-1H-pyrazolo[3,4]c]pyrrole
A mixture of 2-(3,4-dichlorophenyl)-3-methyl-6-oxo-4,6-dihydro-1H-pyrazolo [3,4c]pyrrole (0.20 g, 0.71 mmole) and 60% sodium hydride (0.24 g, 0.71 mmole) in anhydrous tetrahydrofuran (4 ml) was heated to reflux. After 45 minutes, the reaction mixture was cooled to room temperature and bromomethyl cyclopropane (0.11 g, 0.78 mmole) was added. The mixture was then warmed to 50° C. over 24 hours. The solvent was removed under reduced pressure and the residue recrystallized from a mixture of ethyl acetate and hexane to give 0.95 g of a yellow solid. M.P. 149.5°-152° C.; 1 H NMR (250 MHz, CDCl 3 ) δ 0.32-0.36 (m, 2H), 0.57-0.64 (m, 2H), 1.02-1.09 (m, 1h), 2.37 (s, 3H), 3.43 (d, J=7.1 Hz, 2H), 4.33 (s, 2H), 7.48 (d, J=8.8 Hz, 1H), 8.27 (dd, J=2.5 and 8.8 Hz, 1h), 8.48 (d, J=2.5 Hz, 1H); MS m/z 336.
EXAMPLES 21-24
Reaction of the appropriate alkylhalide with the requisite 6-oxo-4,6-dihydro-1H-pyrazolo[3,4-c]pyrrole, analogous to the procedure of Example 20, afforded the following compounds of formula I wherein R 1 , R 2 and R 3 are as defined below and R 4 is hydrogen.
______________________________________ Mass Mass Spectra or Spectra or Analysis Analysis (calcd.) (found) m.p. % C, % H, % C, % H,Ex R.sup.1 R.sup.2 R.sup.3 (°C.) % N % N______________________________________21 ethyl methylene 4- 94.0 68.21, 6.06, 67.93, 5.99, cyclo- fluoro- (sharp) 14.04 13.99 propyl phenyl22 ethyl methyl 4- 89-90 64.85, 5.44, 64.33, 5.18, fluoro- 16.21 16.14 phenyl23 ethyl methyl cyclo- 54-55 66.92, 8.21, 67.18, 8.01, pentyl 18.01 18.2224 ethyl methylene cyclo- oil MW 273.4 MS m/z cyclo- propyl 274 propyl______________________________________
EXAMPLE 25
4.5-Dimethyl-3-ethyl-1-(4-fluorophenyl)-6-oxo-4,6-dihydro-1H-pyrazolo[3,4-c]pyrrole
A mixture of 3-ethyl-1-(4-fluorophenyl)-6-oxo-4,6-dihydro-1H-pyrazolo [3,4c]pyrrole (0.20 g, 0.82 mmole) and 60% sodium hydride (0.49 g, 1.2 mmole) in anhydrous tetrahydrofuran (4 ml) was heated to reflux. After 45 minutes the reaction mixture was cooled to room temperature and methyl iodide (0.29 g, 2.0 mmole) added. The mixture was then heated to reflux over 16 hours. The mixture was treated with methanol (1 ml) and the solvent removed under reduced pressure. The crude residue was chromatographed on a silica column using 1:4 ethyl acetate/hexane as eluent to give 0.12 g of the title compound. Recrystallization from ether/petroleum ether gave white crystals. M.P. 65°-65° C., Anal. calcd. for C 15 H 16 FN 3 O: C, 65.92; H, 5.90; N, 15.37. Found: C, 66.15; H, 5.60; N, 15.53; MS m/z 274.
PREPARATION 1
3-Hydroxy-4-isobutyryl- 2-oxo-1-phenyl-2,5-dihydropyrrole
To a stirred mixture of aniline (0.50 g, 5.4 mmole) and concentrated HCl (0.46 ml) in ethanol (2.5 ml) was added ethyl 5-methyl-2,4-dioxohexanoate (1.0 g, 5.4 mmole) and paraformaldehyde (0.25 g). After heating at reflux over 3 hours hot acetone (13 ml) was added and the resulting solution was cooled to room temperature and concentrated under reduced pressure. The residue was dissolved in 1N NaOH and extracted with methylene chloride. The aqueous layer was acidified to pH 1 with 3N HCl, extracted with methylene chloride, dried over sodium sulfate, filtered and concentrated under reduced pressure. Recrystallization from 10% ether in pet. ether gives 0.42 g of the title compound as a pale yellow solid. M.P. 162°-170° C.; 1 H NMR (250 MHz, CDCl 3 ) δ 1.21 (d, J=6.8 Hz, 6H), 3.24 (heptet, J=6.8 Hz, 1H), 4.52 (s, 2H), 7.23 (m, 1H), 7.43 (t, J=8.0 Hz, 2H), 7.77 (d, J=7.8 Hz); MS m/z 246.
PREPARATIONS 2-7
Reactions of the appropriate 2,4-dioxoalkanoate with the requisite aryl amine, analogous to the procedure of Preparation 1, afforded the following compounds.
______________________________________ ##STR6## III Mass Mass Spectra or Spectra or Analysis Analysis (calcd.) (found) % C, % H, % C, % H,Prep R.sup.1 R.sup.2 m.p. °C. % N % N______________________________________2 isopropyl 4-methoxy- 168-172 65.44, 6.22, 65.27, phenyl 5.09 6.30, 4.753 ethyl phenyl -- MW 231.25 MS m/z 2324 methyl phenyl 180-184 66.35, 5.10, 66.47, 6.45 5.24, 5.445 isopropyl 3-methyl- 155-158 MW 259.31 Ms m/z phenyl 2606 methyl 3-benzoic >275 * * acid (dec)7 methyl 4-benzoic >275 ** ** acid (dec)______________________________________ *.sup.1 H nmr (250 MHz, DMSOd.sub.6) δ 2.42(s, 3H), 4,46(s, 2H), 7.54(t, J=8.0Hz, 1H), 7.74(dd, J=1.1 and 7.8Hz, 1H), 8.02(d, J=8.1Hz, 1H) 8.42(s, 1H), 13.1(broad s, 1H). **.sup.1 H nmr (250 MHz, DMSOD.sub.6 δ 2.42(s, 3H), 4.45(s, 2H), 7.97(s, 4H).
PREPARATION 8
4-Acetyl-3-hydroxy-2-oxo-2,5-dihydropyrrole
A solution of ethyl 2,4-dioxovalerate (1.13 g, 7.11 mmole), dimethylmethylene ammonium chloride (0.67 g, 7.11 mmole) and acetonitrile (3 ml) was stirred at 25° C. over 45 minutes. The resulting yellow homogeneous solution was then cooled to -40° C. and ammonia gas was bubbled through the mixture over 5 minutes, during which time a yellow solid precipitated out of solution. The stirred mixture was allowed to slowly warm to 5° C. over a period of 1 hour before addition of concentrated ammonium hydroxide (4 ml). After stirring for 1 hour, the mixture was concentrated under reduced pressure, diluted with 3N HCl (6 ml) and extracted with ethyl acetate (50 ml×10). The combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure to give 0.34 g of the title compound as a yellow amorphous solid. M.P. 178°-180° C. (dec); 1 H nmr (250 MHz, DMSO-d 6 ) δ 2.42 (s, 3H), 3.78 (s, 2H), 8.87 (s, 1H); Anal. calcd. for C 5 H 7 NO 3 : C, 51.07; H, 5.00; N, 9.92. Found: C, 51.18; H, 5.23; N, 9.73.
PREPARATION 9
3-Hydroxy-2-oxo-4-propionyl-2,5-dihydropyrrole
Reaction of ethyl 2,4-dioxohexanoate with dimethylmethylene ammonium chloride and ammonia, analogous to the procedure in Preparation 8, gave the title compound as an amorphous solid. 1 H nmr (250 MHz, DMSO-d 6 ) δ 0.99 (t, J=7.3 Hz, 3H), 2.75 (q, J=7.3 Hz, 2H), 3.81 (s, 2H), 8.84 (s, 1H). | The compounds of the formula ##STR1## and the pharmaceutically acceptable salts thereof; wherein X 1 , R 1 , R 2 , R 3 and R 4 are as defined herein, are inhibitors of PDE IV and the production of tumor necrosis factor. As such, they are active in the treatment of inflammatory diseases, shock etc. | 2 |
[0001] This application is a continuation-in-part of co-pending U.S. application Ser. No. 10/399,589 filed on Apr. 18, 2003 which is the U.S. national stage of PCT application no. PCT/US02/35547 filed Nov. 6, 2002 which claims the benefit of U.S. provisional 60/344,982 filed Nov. 9, 2001.
BACKGROUND OF THE INVENTION
[0002] When a balloon used for percutaneous transluminal angioplasty (PTA) or percutaneous transluminal coronary angioplasty (PTCA) is inflated and forced into contact with the plaque, the balloon can have a tendency to move or slip longitudinally in relation to the lesion or the vessel wall being treated.
[0003] Cutting balloons (atherotomy) have recently shown clinical efficacy in preventing the reoccurrence of some types of restenosis (specifically calcified lesions and in-stent restenosis). The cutting balloon is a coronary dilatation catheter with 3 to 4 atherotomes (microsurgical blades) bonded longitudinally on the balloon surface. As the cutting balloon is inflated, the atherotomes move radially and open the occluded artery by incising and compressing the arterial plaque in a controlled manner. An additional advantage of the cutting balloon is that it maintains its position during inflation by using the metal blades on the external surface of the balloon to penetrate into the tissue and prevent the balloon from moving.
[0004] Accordingly, it is the principal objective of the present invention to provide a PTA or PTCA balloon that, like a cutting balloon, has a reduced potential of slippage when inflated in a vessel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] [0005]FIG. 1 is a perspective view of an inflated angioplasty balloon incorporating a non-deployable stent according to the present invention.
[0006] [0006]FIG. 2 is a plan view of the inflated angioplasty balloon and non-deployable stent of FIG. 1.
[0007] [0007]FIG. 3 is a perspective view of the non-deployable stent in its expanded condition, as shown in FIG. 1, with the angioplasty balloon removed so as to more clearly show the stent.
[0008] [0008]FIG. 4 is a plan view of the non-deployable stent of FIG. 3.
[0009] [0009]FIG. 5 is a perspective view of an alternate embodiment of the non-deployable stent associated with an angioplasty balloon that has a longer working length than the angioplasty balloon shown in FIGS. 1 and 2.
[0010] [0010]FIG. 6 is an engineering drawing showing, in plan view, the layout of a non-deployable stent adapted to be used with an angioplasty balloon of 20 mm in length. (All dimensions shown in the drawing are in inches.)
[0011] [0011]FIG. 7 is a perspective view of an inflated angioplasty balloon incorporating an alternative embodiment of a non-deployable stent which does not include any connecting elements between the struts intermediate the ends of the balloon.
[0012] [0012]FIG. 8 is a perspective view of the non-deployable stent shown in FIG. 7, with the angioplasty balloon removed so as to more clearly show the stent.
[0013] [0013]FIGS. 9 and 10 are perspective views similar to FIGS. 1, 5, and 7 showing a further embodiment of the invention.
[0014] [0014]FIG. 11 is a perspective view of a further embodiment of the present invention showing the balloon and non-deployable stent in conjunction with a catheter.
[0015] [0015]FIG. 12 is an engineering drawing showing, in plan view, the layout of another embodiment of a non-deployable stent adapted to be used with an angioplasty balloon, in accordance with the present invention.
[0016] [0016]FIG. 13 an engineering drawing showing, in plan view, the layout of an alternate non-deployable stent of the embodiment of FIG. 12.
DESCRIPTION
[0017] The non-deployable stent of the present invention may be used in conjunction with a conventional balloon catheter. A PTA or PTCA catheter (dilatation catheter) may be a coaxial catheter with inner and outer members comprising a guide wire lumen and a balloon inflation lumen, respectively. Each member can have up to 3 layers and can be reinforced with braids. The proximal end of the catheter has a luer hub for connecting an inflation means, and a strain relief tube extends distally a short distance from the luer hub. The distal ends of the outer and inner members may include a taper. The catheter shaft is built using conventional materials and processes. A catheter having multi-durometer tubing with variable stiffness technology is also a possibility. The catheter should be compatible with standard sheaths and guide catheters which are well known in the art. Optionally, the catheter may be a multi-lumen design.
[0018] The balloon 1 may be made of either nylon or nylon copolymer (compliant, non-puncture) or PET (high pressure, non-compliant) with a urethane, polymer, or other coating known in the art to provide tackiness and/or puncture resistance. The balloon may be a multi-layered balloon with a non-compliant inner layer to a most compliant outer layer. For example, a inner most layer of PET, which provides a higher pressure balloon, surrounded by an outer layer of nylon, which provides a more puncture-resistant surface. The balloon may be from 1.5-12 mm in diameter (1.5-4 mm for coronary and 4-12 mm for peripheral vessels) and 15-60 mm in length (5-40 mm for coronary and up to 60 mm for peripheral vessels). The balloon inflation rated pressure will be from 8-20 atmospheres, depending on the wall thickness of the balloon. When inflated, the balloon ends or necks are cone-shaped.
[0019] In keeping with the invention, the balloon is provided with a Nitinol (NiTi) or another material such as for example liquid metal, stainless steel, or other similar material, structure, generally designated 2 , that incorporates bends for both radial and longitudinal expansion of the Nitinol structure 2 in response to longitudinal and radial expansion of the balloon during inflation, so that the Nitinol structure 2 maintains the balloon in its intended position during inflation. This Nitinol structure 2 can be described as a non-deployable or temporary stent that provides for both controlled cracking of vessel occlusion and gripping of vessel wall during an angioplasty procedure. The Nitonol structure 2 comprises a laser cut hypo tube that expands upon inflation of the balloon, but collapses upon deflation of the balloon because of the super-elastic properties of the Nitinol material, rather than remain expanded in the deployed condition, as would stents in general.
[0020] The Nitinol structure or non-deployable stent 2 has a proximal end 3 , a distal end 4 , and, therebetween, anywhere from 3-12 struts or wires 5 (depending on balloon size—but most likely 3-4 struts) with a pattern of radial and longitudinal bends. The use of laser cutting in connection with stent manufacture is well known (See, e.g., Meridan et al. U.S. Pat. No. 5,994,667), as is the use of the super-elastic nickel-titanium alloy Nitinol (see e.g., Huang et al. U.S. Pat. No. 6,312,459).
[0021] As seen in FIGS. 1 - 4 , each end of the four struts 5 has a sinusoidal type bend 6 that allows the laser cut hypo tube to expand longitudinally when the balloon 1 is inflated. The linear length of the sinusoidal type bends 6 is sized to accommodate the longitudinal expansion of the balloon 1 due to inflation. The strut or wire 5 cross sectional shape can be round, triangular, elliptical, oval, or rectangular. Preferred thickness of the struts 5 ranges from 0.003 to 0.010 inch.
[0022] At the longitudinal center of the hypo tube, a U-shaped circumferential connector 7 joins each strut 5 to its adjacent strut. As best seen in FIGS. 3 and 4, the U-shaped connectors 7 are on opposing sides of the central radial axis. The distal end 4 of the hypo tube is adhered to the distal neck of the balloon or the distal end of the catheter shaft, and the proximal end 3 of the hypo tube is either attached to the proximal neck of the balloon or to the proximal end of the catheter shaft. The struts 5 may be attached to the working region of the balloon 1 to assist the hypo tube in staying with the balloon as it inflates and deflates.
[0023] Catheter shafts to which the balloon and laser cut hypo tube are attached can have diameters ranging from 2.5 F to 8 F, and the distal end may be tapered and slightly less in diameter than the proximal end.
[0024] In FIG. 6, the dimensions of the laser cut hypo tube are for use with a 3 mm (0.118 in) diameter by 20 mm length balloon. The circumference of a 3 mm balloon is ΠD=3.14(3 mm)=9.42 mm or 0.37 in. As can be readily appreciated, the total length of all U-shaped connectors 7 (up and back) must be greater than the circumference of the inflated balloon 1 . The length of each U-shaped connector 7 (up and back), may be calculated using the following equation:
Π d n ,
[0025] where d is the diameter of the inflated balloon and n is the number of struts. The total length of the U-shaped bends (up and back) must exceed this length.
[0026] The resulting number is divided by 2 to get the length which each up-and-back side of the U-shaped connector should exceed. For example: for a 3 mm balloon compatible, laser-cut hypo tube with four struts, the length of each U-shaped connector (up and back) is 0.37 inch divided by 4=0.0925 in. Further divide by 2 and to get 0.04625 in. This is the length that each side of the U-shaped connector must exceed.
[0027] There is also one or more sets of U-shaped connectors 7 in between the sinusoidal bends 6 . The set includes one U-shaped connector for each strut (3 struts—a set of 3 U-shaped connectors; 4 struts—a set of 4 U-shaped connector; and so on). The number of U-shaped connector sets depends on the length of the balloon and thus, the length of the laser cut hypo tube. For a 20 mm length balloon, there is one set of U-shaped connectors spaced 10 mm from the end (at the halfway point along length of balloon). For a 40 mm length balloon, there are three sets of U-shaped connectors spaced in 10 mm increments (the first set is spaced 10 mm from one end; the second set is spaced 10 mm from first set; and the third set is spaced 10 mm from each the second set and the other end). The equation for number of sets of U-shaped connectors.
L 10 - 1 ,
[0028] where L=length of balloon in mm. Other embodiments, such as those shown in FIGS. 7 and 8, do not incorporate the intermediate U-shaped connectors.
[0029] [0029]FIG. 12 is directed to another embodiment of a non-deployable stent 102 which can be used with a conventional balloon catheter, in accordance with the present invention. The stent of this embodiment preferably has a Nitinol structure, though other materials can be used as discussed supra, that incorporates bends for both radial and longitudinal expansion of the stent in response to radial and longitudinal expansion of the balloon during inflation, so that the stent 102 maintains the balloon in its intended position. Similar to the stents of the other embodiments of the present invention discussed supra, the stent comprises a laser cut hypo tube that expands upon inflation of the balloon and collapses upon deflation of the balloon. Further, the stent is preferably secured to the balloon with some type of anchoring means. Preferably, such anchoring means are utilized at the ends of the stent and around the neck of the balloon. Examples of such anchoring means include an adhesive such as for example a UV adhesive, cyanoacrylate, or a two-part epoxy, RF heat welding, solvent bonding, or crimping or swaging the ends of the stent to the shaft. Alternatively, a mechanical anchoring means can be used to anchor the stent to the balloon. With such a means, a small sleeve made of a similar material as the shaft of the catheter is mounted over the ends of the stent and heat welded together where the ends of the stent are sandwiched between the shaft and the sleeve.
[0030] [0030]FIG. 12 shows the hypo tube of the stent in an unrolled (flat) and non-extended state. The stent 102 has a proximal end 103 and a distal end 104 . At each end, there are cage mounted flanges 110 . These flanges can be used to attach the stent to the neck of the balloon. The flanges also spring open radially to permit insertion of the balloon during assembly. Between the ends, the stent 102 includes extension sections 112 , serpentine rings 114 and elongation links 116 .
[0031] Serpentine rings 114 have a serpentine shape and allow the stent 102 to expand radially when a balloon in the stent is inflated. However, as the balloon expands, the serpentine rings 114 will shorten in length. Accordingly, extension sections 112 and elongation links 116 expand longitudinally to compensate for any shortening of the length of serpentine rings 114 . Preferably, elongation links 116 have a z-shape or accordion shape, as shown in FIG. 12.
[0032] [0032]FIG. 13 is an alternative embodiment showing a stent 202 having the same features as the stent in FIG. 12 except that stent 202 in FIG. 13 has elongated links 216 with a different pattern than the elongated links 116 in stent 102 of FIG. 12. More specifically, elongated links 216 have a zig zag pattern. Stent 202 of FIG. 13 operates in a substantially similar manner to that of stent 102 in FIG. 12.
[0033] While the present invention is not limited in the number of serpentine rings, extension sections and elongated links used in the stent, FIG. 13 illustrates a preferred embodiment. The stent 202 in FIG. 13 has from proximal end 103 to distal end 104 , a first extension section 112 , a first set of serpentine rings 114 , a first set of elongated links 216 , a second set of serpentine rings 114 , a second set of elongated links 216 , a third set of serpentine rings 114 , a third set of elongated links 216 , a fourth set of serpentine rings 114 , and a second extension section 112 .
[0034] [0034]FIG. 13 also shows an example of possible dimensions, in inches, of each of the components of the stent 202 . These dimensions would also be used for each of the similar components in stent 102 in FIG. 12.
[0035] It will be understood that the embodiments and examples of the present invention, which have been described, are illustrative of some of the applications of the principles of the present invention. Numerous modifications may be made by those skilled in the art without departing from the true spirit and scope of the invention. | An angioplasty balloon including a non-deployable stent to prevent or reduce the potential for slippage of the inflated balloon with respect to the vessel wall being treated. The balloon includes a non-deployable stent that is adapted to be secured to the balloon or angioplasty balloon catheter. The stent has a proximal end, a distal end, and at least one extension section, at least one set of serpentine rings and at least one set of elongation links that allow expansion of the strut to accommodate the inflation of the balloon. The stent is made of a material so that the stent collapses upon deflation of the balloon. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to a hydroxyethyl sulfonate of a cyclin-dependent kinase (CDK4&6) inhibitor, crystal form I and preparation method thereof.
BACKGROUND OF THE INVENTION
[0002] Breast cancer is one of the most common malignant tumors in women, with a high incidence rate and invasiveness, but the course of progression is slow. “Chinese Breast Disease Investigation Report” issued in Beijing on 1 Feb. 2010 by Chinese Population Association showed that the death rate of breast cancer in Chinese urban areas has increased by 38.91%, and that breast cancer has become the greatest threat to women's health. At present, there are at least 156 drugs for breast cancer under development or on the market, in which 68% are targeted drugs. A number of researchers have shown that tumor is related to cell cycle abnormalities, mutations of mitotic signaling proteins and defects of anti-mitotic signaling proteins in tumor cells leading to proliferation disorders. Meanwhile, most of the tumors have genomic instability (GIN) and chromosome complement instability (CIN), and these three basic cell cycle defects are all induced directly or indirectly by out of control of cyclin dependent kinases (CDKs). Cyclin Dependent Kinase (CDK) has become an increasingly popular target.
[0003] Currently, many first- and second-generation CDK inhibitors have been developed. The most noticed second-generation drug includes a CDK4&6 inhibitor PD-0332991, which was jointly developed by Pfizer and Onyx. It inhibits the phosphorylation of Rb by inhibiting the activity of CDK4&6, enables the E2F-Rb complex to be detained in the cytoplasm, and blocks initiation of the cell cycle. The results of a clinical trial (NCT00721409) showed that the progression-free survival (PFS) of patients treated with letrozole alone was 7.5 months, whereas the progression-free survival of patients subjected to combined treatment of letrozole and PD-0332991 was extended to 26.1 months. This remarkable advantage has received widespread attention. At the beginning of 2013, the FDA considered that it might be a groundbreaking anticancer drug after reviewing the mid-term result of the drug.
[0004] International Patent Application Publication WO2014183520 discloses CDK4&6 inhibitors similar to PD-0332991 in structure, with significant inhibitory activity and high selectivity for CDK4&6, comprising the following compound:
[0000]
[0005] However, this compound has poor solubility, and cannot be used directly as a drug. There is a need to find a pharmaceutically acceptable form, which makes it possible to enhance its solubility and bioavailability.
[0006] On the other hand, it is known to those skilled in the art that the crystal structure of the pharmaceutically active ingredient often affects the chemical stability of the drug. Different crystallization conditions and storage conditions can lead to changes in the crystal structure of the compound, and sometimes the accompanying production of other crystal forms. In general, an amorphous drug product does not have a regular crystal structure, and often has other defects such as poor product stability, smaller particle size, difficult filtration, easy agglomeration, and poor liquidity. Thus, it is necessary to improve the various properties of the above product. There is a need to identify a new crystal form with high purity and good chemical stability.
SUMMARY OF THE INVENTION
[0007] The present invention provides a 6-acetyl-8-cyclopentyl-5-methyl-2-((5-(piperidin-4-yl)pyridin-2-yl)amino)pyrido[2,3-d]pyrimidin-7(8H)-one hydroxyethyl sulfonate (as shown in formula (I)).
[0000]
[0008] The compound of formula (I) can be obtained by reacting tert-butyl 4-(6-((6-acetyl-8-cyclopentyl-5-methyl-7-oxo-7,8-dihydropyrido[2,3-d]pyrimidin-2-yl)amino)pyridin-3-yl)piperidine-1-formate with hydroxyethyl sulfonic acid.
[0009] The solubility of the compound of formula (I) has been greatly improved compared to 6-acetyl-8-cyclopentyl-5-methyl-2-((5-(piperidin-4-yl)pyridin-2-yl)amino)pyrido[2,3-d]pyrimidin-7(8H)-one. Its solubility in water reaches 8.33 mg/mL.
[0010] In another aspect, the present invention provides crystal form I of the compound of formula (I).
[0011] A series of crystal products of the compound of formula (I) have been obtained under various crystallization conditions, and X-ray diffraction and differential scanning calorimetry (DSC) measurement have been conducted on the crystal products obtained. It was found that a stable crystal form of the compound of formula (I), which is referred to as crystal form I, can be obtained under normal crystallization conditions. The DSC spectrum of crystal form I of the present application shows a melting endothermic peak at about 324° C. The X-ray powder diffraction spectrum, which is obtained by using Cu-Ka radiation and represented by 2θ angle and interplanar spacing (d value), is shown in FIG. 1 , in which there are characteristic peaks at 4.17 (21.17), 8.26 (10.69), 9.04 (9.77), 10.78 (8.20), 12.38 (7.14), 14.01 (6.32), 18.50 (4.79), 18.89 (4.70), 20.69 (4.29), 21.58 (4.11), 23.87 (3.73) and 28.15 (3.17).
[0012] The present invention also provides a method for preparing crystal form I of 6-acetyl-8-cyclopentyl-5-methyl-2-((5-(piperidin-4-yl)pyridin-2-yl)amino)pyrido[2,3-d]pyrimidin-7(8H)-one hydroxyethyl sulfonate. The method comprises the following steps of:
[0013] 1) dissolving tert-butyl 4-(6-((6-acetyl-8-cyclopentyl-5-methyl-7-oxo-7,8-dihydropyrido[2,3-d]pyrimidin-2-yl)amino)pyridin-3-yl)piperidine-1-formate and hydroxyethyl sulfonic acid, or any crystal form or amorphous form of the compound of formula (I) into a crystallization solvent to precipitate a crystal; or to precipitate a crystal after adding an anti-solvent, wherein the crystallization solvent is selected from water, an organic solvent, or a mixed solvent of water and an organic solvent; the organic solvent is at least one selected from alcohols, ketones and nitriles having 3 or less carbon atoms, or a mixed solvent of at least one solvent mentioned above and a halohydrocarbon having 3 or less carbon atoms; the anti-solvent is at least one selected from alcohols, ketones and nitriles having 3 or less carbon atoms; and
[0014] 2) filtering the crystal, then washing and drying it.
[0015] In a preferable embodiment of the present invention, the crystallization solvent of step 1) is methanol/water, ethanol/water, isopropanol/water, acetone/water or acetonitrile/water, wherein most preferably the organic solvent is ethanol/water, and the ratio of the two is not particularly limited. In a preferred embodiment of the present invention, the volume ratio of the two is 3:1. In a preferred embodiment of the present invention, the anti-solvent of step 1) is methanol, ethanol, isopropanol, acetone or acetonitrile, wherein most preferably the anti-solvent is ethanol.
[0016] The present invention also provides a compound, i.e., tert-butyl 4-(6-((6-acetyl-8-cyclopentyl-5-methyl-7-oxo-7,8-dihydropyrido[2,3-d]pyrimidin-2-yl)amino)pyridin-3-yl)piperidine-1-formate. This compound is useful in the preparation of the desired compound of formula (I) and crystal form I thereof of the present invention.
[0017] The crystallization method is not particularly limited, and can be carried out by a conventional crystallization process. For example, the material, i.e., the compound of formula (I), can be dissolved in an organic solvent under heating, then an anti-solvent is added to precipitate a crystal by cooling. After the completion of crystallization, the desired crystal can be obtained via filtering and drying. In particular, the crystal obtained by filtration is usually dried in a vacuum under reduced pressure at a heating temperature of about 30 to 100° C., preferably 40 to 60° C., to remove the crystallization solvent.
[0018] The resulting crystal form of the compound of formula (I) is determined by differential scanning calorimetry (DSC) and X-ray diffraction spectra. Meanwhile, the residual solvent in the obtained crystal is also determined.
[0019] Crystal form I of the compound of formula (I) prepared according to the method of the present invention does not contain or contains only a relatively low content of residual solvent, which meets the requirement of the National Pharmacopoeia concerning the limitation of the residual solvent of drug products. Therefore, the crystal of the present invention is suitable for use as a pharmaceutical active ingredient.
[0020] The research results show that crystal form I of the compound of formula (I) prepared according to the present invention is stable under conditions of lighting, high temperature and high humidity. Crystal form I is also stable under conditions of grinding, pressure and heating, which meets the production, transportation and storage requirements of drug products. The preparation process thereof is stable, reproducible and controllable, which is suitable for industrial production.
DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 shows the X-ray powder diffraction spectrum of crystal form I of the compound of formula (I); and
[0022] FIG. 2 shows the DSC spectrum of crystal form I of the compound of formula (I).
DETAILED DESCRIPTION OF THE INVENTION
[0023] The present invention is illustrated by the following examples in detail. The examples of the present invention are merely intended to describe the technical solution of the present invention, and should not be considered as limiting the scope of the present invention.
[0024] Test Instruments Used in the Experiments
[0025] 1. DSC Spectrum
[0026] Instrument type: Mettler Toledo DSC 1 Staree System
[0027] Purging gas: Nitrogen
[0028] Heating rate: 10.0° C./min
[0029] Temperature range: 40-300° C.
[0030] 2. X-Ray Diffraction Spectrum
[0031] Instrument type: Bruker D8 Focus X-ray powder diffractometer
[0032] Ray: monochromatic Cu-Kα ray (λ=1.5406)
[0033] Scanning mode: θ/2θ, Scanning range: 2-40°
[0034] Voltage: 40 KV, Electric current: 40 mA
Example 1: Preparation of 6-acetyl-8-cyclopentyl-5-methyl-2-((5-(piperidin-4-yl)pyridin-2-yl)amino)pyrido[2,3-d]pyrimidin-7(8H)-one hydroxyethyl sulfonate
Step 1: Preparation of tert-butyl 6-((6-(1-butoxyethenyl)-8-cyclopentyl-5-methyl-7-oxo-7,8-dihydropyrido[2,3-d]pyrimidin-2-yl)amino)-5′,6′-dihydro-[3,4′-bipyridyl]-1′(2′H)-formate
[0035]
[0036] 2-Amino-6-(1-butoxyethenyl)-8-cyclopentyl-5-methylpyrido[2,3-d]pyrimidin-7(8H)-one (prepared according to the method disclosed in International Patent Application Publication WO2014183520) (10 g, 29.06 mmol), cesium carbonate (14.22 g, 43.75 mmol), Pd 2 (dba) 3 (2.12 g, 2.31 mmol), 4,5-bis(diphenylphosphine)-9,9-dimethyl xanthene (2.69 g, 4.69 mmol) and 125.00 g of dioxane were added to a three-necked reaction flask under argon, and the mixture was stirred well and heated to reflux. A mixed solution of the material tert-butyl 4-(6-chloropyridin-3-yl)-5,6-dihydropyridin-1(2H)-carboxylate (10.34 g, 35.00 mmol, purchased from Yancheng Ruikang Pharmaceutical Chemical Co., Ltd.) and dioxane (65.62 g, 0.74 mol) was slowly added dropwise for about 5 hours. After completion of dropwise addition, the reaction mixture was refluxed for another 1-1.5 hours under stirring. The reaction process was monitored by TLC until the starting material 2-amino-6-(1-butoxyethenyl)-8-cyclopentyl-5-methylpyrido[2,3-d]pyrimidin-7(8H)-one was used completely (eluent: petroleum ether:ethyl acetate=2:1, R f of starting material=0.6, R f of product=0.7), then the reaction was terminated. The reaction solution was cooled to room temperature and filtered, and the filter cake was washed with dichloromethane (17.19 g×3). The filtrate was concentrated to dryness under reduced pressure at 65° C. Then, dichloromethane (137.50 g) was added to dissolve the residue, then 56.25 g of purified water were added. The reaction solution was separated, and the aqueous phase was extracted with 68.75 g of dichloromethane. The organic phases were combined, dried over anhydrous sodium sulfate, and filtered The filter cake was washed with 23.44 g of dichloromethane, and the filtrate was concentrated to obtain an oily liquid under reduced pressure at 45° C. Acetone (150 g) was added, then the mixture was stirred for about 2 hours at room temperature, and stirred for about 3 hours in an ice water bath. The mixture was filtered, the filter cake was washed with cold acetone (25 g×4), and dried at room temperature under reduced pressure for 8-10 hours to obtain a solid (about 14.84 g), in a yield of 80-92%, with a purity detected by HPLC of not less than 90%. ESI/MS:[M+H]=601.43.
Step 2: Preparation of tert-butyl 4-(6-((6-acetyl-8-cyclopentyl-5-methyl-7-oxo-7,8-dihydropyrido[2,3-d]pyrimidin-2-yl)amino)pyridin-3-yl)piperidine-1-formate
[0037]
[0038] Tert-butyl 6-((6-(1-butoxyethenyl)-8-cyclopentyl-5-methyl-7-oxo-7,8-dihydropyrido[2,3-d]pyrimidin-2-yl)amino)-5′,6′-dihydro-[3,4′-bipyridyl]-1′(2′H)-formate (14.84 g, 24.69 mmol) and 75 g of acetic acid were added to a three-necked reaction flask under argon. 10% Pd/C (5 g) was added, the flask was purged with hydrogen three times, and the hydrogenation reaction was carried out at 50-60° C. under stirring and normal pressure for 30-32 hours. When the remaining amount of the intermediate state (an intermediate derived from tert-butyl 6-((6-(1-butoxyethenyl)-8-cyclopentyl-5-methyl-7-oxo-7,8-dihydropyrido[2,3-d]pyrimidin-2-yl)amino)-5′,6′-dihydro-[3,4′-bipyridyl]-1′(2′H)-formate, wherein the protecting group of tert-butyl has been removed while the double bond has not yet been reduced) is <0.3% monitored by HPLC, the reaction was terminated. The reaction solution was cooled to room temperature, and the system was purged with argon. Then, the reaction solution was filtered, and the filter cake was washed with 37.50 g of dichloromethane. The filtrate was concentrated to dryness at 65° C. under reduced pressure. The residue was dissolved in 50 g of anhydrous ethanol and heated to reflux for 0.5 hours under argon, then the mixture was naturally cooled to room temperature under stirring, and stirred in an ice bath for about 4 hours. The mixture was filtered, and the filter cake was washed with cold anhydrous ethanol (12.50 g×2). The wet product obtained was stirred in 31.25 g of dichloromethane, and the insoluble material was filtered. Isopropanol (118.75 g) was slowly added to the filtrate under stirring. The mixture was stirred for about 3 hours in an ice bath, filtered and dried under reduced pressure for 8-10 hours to obtain a solid (about 8.75 g) in a yield of 60-72%, with a purity detected by HPLC of not less than 98%. ESI/MS:[M+H]=547.26.
Step 3: Preparation of 6-acetyl-8-cyclopentyl-5-methyl-2-((5-(piperidin-4-yl)pyridin-2-yl)amino)pyrido[2,3-d]pyrimidin-7(8H)-one hydroxyethyl sulfonate
[0039]
[0040] Tert-butyl 4-(6-((6-acetyl-8-cyclopentyl-5-methyl-7-oxo-7,8-dihydropyrido[2,3-d]pyrimidin-2-yl)amino)pyridin-3-yl)piperidine-1-formate (8.75 g, 15.94 mmol) and 56.25 g of anhydrous methanol were added to a three-necked reaction flask, and stirred well. Then, 80% hydroxyethyl sulfonic acid (8.81 g, 55.94 mmol) and 0.94 g of water were dissolved in 13.75 g of anhydrous methanol, and added dropwise to the above solution, which then became clear. After completion of dropwise addition, the reaction mixture was refluxed for 3-3.5 hours under stirring. The reaction process was monitored by TLC until the starting material was used completely (petroleum ether:ethyl acetate=1:1, R f of starting material=0.3, R f of product=0), then the reaction was terminated and filtered while it was hot. Triethylamine (4.00 g, 39.38 mmol) was added dropwise to the filtrate under stirring. After completion of dropwise addition, the mixture was stirred for about 1 hour, and stirred in an ice bath for about 3 hours. The mixture was filtered, the filter cake was washed with cold anhydrous methanol (7.19 g×2), dried at 40° C. under reduced pressure for 6-8 hours to obtain a solid (about 7.97 g) in a yield of 82-93%, with a purity detected by HPLC of not less than 98%. TOF-MS: [M+H]=447.2503 (an ion peak of 6-acetyl-8-cyclopentyl-5-methyl-2-((5-(piperidin-4-yl)pyridin-2-yl)amino)pyrido[2,3-d]pyrimidin-7(8H)-one binding with one hydrogen ion). The X-ray powder diffraction spectrum of the crystal sample is shown in FIG. 1 , in which there are characteristic peaks at 4.17 (21.17), 8.26 (10.69), 9.04 (9.77), 10.78 (8.20), 12.38 (7.14), 14.01 (6.32), 18.50 (4.79), 18.89 (4.70), 20.69 (4.29), 21.58 (4.11), 23.87 (3.73) and 28.15 (3.17). The DSC spectrum is shown in FIG. 2 , having a melting endothermic peak at about 324° C. The crystal form was defined as crystal form I.
Example 2
[0041] The compound of formula I (1.0 g, 1.75 mmol) was added to a 50 ml one-necked flask, followed by addition of 11 mL of 75% ethanol. The mixture was heated to reflux under stirring until the solution was clear. The mixture was filtered while it was hot, and anhydrous ethanol (11 mL) was slowly added to the filtrate under stirring. The mixture was naturally cooled to room temperature to precipitate a crystal under stirring. The mixture was filtered, washed and dried to obtain a solid (860 mg, yield: 82.1%). The product was identified as crystal form I after studying and comparing the X-ray diffraction and DSC spectra.
Example 3
[0042] The compound of formula I (1.0 g, 1.75 mmol) was added to a 25 ml one-necked flask, followed by addition of 2.5 mL of water. The mixture was heated to reflux until the solution was clear, then 15 mL of ethanol was added slowly. The mixture was cooled to precipitate a crystal under stirring. On the next day, the mixture was filtered and dried to obtain a white solid (268 mg, yield: 53.6%). The product was identified as crystal form I after studying and comparing the X-ray diffraction and DSC spectra.
Example 4
[0043] The compound of formula I (1.0 g, 1.75 mmol) was added to a 25 ml one-necked flask, followed by addition of 2.5 mL of water. The mixture was heated to reflux until the solution was clear, then isopropanol (15 mL) was added slowly. The mixture was cooled to precipitate a crystal under stirring. On the next day, the mixture was filtered and dried to obtain a white solid (201 mg, yield: 40.2%). The product was identified as crystal form I after studying and comparing the X-ray diffraction and DSC spectra.
Example 5
[0044] The compound of formula I (1.0 g, 1.75 mmol) was added to a 25 ml one-necked flask, followed by addition of 2.5 mL of water. The mixture was heated to reflux until the solution was clear, then acetone (15 mL) was added slowly. The mixture was cooled to precipitate a crystal under stirring. On the next day, the mixture was filtered and dried to obtain a white solid (332 mg, yield: 66.4%). The product was identified as crystal form I after studying and comparing the X-ray diffraction and DSC spectra.
Example 6
[0045] The compound of formula I (1.0 g, 1.75 mmol) was added to a 25 mL one-necked flask, followed by addition of 2.5 mL of water. The mixture was heated to reflux until the solution was clear, then acetonitrile (15 mL) was added slowly. The mixture was cooled to precipitate a crystal under stirring. On the next day, the mixture was filtered and dried to obtain a white solid (298 mg, yield: 59.6%). The product was identified as crystal form I after studying and comparing the X-ray diffraction and DSC spectra.
Example 7
[0046] The compound of formula I (1.0 g, 1.75 mmol) was added to a 25 mL one-necked flask, followed by addition of 4 mL of 75% ethanol. The mixture was heated to reflux until the solution was clear, then ethanol (4 mL) was added slowly. The mixture was cooled to precipitate a crystal under stirring. On the next day, the mixture was filtered and dried to obtain a white solid (407 mg, yield: 81.4%). The product was identified as crystal form I after studying and comparing the X-ray diffraction and DSC spectra.
Example 8
[0047] The compound of formula I (1.0 g, 1.75 mmol) was added to a 25 ml one-necked flask, followed by addition of 4 mL of 75% ethanol. The mixture was heated to reflux until the solution was clear, then ethanol (4 mL) was added slowly. The mixture was cooled to precipitate a crystal under stirring. On the next day, the mixture was filtered and dried to obtain a white solid (418 mg, yield: 83.6%). The product was identified as crystal form I after studying and comparing the X-ray diffraction and DSC spectra.
Example 9
[0048] The product sample of crystal form I prepared in Example 1 was spread flat in the air to test its stability under conditions of lighting (4500 Lux), heating (40° C., 60° C.), and high humidity (RH 75%, RH 90%). Samplings were carried out on Day 5 and Day 10. The purity as detected by HPLC is shown in Table 1.
[0000]
TABLE 1
Stability comparison of crystal form
I of the compound of formula (I)
Batch
Time
Light-
RH
RH
number
(day)
ing
40° C.
60° C.
75%
90%
S011305130806
0
99.36%
99.36%
99.36%
99.36%
99.36%
5
99.36%
99.40%
99.40%
99.33%
99.36%
10
99.38%
99.40%
99.38%
99.34%
99.37%
[0049] The results of the stability study showed that crystal form I of the compound of formula (I) had good stability when it was spread flat in the air under conditions of lighting, high temperature and high humidity.
Example 10
[0050] Crystal form I of the compound of formula (I) prepared according to the method of Example 1 was ground, heated and pressed. The results showed that the crystal form is stable. The detailed experimental data are shown in Table 2 below.
[0000]
TABLE 2
Special stability study of crystal form I of the compound of formula (I)
Treatment
Crystal
Batch number
Process
Experimental procedure
form
DSC peak
S011305130808G
Grinding
1 g sample of crystal form I
Crystal
DSC peak
treatment
of the compound of formula
form I
324.71° C.
for 10 min
(I) was ground for 10 min in
a mortar under nitrogen
atmosphere.
S011305130808H
Heating
1 g sample of crystal form I
Crystal
DSC peak
treatment
of the compound of formula
form I
324.77° C.
for 3 h at
(I) was spread flat and heated
80° C.
at 80° C. for 3 h.
S011305130808P
Pressing
Sample of crystal form I of
Crystal
DSC peak
treatment
the compound of formula (I)
form I
324.42° C.
was pressed to a slice. | Provided are a hydroxyethyl sulfonate of a cyclin-dependent protein kinase inhibitor, a crystalline form thereof and a preparation method therefor. Specifically, 6-acetyl-8-cyclopentyl-5-methyl-2-((5-(piperidin-4-yl)pyridin-2-yl)amino)pyrido[2,3-d]pyrimidin-7(8H)-one hydroxyethyl sulfonate (compound of formula (I)), a crystal form I thereof and a preparation method therefor are provided. Crystal form I of the compound of formula (I) has good chemical and crystalline stability, low toxicity, and low residual crystallization solvent. Therefore, the crystal form I can be used in improved clinical therapy. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to an electrochemical generator, usable more particularly as a battery. More specifically, it relates to electrochemical generators, in which use is made of an organic polymer as the active electrode material in at least one of the anode or cathode compartments of the generator.
For some years, consideration has been given to the use as active electrode materials of organic materials formed either by polymers, which store the energy by a phenomenon of the "charge transfer complex type", or by doped polymers such as polyacetylene (cf A. Schneider, W. Greatbatch, R. Mead, "Performance characteristics of a long-life pacemaker cell" 9th International Power Sources Symb. 651-659 (1974) F. Beniere, "La percee des piles plastiques", La Recherche 12, 1132, 1981).
It is also possible to use polyparaphenylene, polythiophene, polypyrrole, polyaniline or other highly conjugated polymers as the electronic conductive organic polymer in generators of this type.
However, although such generators have satisfactory characteristics, they have the disadvantage of not being able to have a high capacity, which it is wished to obtain a rapid discharge of the battery. Thus, in order to have said rapid discharge, it is necessary to limit the thickness of the active electrode material, which does not make it possible to obtain a high capacity and limit the use of such generators as power batteries for starting motor vehicles.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to an electrochemical generator, which obviates the aforementioned disadvantage.
This electrochemical generator comprises an anode compartment and a cathode compartment separated by a semipermeable diaphragm, each of which contains an active electrode material and an electrolyte. The active electrode material of at least one of these compartments is formed by an electronically conductive organic polymer. In one of these compartments, where the active electrode material is an organic polymer, the electrolyte of the said compartment comprises an electroactive compound, which is soluble in the electrolyte and has a redox potential which is close to that of the organic polymer forming the active material with which it is in contact.
As a result of the presence of this electroactive compound in contact with the active electrode material constituted by an organic polymer, the transfer of electrons into the latter is accelerated and at the same time there is an improvement to the diffusion into said polymer of opposed ions from the electrolyte.
According to the invention, the electroactive compound constitutes a reversible redox couple, whose redox potential is close to that of the polymer with which it is in contact. Generally, this potential is slightly different from the redox potential of the polymer, the variation between these two potentials possibly being up to 500 mV.
When the electronically conductive organic polymer in contact with the electroactive compound constitutes the positive electrode material, the electroactive compound present in the anode compartment is advantageously chosen from ferrocene and its derivatives, methoxylated derivatives of benzene, diphenyl-9-10-anthracene and its methoxylated derivatives, di-(α-naphthyl)-9,10-anthracene and its methoxylated derivatives, heterocyclic aromatic compounds and aromatic amines.
The derivatives of ferrocene are in accordance with the formula: ##STR1## in which R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 and R 8 , which can then be the same or different, represent hydrogen NO 2 , SO 2 , CN, OCH 3 , Cl, F, SCN, OCN, ##STR2## and ##STR3## OR, SR and R with R representing an alkyl or aryl radical.
Advantageously, when the electronically conductive organic polymer is polypyrrole, the electroactive compound is ferrocene, i.e. the compound of formula (I) in which R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 and R 8 represent hydrogen. When use is made of ferrocene derivatives in accordance with formula (I), the nature of the groups R 1 to R 8 is chosen in such a way as to adapt the redox potential of the ferrocene derivative to the polymer used as the positive electrode material.
The methoxylated derivatives of benzene which can be used are in accordance with formula: ##STR4## in which R 9 , R 10 , R 11 , R 12 , R 13 , R 14 which can be the same or different, represent hydrogen, a methyl radical or a methoxy radical, provided that at least one of the R 9 , R 10 , R 11 , R 12 , R 13 , R 14 represent the methoxy radical.
The heterocyclic aromatic compounds which can be used are in accordance with the formula: ##STR5## in which X and Y, which can be the same or different, represent NH, N-phenyl, N-alkyl, O or S. It is also possible to use methoxylate derivatives of these heterocyclic aromatic compounds. An example of such a compound is phenothiazine (compound of formula III with X=NH and Y=S).
The aromatic amines which can be used are triphenyl amines, benzidines, paraphenylene diamines and hydrazines.
The triphenylamines are in accordance with the formula: ##STR6## in which R 15 , R 16 and R 17 , which can be the same or different, represent hydrogen, Cl, Br, F, NO 2 , OCH 3 , SO 2 , CN, SCN, OCN, ##STR7## OR, SR and R with R representing an alkyl or aryl radical.
The benzidines which can be used are in accordance with formula: ##STR8## in which R 18 , R 19 , R 20 , R 21 which can be the same or different, represent hydrogen, an alkyl radical or a phenyl radical.
The paraphenylene diamines which can be used are in accordance with the formula: ##STR9## in which R 22 , R 23 , R 24 and R 25 , which can be the same or different, represents hydrogen, an alkyl radical or a phenyl radical.
For example, it is possible to use tetraphenyl paraphenylenediamine, i.e. the compound of formula VI with R 22 , R 23 , R 24 and R 25 =C 6 H 5 .
The hydrazines which can be used are in accordance with the formula: ##STR10## in which R 26 , R 27 , R 28 and R 29 , which can be the same or different, represent an alkyl or phenyl radical.
In the electroactive compounds according to the invention, the alkyl radicals which can be used are straight or branched alkyl groups in C 1 to C 10 such as methyl, ethyl, propyl, butyl, etc. The aryl radicals which can be used are phenyl, benzyl and similar radicals.
When the organic polymer in contact with the electroactive compound constitutes the negative electrode material, the following electroactive compounds can be used in the cathode compartment:
aromatic polycyclic hydrocarbons, such as naphthalene, anthracene, phenanthrene, pyrene, chrysene and rubene;
quinone derivatives, such as benzophenone, anthraquinone and benzoquinone, etc;
aromatic nitro derivatives, such as mononitrobenzene, dinitrobenzenes and trinitrobenzenes, which may or may not be substituted by alkyl groups, e.g. trinitromesitylene, dinitromesitylene, nitromesitylene, dinitrodurene and nitrodurene.
When the negative active material is formed by polymer and lithium at one and the same time, it seems that these additives can also play the role of glossing agent for the lithium deposit and prevent the formation of dendrites.
According to the invention, choice is also made of the electroactive compound as a function of its diffusion coefficient into the active organic polymer material in such a way as to obtain the fastest diffusion of the oxidized or reducing species into the polymer. When the organic polymer is polypyrrole, it has been found that ferrocene makes it possible to achieve a diffusion coefficient of approximately 10 -8 cm 2 /s and to consequently gain a factor of 50 compared with the system when ferrocene is absent and when the diffusion coefficient is approximately 2 to 5.10×10 -10 cm 2 /s and, in the case where lithium perchlorate is used as the electrolyte.
According to the invention, the addition of a small amount of electroactive compound to the electrolyte is adequate to significantly improve the electrical characteristics of the electrochemical generator. When the electrolyte is in solution, the quantity of electroactive compound used is advantageously 10 -3 to 1 mole/1 of electrolyte.
According to the invention, when the active electrode materials present in each of the anode and cathode compartments are electronically conductive organic polymers, it is possible to add to each of the compartments an electroactive compound having the aforementioned characteristics, i.e. a redox potential close to that of the polymer with which it is in contact, provided that use is made of different electroactive compounds in each of the two compartments or an electroactive compound with two electroactive sites, such as ferrocene phenyl ketone.
In this case, the electrolyte of the anode compartment comprises an electroactive compound, which is soluble in the electrolyte and which has a redox potential close to that of the organic polymer of the anode compartment, whilst the electrolyte of the cathode compartment comprises an electroactive compound different from that of the anode compartment and which is soluble in the electrolyte, whilst having a redox potential which is close to that of the organic polymer present in the cathode compartment.
According to the invention, one of the active electrode materials is advantageously polypyrrole, i.e. a polymer of pyrrole or a pyrrole derivative, or a copolymer of pyrrole and/or pyrrole derivatives.
This polypyrrole is in accordance with the following formula: ##STR11## in which R 30 , R 31 and R 32 , which can be the same or different, represent a hydrogen atom, a group chosen from among NO 2 , SO 2 , CN, OCH 3 , Cl and F, ##STR12## SCN, OCN, ##STR13## SR (with R=an alkyl or aryl radical) or a radical chosen from among the alkyl and aryl radicals optionally having one or several substituents chosen from the group including NO 2 , SO 2 , CN, OCH 3 , Cl and F, SCN, OCN, ##STR14## SO 2 R, ##STR15## SR (with R=an alkyl or aryl radical) and n is a number higher than 5 and preferably between 5 and 200,000.
The alkyl radicals which can be used are straight or branched alkyl groups in C 1 to C 10 , such as methyl, ethyl, propyl, butyl, etc. Aryl radicals which can be used, are phenyl, benzyl and similar radicals.
This polymer can be obtained by the polymerization of the pyrrole of formula: ##STR16## in which R 30 , R 31 and R 32 have the meanings given hereinbefore. This polymerization can either be carried out chemically or electrochemically.
In order to obtain polypyrrole chemically, use is made of oxidizing agents in order to polymerize the pyrrole of formula XI dissolved in an appropriate solvent. The polymer obtained is precipitated in the form of a powder, which can then be agglomerated, e.g. by fritting, to constitute the active material of the electrode. The oxidizing agents used are agents, whose redox potential is close to that of pyrrole (0.7 Vs Ag/Ag + ).
Examples of such oxidizing agents are ferric perchlorate, ferric sulphate, double ammonium and cerium nitrate, ammonium persulphate and cation salts or organic cation radicals, e.g. 10-methyl phenothiazine perchlorate.
Widely differing solvents can be used. Thus, it is possible to use water, aqueous solutions of acid such as sulphuric and perchloric acids, and organic solvents such as acetonitrile, methanol and dichloromethane.
In order to obtain polypyrrole electrochemically, this is deposited on an electrode from an electrolytic solution containing pyrrole of formula (IX), or an oligomer formed from the latter, a support electrolyte and a solvent, by passing an electrical current between the electrode and a counter-electrode, which is also immersed in the electrolytic solution.
In this case, polymerization takes place by oxidation of the monomer on the electrode and it is possible to check the electrical conductivity, adhesion and morphology properties of the polymers deposited, by appropriately choosing the solvent, the support electrolyte and the electrode material, whilst also regulating the current density.
Support electrolytes which can be used are salts such as lithium perchlorate LiClO 4 , sodium hexafluorophosphate NaPF 6 , tetraethylammonium borofluoride N(C 2 H 5 ) 4 BF 4 and tetraethylammonium chloride N(C 2 H 5 ) 4 Cl.
The solvents can also vary widely and it is possible e.g. to use acetonitrile, propylene carbonate, methanol and water.
This electrochemical method of preparing the polypyrrole has the advantage of directly leading to the obtaining of a polypyrrole layer deposited on an electrode, which can constitute the current collector of the electrochemical generator, which combines the advantage of simple, inexpensive synthesis, with the obtaining of a good cohesion between the polypyrrole and the current collector.
Moreover, in this case, polypyrrole doped by the anion of the salt used as the support electrolyte is directly obtained. Therefore, when use is made of this polypyrrole as the active positive electrode material, it is not necessary to charge the generator at once.
In the electrochemical generator according to the invention, the active electrode material formed by the electronically conductive organic polymer is intimately combined with a current collector generally constituted by a plate or grid. In materials which can be used for forming the current collector are metals, e.g. nickel or stainless steel in the form of plates or grids, graphite in the form of a fabric or plate and organic conductive materials such as polyacetylene (CH) x .
The other active electrode material can be formed by a reactive metal such as lithium, as well as by an electronically conductive organic polymer, which can be the same or different to the polymer forming the first active electrode material. It is also possible to use other compounds such as graphite or composite materials, e.g. ceramics such as tin oxide, indium oxide and titanium oxide, doped with fluorine or antimony. Use is generally made of a reactive metal such as lithium.
This other active electrode material is also associated with a current collector, which can be produced in the same way and from the same materials as the current collector of the first active electrode material.
In the electrochemical generator according to the invention, the electrolyte is advantageously constituted by a non-aqueous solution or by a solid electrolyte such as an ethylene polyoxide. For example, the electrolyte can be constituted by a solution of at least one lithium salt, such as perchlorate, tetrafluoborate, tetrachloroaluminate, hexafluorophosphate or hexafluoroarsenate of lithium in an organic solvent.
The most varied organic solvents and their mixtures can be used. Examples of such solvents are linear ethers such as dimethoxyethane, cyclic ethers such as tetrahydrofuran and dioxolane, as well as esters such as propylene carbonate. Generally, the lithium salt concentration of the solvent is 1 to 3 mole/1.
In the electrochemical generator according to the invention, the semipermeable diaphragm separating the anode and cathode compartments serve to prevent the migration of oxidized or reduced species of the additive formed in the compartment to which this additive has been added, whilst remaining permeable to the ions of the electrolyte. Thus, when the electroactive compound is added to the cathode compartment, the diaphragm must be impermeable to the reduced species of the electroactive compound, whilst in the case where said compound is added to the anode compartment, the diaphragm must be impermeable to the oxidized species of the electroactive compound. When the electroactive compound is ferrocene, the semipermeable diaphragm can be made from Nafion.
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. 1 a vertical section through an electrochemical generator according to the invention.
FIG. 2 a graph illustrating the cyclic voltametry curve obtained with the generator according to the invention incorporating polypyrrole and ferrocene (curve 1) and a generator only using polypyrrole (curve 2) as the active positive material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, the generator comprises a tight box or case 1 formed from two parts 1a and 1b and made e.g. from polyethylene. Within said box are successively provided a first stainless steel current collector 3, a positive active material 5 constituted by a 10 micron thick polypyrrole film, a semipermeable diaphragm 7 made from Nafion, a mineral fibre separating material 9, an active negative material 11 constituted by lithium and a second stainless steel current collector 13. The Nafion diaphragm 7 defines within the said box an anode compartment 15 and a cathode compartment 17. Each of these compartments is filled with electrolyte, constituted by a solution of lithium perchlorate in propylene carbonate with a lithium perchlorate concentration of 2 mole/1, which also contains 10 -2 mole/1 of ferrocene in anode compartment 15 or positive electrode compartment only. This compartment is anodic during charging and cathodic during discharging.
It is pointed out that several elements of this type can be arranged in series to form an electrochemical accumulator.
In this embodiment, the active positive material 5 consituted by polypyrrole has been obtained by the electrolytic polymerization of pyrrole of formula: ##STR17## in a solvent constituted by propylene carbonate or acetonitrile containing approximately 1 mole/1 of lithium perchlorate as the support electrolyte and by using as the electrode a stainless steel grid and a lithium or stainless steel counter-electrode. Under these conditions, by operating under a current density of 0.2 mA/cm 2 , a 10 μm thick ClO 4 - -doped polypyrrole electrolytic deposit is obtained on the electrode constituted by the stainless steel grid. This grid is then welded to the stainless steel collector 3, which has a surface of 16 cm 2 .
The negative active material 11 formed by lithium is deposited by electrolysis on a stainless steel grid, which is also welded to the second stainless steel current collector 13.
As is shown in the drawing, the first current collector 3 constitutes the positive pole of the generator and the second current collector 13 constitutes its negative pole. Connections passing out of box 1 make it possible to respectively connect current collectors 3 and 13 to an electrical generator or to a load circuit.
This generator has an electromotive force of 3.3 V with a current density of approximately 1 mA/cm 2 . It can be completely discharged in 3 minutes whereas in the case of a generator not having ferrocene in compartment 15 this can only be brought about when the polypyrrole deposit does not exceed 2.5 microns, naturally with a much lower current density. Thus, due to the invention, it is possible to obtain the discharge under the same conditions, but whilst increasing the power of the battery by a factor of close to 4.
FIG. 2 shows the cyclic voltametry curve obtained with a sweep velocity of 0.1 V/s obtained with the active material of a generator of the same type having (for curve 1) a 3×10 -2 μm thick polypyrrole layer, an electrolyte constituted by acetonitrile having a lithium perchlorate concentration of 0.1 mole/1 and ferrocene with a concentration of 1.5×10 -3 mole/1 -1 in the anode compartment. Cathode 2 is obtained under the same conditions as curve 1, but without the addition of ferrocene to the anode compartment. These curves are recorded by means of a potentiostat. The potentials are controlled with respect to the reference electrode Ag/Ag + 10 -2 M. The peaks O 1 and R 1 of curve 1 correspond to the redox couple of ferrocene in the polymer. O 1 is the oxidation peak of ferrocene into ferricine, whilst R 1 is the reduction peak of ferricine into the polymer. Curve 2 shows the redox system of the polymer when ferrocene is absent. O 2 is the oxidation peak of the neutral polymer, its potential being an estimate of the redox potential of the polymer. R 2 is the reduction peak of the oxidized polymer. The potential difference between O 2 and R 2 is close to 200 mV. This difference illustrates the slowness of the electrochemical system of the polymer and leads to a limit to the power of the batteries. Thus, if the polymer system was NERNSTIEN and in accordance with thermodynamic laws, the potential difference of peaks O 2 and R 2 would be equal to zero.
In the presence of ferrocene, peaks O 2 and R 2 are replaced on curve 1 by O 2 ' and the shoulder R 2 '. The positions of O 2 ' and O 2 are close to one another, whilst the value of the potential R 2 ' is close to that of O 2 ' and the potential difference between O 2 ' and R 2 ' is virtually zero. This explains how a fast battery discharge can be obtained, because the redox system of the polymer now has all the characteristics of a thermodynamic behaviour without any apparent kinetic limitation.
The following Examples 1 to 7 illustrate variant embodiments of the electrochemical generator disclosed hereinbefore.
In all the Examples the same generator structure is used as that shown in FIG. 1, with stainless steel current collectors 3 and 13, a semipermeable membrane 7 made of Nafion®, a separating material 9 of mineral fibres and an electrolyte formed by a solution of lithium perchlorate in propylene carbonate in a 2 mole/1 concentration of lithium perchlorate.
EXAMPLE 1
In this example the positive active material 5 is formed by a film of polypyrrole is formed by a film of polypyrrole 10 μm in thickness which was produced by electrolytic polymerization in the conditions set forth hereinbefore. The negative active material 11 is formed by a 5 μm layer of polypyrrole deposited on the stainless steel support 13 and coated with a second deposit of lithium obtained by electrolysis of lithium perchlorate in propylene carbonate.
In the compartment 15 of the positive electrode, 10 -2 mole/1 of ferrocene is added, and 2×10 -2 mole/1 of benzophenone is added in the compartment 17 of the negative electrode.
This generator has an electromotive force of 3.4 volts with a current density of about 1.2 mA/cm 2 .
EXAMPLE 2
In this example the positive active material 5 is formed by a 100 μm polyacetylene film prepared by the Shirakawa method, the negative active material 11 being formed by lithium. A 10 -2 mole/1 concentration of 1,1'-dicarbomethoxy-ferrocene is added to the electrolyte of the compartment 15.
This generator has an electromotive force of 3.9 volts, with a current density of 1.3 mA/cm 2 .
EXAMPLE 3
In this example the positive active material 5 is formed by a 100 μm polyaniline film, the active material 11 of the negative electrode being formed by lithium. A concentration of 5×10 -3 mole/1 of N-methylpheno-thiazine is added to the electrolyte of compartment 15 of the positive electrode.
This generator has an electromotive force of 3.8 volts, with a current density of 1.4 mA/cm 2 .
EXAMPLE 4
In this example the current collector 13 is in graphite, not stainless steel, and the negative active material 11 is formed by a first deposit of 10 μm of polyaniline and a second deposit of lithium obtained by electrolysis. The positive active material 5 is in this case a 10 μm polypyrrole film. A concentration of 10 -2 mole/1 of ferrocene is added to the electrolyte of the compartment (15) and a concentration of 5.10 -3 mole/1 of 9,10-anthraquinone is added to the electrolyte of the compartment (17).
This generator has an electromotive force of 3.7 volts, with a current density of 1.1 mA/cm 2 .
EXAMPLE 5
The negative active material 11 is formed by a 200 μm polyacetylene film prepared by the Shirikawa method and coated with lithium, the positive active material 5 being formed by a 10 μm polypyrrole film. A concentration of 10 -2 mole/1 of dinitromesitylene is added to the electrolyte of the component (15).
This generator has an electromotive force of 2.5 volts, with a current density of 1.15 mA/cm 2 .
EXAMPLE 6
The positive active material 5 is formed by a sheet of polyphenylene prepared in the conventional chemical manner and fritted under a pressure of 4 tonnes, the thickness of the sheet being about 500 μm. The negative active material 11 is formed by lithium, and 10 -2 mole/1 of trinitro-triphenyl amine is added to the electrolyte of the component 15.
This generator has an electromotive force of 4 volts, with a current density of 1.2 mA/cm 2 .
EXAMPLE 7
The positive active material 5 is formed by a 150 μm polythiophene film by electrolysis from acetonitrile containing 10 -2 mole/1 of bithiophene. The negative active material 11 is formed by lithium, and 10 -2 mole 1 of thianthrene is added to the electrolyte of the compartment 15.
This generator has an electromotive force of 4.1 volts and a current density of 1.2 mA/cm 2 . | Electrochemical generator comprising an anode compartment and a cathode compartment, separated by a semipermeable diaphragm and each containing an active electrode material and an electrolyte, the active electrode material of at least one of the compartments being constituted by an electronically conductive organic polymer, wherein in one of these compartments in which the active electrode material is an organic polymer, the electrolyte of said compartment comprises an electroactive compound, which is soluble in the electrolyte and has a redox potential which is close to that of the organic polymer with which it is in contact. | 2 |
BACKGROUND
[0001] The present invention relates to a safety belt apparatus for vehicles. In particular, the invention relates to a safety belt tensioner.
[0002] A typical safety belt apparatus may include a safety belt and a belt reel. The belt reel, which may takes up a greater or lesser proportion of the belt, is fixed rotatably on the vehicle chassis and is preloaded in the direction of belt winding by a torque-producing mechanism, typically a spiral spring. The reel may include a belt unwinding blocking arrangement, that blocks the unwinding of the belt against the force of the torque-producing mechanism if there is an attempt to pull the belt out quickly. The blocking arrangement also preferably acts to block the unwinding of the belt when an acceleration relating to an accident is sensed. Furthermore, the apparatus may include a belt redirection device, which is typically arranged above the shoulder of occupants held by the safety belt. The is fed by the belt reel to the redirection device and may be redirected toward the occupant. The apparatus may also include a belt buckle, to which the belt extends from the belt apparatus and which is fixed on a tension member mounted on a vehicle chassis. A typical example of the structure described above is disclosed in DE 199 15 024 (incorporated by reference herein in its entirety).
[0003] Since the safety belt rests only relatively loosely on the occupant owing to the action of the torque-producing mechanism on the belt reel, belt tensioners (i.e. pretensioners) are often used. A belt tensioner acts to tension the safety belt abruptly in the event of an accident so that it comes to rest firmly against the occupant. Belt tensioners of this kind normally act on the belt reel. The belt reel is typically rapidly rotated in the belt winding direction by a pyrotechnic charge, for example, if when acceleration due to an accident is sensed to be occurring. An example of such a structure is disclosed in EP 581 288 B1 (incorporated by reference herein in its entirety.
[0004] DE 199 57 794 A1 (incorporated by reference herein) discloses a safety belt arrangement in which the belt redirection apparatus is also used for belt tensioning by appropriately displaceable arrangement on the vehicle chassis.
[0005] Safety belt arrangements with belt-force limiters are also known. In principle, limitation of the belt force is achieved through the twisting of a torsion bar, typically located within the reel structure. Such belt-force limiters generally have a flange, a spindle for winding and unwinding the belt, and a torsion bar. In the event of an accident, the flange is connected to the body of the motor vehicle with the aid of a locking apparatus in a manner that prevents twisting. In certain circumstances, it is possible for the belt wound onto the spindle to be unwound with a limited force resulting from the torsional moment of the torsion bar.
[0006] One disadvantage of the above-mentioned design is that the torsion bar requires a certain angle of twist to reach its maximum level of counter force, at which point limitation of the belt tension in a manner optimum for occupant protection is achieved. During the twisting of the torsion bar through this certain angle of twist, the occupant is not restrained with the maximum possible shoulder force. As a result, increased forward displacement of the vehicle occupant may occur.
SUMMARY OF THE INVENTION
[0007] One object of the present invention is to mitigate the disadvantages discussed above. According to the present invention, a safety belt apparatus for a vehicle is provided. The apparatus includes a belt reel, a belt buckle, a belt redirection apparatus mounted on the B-post of the vehicle, a belt-force limiter with a torsion bar, and a belt tensioner or pretensioner. In the event of an accident, the belt tensioner is triggered and, as a result, pretorsioning of the torsion bar occurs. The pretorsion preferably results from the forces that arise during belt tensioning. The pretorsion allows the force limiting action of the torsion bar to start an optimum force level with regard to both the required retention force and the force required for protection of the occupant.
[0008] According to the invention, a belt-force limiter is provided for a safety belt apparatus of a vehicle, with a torsion bar and a pretorsioning device for pretorsioning the torsion bar when an accident is detected. Because the torsion bar is pretorsioned when an accident is detected, belt force limitation starts at a higher level of force when a vehicle occupant is forced into the safety belt. As a result, the amount that the belt pulls-out from the reel is limited and the vehicle occupant is better protected.
[0009] The pretorsioning can be achieved in various ways. For example, a pyrotechnic or electromagnetic device can be provided to twist the torsion bar.
[0010] According to another embodiment of the present invention a safety belt apparatus for a vehicle having a belt tensioner; and a belt-force limiter is provided. In such a safety belt apparatus, the twisting of the torsion bar is not effected only due to the force resulting from the vehicle occupant contacting the belt but also occurs prior to that point due to a pretorsioning device.
[0011] The safety apparatus preferably has an activation device for the essentially simultaneous activation of the belt tensioner and the pretorsioning device. The time immediately after detection of an accident before the vehicle occupant plunges into the belt is thus used to pretension the belt and pretorsion the torsion bar. Thus, as a result of essentially simultaneous triggering of the belt-force limiter and of the belt pretensioner, the belt tensioning can be used to pretorsion the torsion bar and essentially convert it to the torque level at which an optimum ratio of retention force and force limitation is achieved. Optimum use is accordingly made of the available space for the forward displacement of the vehicle occupant during belt tensioning to pretorsion the torque rod.
[0012] In another alternative embodiment of the present invention a safety belt apparatus for a vehicle is provided. The apparatus includes a safety belt; a belt reel fixed rotatably on the vehicle chassis and provided for winding and unwinding the safety belt; a belt buckle for the releasable anchoring of the safety belt on the vehicle; a belt redirection apparatus for redirecting the safety belt between the belt reel and the belt buckle; and a locking apparatus for locking the torsion bar between the belt reel and the vehicle chassis, the belt-force limiter being triggerable by activating the locking apparatus.
[0013] In another alternative embodiment of the present invention, the belt tensioner may include a motion-producing apparatus for displacing at least one part of the belt redirection apparatus in the direction of belt tensioning when the belt tensioner is triggered by the activation device. In this embodiment, the motion of the at least one part of the belt redirection apparatus in the direction of belt tensioning is advantageously used to bring about a pretorsion in the torsion bar.
[0014] Moreover, according to yet another alternative embodiment of the present invention, a method is provided for actuating a safety belt system in a vehicle, with a belt-force limiter with a torsion bar. The method preferably includes the steps of detecting an accident and pretorsioning the torsion bar before the application of a torque acting on the torsion bar resulting from a vehicle occupant plunging into the safety belt. According to this method, pretorsioning is carried out before the maximum belt force due to a vehicle occupant plunging into the belt occurs. As a result, none of the valuable belt length required to restrain the occupant is lost in force limitation.
[0015] The tensioning of the safety belt is preferably brought about by motion of at least one part of a belt redirection apparatus in the direction of belt tensioning. The forces acting on the belt during tensioning can thereby advantageously be used to pretorsion the torsion bar. This can be achieved in a particularly simple manner if the torsion bar is coupled to a belt reel, with the result that a torque is exerted on the belt reel and thus on the torsion bar during belt tensioning.
[0016] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] These and other features, aspects and advantages of the present invention will become apparent from the following description, appended claims, and the accompanying exemplary embodiments shown in the drawings, which are briefly described below.
[0018] [0018]FIG. 1 is a schematic partial cross section through a belt-force limiter according to the present invention;
[0019] [0019]FIG. 2 is an exploded schematic perspective view of the individual components of the belt-force limiter of FIG. 1;
[0020] [0020]FIG. 3 is a perspective exploded representation of a safety belt apparatus in the region of a belt redirection apparatus in accordance with one exemplary embodiment of the present invention;
[0021] [0021]FIG. 4 is a schematic partially sectioned side view of a safety belt apparatus in the region of the belt redirection apparatus and the belt reel in the normal operating state;
[0022] [0022]FIG. 5 is a is a schematic partially sectioned side view of a safety belt apparatus in the region of the belt redirection apparatus and the belt reel similar to FIG. 4, after the triggering of the motion-producing apparatus;
[0023] [0023]FIG. 6 shows an enlarged schematic perspective view of a piston, of the piston rod and of a part of the cylinder of the safety belt apparatus shown in FIG. 3, during triggering of a motion-producing apparatus;
[0024] [0024]FIG. 7 shows a view similar to that in FIG. 6 on completion of a belt-tensioning operation; and
[0025] FIGS. 8 to 12 show schematically the operation and the resulting belt forces of a belt system in accordance with a refinement of the invention.
DETAILED DESCRIPTION
[0026] [0026]FIG. 1 shows schematically the cross section of a force limiter for a belt system in accordance with the first exemplary embodiment of the invention. FIG. 2 shows the individual components of the limiter of FIG. 1 in perspective view. The force limiter comprises a rotatable spindle 1 with a spindle bearing 2 , onto and from which a retention belt (not shown) can be wound. A flange 3 , which can be rotated relative to the spindle 1 , is arranged at one end of the spindle 1 along the axis of rotation. Also provided is a pawl 4 , which locks the flange 3 in the event of an accident.
[0027] A torsion bar or torque rod 5 is also provided. The torsion bar 5 has a toothed ring at one of two ends. The toothed ring is anchored in corresponding apertures in the spindle 1 and the flange 3 and prevents the torsion bar 5 from rotating. The torsion bar 5 locks the spindle 1 and the flange 3 to one another, thereby allowing the spindle 1 and the flange 3 to rotate together about an axis 7 of rotation when the limiter is in a state of rest (i.e. in the absence of an accident) in order to wind or unwind the belt onto or off of the spindle 1 . The two ends of the torque rod 5 can be twisted relative to one another. This twisting property is used to limit the belt force.
[0028] In the event of an accident, the pawl 4 anchors the flange 3 and thus one end of the torque rod 5 on the frame of the belt arrangement. If the torque acting on the torque rod 5 exceeds a predetermined value, the torque rod 5 twists as a function of this torque and thus allows a rotation of the spindle 1 proportional to the twist of the torque rod 5 . The rotation of the spindle allows the belt to unwind, thereby limiting the belt force. Belt-force limitation continues until the torque rod has been fully twisted.
[0029] FIGS. 3 to 7 show schematically the belt tensioner of a belt system according to an embodiment of the present invention. As shown in FIG. 3, a sectional rail 23 of essentially rectangular cross section provided with lateral guide grooves 23 ′ is fastened to the vehicle, by means of bolts 34 screwed through holes 35 into threaded holes 36 in the B-post of the vehicle chassis 11 , so that a flat side of the sectional rail 23 rests against the B-post and the grooves 23 ′ on both narrow sides of the rail are freely accessible.
[0030] A belt deflection member 21 , which has a mounting aperture 38 complementary to the rail 23 with tongues 39 engaging laterally in the grooves 23 ′, is engaged on the rail 23 . In the area away from the mounting aperture 38 , the belt deflection member 21 has a vertical through channel 37 for the safety belt 15 to pass through.
[0031] Provided above the rail 23 is a frame 26 , which carries a belt redirection roller 20 and is connected firmly at the bottom to a piston rod 25 and to downward-extending guide bars 28 arranged at the side.
[0032] Adjoining the piston rod 25 at the bottom, via a peripheral groove 30 , is a piston 19 with an O-seal 19 ′. Provided centrally in the rail 23 is a through hole, which forms a vertical cylinder 22 and into which a gas generator 27 is inserted from below. The piston 19 engages in the cylinder 22 from above when the frame 26 is mounted on the rail 23 , as shown in FIG. 4, to such an extent that the bottom 26 ′ of the frame 26 rests on the upper side of the rail 23 .
[0033] In the assembled state shown in FIG. 4, the piston 19 and the piston rod 25 are completely within the cylinder 22 . The piston rod 25 then extends through the upper opening 24 of the cylinder 22 . The piston 19 , the cylinder 22 and the gas generator 27 together form a motion-producing apparatus 16 .
[0034] The belt redirection member 20 , 26 and the belt deflection member 21 are provided in a vertically adjustable manner on the rail 23 below the latter together form the belt redirection apparatus 17 , which ensures that the belt assumes the correct vertical position relative to the shoulder of the belted occupant.
[0035] As shown in FIG. 4, one strand of the safety belt 15 extends essentially vertically from the belt reel 12 , which is fixed at a suitable point on the vehicle chassis 11 , through the through channel 37 of the belt deflection member 21 to the belt redirection roller 20 , around which the belt is wrapped to change direction approximately 180 degrees. The other strand of the safety belt 15 , that faces away from the B-post, then extends from above through the same through channel 37 , from which it leads to the shoulder (not shown) of the occupant and onward to the belt buckle (not shown). To obtain a more gentle transition of this strand from the vertical position to the oblique path toward the occupant, the belt deflection member has a rounded portion 21 ′ in the area facing the interior of the vehicle.
[0036] Arranged on the belt reel 12 is a spiral spring 13 , which is indicated schematically in FIGS. 4 and 5. The spring 13 exerts a pretensioning force on the belt reel 12 in the belt winding direction. Also provided on the belt reel 12 is an belt unwinding blocking arrangement 14 , which blocks the rotation of the belt reel 12 in the direction of belt withdrawal if there is an attempt to pull the belt out quickly and preferably also if there are accelerations due to an accident.
[0037] According to FIGS. 3, 6 and 7 , there is in the circumference of the piston 19 a peripheral groove 30 , which merges into the normal diameter of the piston 19 and the piston rod 25 respectively via an annular step 31 at the bottom of the piston and via a wedging surface 32 at the top of the piston. Wedging balls 33 are arranged in the peripheral groove so that they form a one-way clutch with the peripheral groove 30 , allowing the piston 19 to move upward but blocking its downward movement.
[0038] The safety apparatus described is assembled and used as follows. Once the rail 23 has been mounted on the B-post of the vehicle, the belt deflection member 21 is first pushed onto the rail 23 . The belt deflection member 21 is preferably be fixed in a desired vertical position on the rail 23 . The frame 26 with the attached piston 19 will then pass through the opening 24 into the cylinder 22 . The guide bars 28 will enter the grooves 23 ′ of the rail 23 and slide downward. Finally, the bottom 26 ′ of the frame 26 strikes the upper narrow side of the rail 23 , as shown in FIG. 4.
[0039] There is also provided a stop 40 (FIG. 3) in the lower area of the rail 23 . The stop 23 prevents the belt deflection member 21 from being pushed downward out of the rail 23 . The upward movement of the belt redirection member 20 , 26 is limited so that the piston 19 and the guide bars 28 cannot come away from the rail 23 . Retention means 41 of this kind are indicated in a purely schematic way by broken lines in FIG. 5.
[0040] When inserting the piston 19 into the cylinder 22 , care is taken to ensure that the ball-type locking mechanism 29 does not lock. One way of achieving this is, for example, by inverting the frame 26 before mounting the rail 23 on the vehicle chassis 11 , the piston 19 thus being introduced into the opening 24 from below.
[0041] If an accident occurs after the assembly of the safety belt apparatus according to the invention shown in FIG. 4, the gas generator 27 ignites and generates in the cylinder 22 a pressure that moves the piston 19 abruptly upward into the position visible in FIG. 5. During this process, corresponding tensile forces are exerted on the two strands of the safety belt 15 , and these cause the unwind-blocking arrangement 14 to lock the belt reel 12 , the safety belt 15 being tensioned in the desired manner. At the same time, belt-force limitation is activated, as described in greater detail below with reference to FIGS. 8 to 12 .
[0042] As a result of the design of the ball-type locking mechanism 29 , the upward movement of the piston 19 is not hindered, as is indicated in FIG. 6. However, once the piston 19 has reached the uppermost position indicated in FIG. 5, which is determined by the retention means 41 , the pressure on the cylinder 22 finally diminishes because the pressurized gas has been consumed, the piston 19 moves downward slightly under the action of the tensile forces on the belt, the wedging balls 33 being pressed radially outward against the inner wall of the cylinder 22 by the correspondingly formed wedging surface 32 . The balls 33 jam between the wall and the piston, preferably forming wedging depressions 18 (FIG. 7). As a result further lowering of the piston 19 within the cylinder 22 is thereby prevented.
[0043] The gas generator 27 is connected by a control line 42 to a triggering apparatus (not shown), which outputs a trigger pulse to the gas generator 27 via the control line 42 when accident-related accelerations occur, causing the gas generator 27 to ignite and send pressurized gas into the cylinder 22 .
[0044] FIGS. 8 to 12 illustrate schematically the operation and the resulting shoulder forces of a belt system according to one embodiment of the invention.
[0045] The belt reel 12 is coupled to a belt-force limiter (not shown) of the type shown in FIGS. 1 and 2. FIG. 8 represents the belt system in the state of rest (at time t 0 ), i.e. no forces are as yet being exerted on the shoulder of a vehicle occupant by the safety belt 15 .
[0046] [0046]FIG. 9 shows the belt system shortly after activation of the belt tensioner and the belt-force limiter in the case of an accident. At this point in time, there is a force Fp acting on the redirection roller 20 in the direction of belt tensioning. The redirection roller 20 is thereby displaced upward by a distance Sp, as described in FIGS. 3 to 7 .
[0047] The shoulder force F 1 acting on the vehicle occupants is determined by the forces Fp and F 2 . F 2 is the force acting on the safety belt 15 at the belt reel 12 . This force is determined by the incipient twisting of the torsion bar of the belt-force limiter, as described with reference to FIGS. 1 and 2.
[0048] The twisting of the torsion bar is initiated by the tightening belt. In this way, the torsion bar is pretorsioned, with the result that belt-force limitation is brought to an optimum level during the belt-tensioning phase.
[0049] The profile of the shoulder force F 1 against time is illustrated as a solid line at the bottom of FIG. 9. The shoulder force in a belt system in which there is no pretorsioning of the torsion bar during the belt-tensioning phase is illustrated in comparison as a broken line. Since there is no pretorsioning of the torsion bar during belt tensioning here, the shoulder force rises only with a delay.
[0050] [0050]FIG. 10 illustrates the belt system and the resulting shoulder force on completion of belt tensioning. The redirection roller 20 has been displaced upward by a maximum distance S Pmax . Since no further belt tensioning takes place after this point in time, the shoulder force F 1 acting on the vehicle occupant likewise temporarily ceases to rise.
[0051] At this point in time, the torsion bar has been twisted to such an extent that optimum belt-force limitation to a maximum force level can now be achieved. As the vehicle occupant subsequently plunges fully into the safety belt, force limitation to a maximum level takes place immediately, not with a delay.
[0052] In terms of forces, FIG. 11 corresponds to the period of time in which the direction of motion of the redirection roller 20 is reversed on completion of belt tensioning. As a result, the shoulder force F 1 even decreases briefly. Shortly after this reversal of motion, the piston 19 connected to the redirection roller 20 engages and prevents the belt 15 from giving further, as described above with reference to FIG. 7. The shoulder force then increases again due to the vehicle occupant now plunging into the belt 15 .
[0053] In terms of forces, FIG. 12 corresponds to the period of time after the vehicle occupant has plunged completely into the safety belt and a constant movement of force to the maximum level has been achieved. The broken line shows that this state is achieved only later in the conventional belt system.
[0054] The priority application, German Patent Application No. 102 13 065.5, filed on Mar. 18, 2002, is hereby incorporated by reference herein in its entirety.
[0055] Given the disclosure of the present invention, one versed in the art would appreciate that there may be other embodiments and modifications within the scope and spirit of the invention. Accordingly, all modifications attainable by one versed in the art from the present disclosure within the scope and spirit of the present invention are to be included as further embodiments of the present invention. The scope of the present invention is to be defined as set forth in the following claims. | A safety belt apparatus for a vehicle, having a belt reel, a belt buckle, a belt redirection apparatus mounted on the B-post of the vehicle. The apparatus also includes, a belt-force limiter with a torsion bar and a belt tensioner. In the event of an accident, the belt tensioner is triggered, and pretorsioning of the torsion bar is simultaneously effected. The pretorsion is preferably brought about by the forces that arise during belt tensioning. The pretorsion allows for the force limitation to start at an optimum force level with regard to the retention force and the protection of the occupant. | 1 |
REFERENCE TO RELATED APPLICATION
This is a continuation of application Ser. No. 09/655,858, filed Sep. 6, 2000, and now U.S. Pat. No. 6,443,196 based on and claiming the benefit of provisional application no. 60/157,125, filed Oct. 4, 1999.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to achieving more energy-efficient horizontal movement of a tree-working tool being carried on the end of a two-member knuckle boom. The term “tree-working tool” throughout this specification is intended to encompass, for example, saw heads and other devices (such as shear heads, for example), for cutting trees at the stump; tree delimbing heads; tree processing heads; wood-handling grapples for piling or loading trees or logs; and other such tools in the tree-harvesting industry.
FIGS. 1A and 1B show an example of such a two-member knuckle boom, used in the tree harvesting industry for tree felling with a disc saw. It must often move a tree-harvesting implement in and out about 12 feet while not changing its height above the ground. It comprises a “hoist boom” having a proximal end pivoted to the machine base, and a “stick boom” having a proximal end pivoted to the distal end of the hoist boom. The disc saw is mounted on the distal end of the stick boom.
A particular concern in the tree harvesting industry, but in other industries as well, is the large amount of diesel fuel that is consumed when felling or delimbing or otherwise processing trees using tools carried by such knuckle booms.
Another concern in the industry is to improve the machine operator's ability to achieve near horizontal tool travel at a controlled velocity, as easily as possible. As noted in the present inventor's U.S. Pat. No. 5,794,674, it is a burden on saw designers to provide saws that are light enough for long reaches yet durable enough to withstand the often errant feed of two-lever manual control. This invention provides control of horizontal tool motion with a single control movement, such as forward and back movement of a hand lever.
2. Description of the Prior Art
Most logging machine reaching is done with knuckle booms that retain the energy-wasteful reaching characteristics of digging and load lifting machines, from which they were originally adapted. There is concern about the amount of hydraulic oil heat generated, and corresponding fuel consumed, that result when the tool, with or without a load, is moved horizontally with the knuckle boom, towards and away from the machine.
Some other prior art machinery uses sliding (or telescopic) booms to get energy-efficient linear movement and ease of operation on “reaching boom” applications, but these present major problems in design for reliability—for example in the hose runs to feed the implement being carried out on the end, and in providing wear surfaces or rollers and raceways to accommodate continuous sliding action in adverse conditions. U.S. Pat. No. 3,981,336 (Levesque) shows a felling and delimbing device that was intended to telescope horizontally. U.S. Pat. No. 4,276,918 (Sigouin) and U.S. Pat. No. 4,428,407 (Bourbeau) are examples of telescopic and horizontally sliding delimbers that have proven to be difficult to maintain.
Still others have chosen to ease operator requirements and reduce reach energy losses by designing their booms with built-in parallelograms, but the additional links, pins and levers needed to achieve the desired boom end coverage geometry add much to machine weight and promise poor reliability when used in adverse logging conditions. U.S. Pat. No. 5,170,825 (Elliot) shows one such linkage boom and describes well the recently evolving needs to support and move a disc saw felling head along a suitable path. Other earlier linkage type booms that had not anticipated disc saw felling and boom delimbing are represented by illustrations in U.S. Pat. No. 3,590,760 (Boyd). The present inventor's U.S. Pat. No. 4,446,897 is an example of side-cut (swing-cut) being substituted for a preferred but uncertain reach-cut.
On knuckle boom machines the diesel engine power used for horizontal reaching can be measured from determining the amount of hydraulic oil pumped and its pressure, and then adding a small amount for friction losses.
To help visualize the wastefulness of a prior art boom during a full reach action, it should be noted that when horizontal reach action is being achieved by simultaneously supplying oil to both the hoist and stick cylinders in the right proportions, the amount of oil needed and its pressures are nearly the same as if the load (boom members, tool and tree) was sequentially first fully lifted by one cylinder and then lowered by the other. For example, to extend a disc saw or other tool out horizontally, hydraulic oil being pumped from the reservoir at a working pressure is directed by a stick valve to the base of a stick cylinder while a hoist directional-control valve drains already pumped oil from the base end of the hoist cylinder to the reservoir. The stick valve also drains oil from the stick cylinder rod-end to the reservoir; and the hoist valve also sends pumped oil from the reservoir to the hoist cylinder rod end. In other words, on prior art knuckle boom machines, near-horizontal travel paths for the end point of a knuckle boom are now typically achieved by simultaneously feeding to and removing the correct amount of hydraulic oil from hydraulic cylinders. A definite amount of oil heat is generated, and is readily calculable by those knowledgeable in the field of the invention. When closely examined it can be seen that such oil flows are very inefficient and require installation of high horsepower diesel engines and large cooling systems, causing high fuel consumption.
SUMMARY OF THE INVENTION
It is an object of this invention to avoid excessive hydraulic oil heat generation and excessive fuel consumption during reaching in and out, and to do this without significantly changing the hydraulic pump and valve systems of the carrier machines, nor departing from the structural compactness of the prior art knuckle booms.
Another object of the preferred embodiment of the invention is to provide for easier operation and training, by allowing a beginner operator to achieve horizontal tool path travel using only one control motion, for example a back and forth hand control lever, resulting in a much shorter learning time than with the two levers of the prior art. The operator's other hand is thus freed for controlling the tilt of the tool.
In the invention, therefore, hydraulic line connections are arranged so that simultaneous supply and dumping of load-supporting pressurized oil during reaching is avoided, so that engine power is needed primarily for friction and flow losses.
This invention therefore shunts pressurized oil directly from the collapsing hoist cylinder base-end to the extending cylinder base-end, where it continues to do useful load support work and thereby avoids most of the problematic heat generation.
This invention separates out the load-carrying work from the reach positioning function of the knuckle boom and leaves that load-carrying work with the hoist and stick cylinders. A separate “reach” cylinder is introduced, which does not carry load but instead controls the reach action. Because in good knuckle boom designs the hoist and stick cylinders have always carried their loads at nearly equal pressures, although on separate circuits, it is possible to connect their base ends together with a hydraulic line so that a load-supporting pressurized volume or “slug” of oil can flow between them, while the reach cylinder alters the knuckle angle to get reach action. The reach cylinder also provides the make-up force which is needed to stabilize the knuckle boom, since the hoist and stick cylinders operate at exactly the same oil pressure.
Although in theory the reach cylinder needs to be only large enough to overcome all the frictions and to make up any mismatching between the hoist and stick cylinders, in practice it preferably is sized to be robust like the other cylinders, so that it is not easily damaged and so that it can be used to do push and pull work if desired. The oil that this cylinder receives from the pump and dumps to the reservoir is not as wasteful as the hoist and stick oil of the prior art. That is because its pressure for unloaded reach is not far from the theoretical zero, and when useful reach work is being done, such as pushing or pulling a saw head, that is where the energy goes, i.e. into external work done, not into oil heat.
Ideally, the cylinder sizing and pinning geometry can be designed so that the volume of hydraulic oil in the stick cylinder base, added to that in the hoist cylinder base, is approximately constant as the stick boom point moves on a horizontal path. When this is done, energy saving is maximized and a single-action control gives horizontal tool travel. A slight departure from this rule will not result in a failure of this invention, but will result in a corresponding slight reduction in energy savings, and will require some use of a second control action to get more exact horizontal tool travel, if needed.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described with reference to the accompanying drawings of the preferred and alternative embodiments, by way of example only. In the drawings:
FIGS. 1A and 1B (both prior art) are side elevation views showing how prior art knuckle boom geometry is typically arranged and how the cylinders must alternately contract and extend to achieve tucking-in to reaching-out action. FIG. 1A shows the knuckle boom retracted, and FIG. 1B shows it extended.
FIG. 2 (prior art) is a schematic diagram of typical prior art oil flow conduit connections between the major components.
FIGS. 3A and 3B are side elevation views of the preferred embodiment of the invention, similar to prior art FIGS. 1A and 1B, showing a preferred location where the “reach” cylinder of this invention can be pinned into the knuckle boom geometry, and showing how the cylinders extend and contract between retracted and extended boom positions.
FIG. 4 is a schematic diagram of oil flow conduit connections between the major components of the preferred embodiment of the invention.
FIG. 5 is a side elevation view showing a simple use of the invention, in which there is no power tilt for the tool or head. The hydraulic components and the essential conduit lines that connect them are shown schematically.
FIG. 6 is a hydraulic circuit option for the machine in FIG. 5 .
FIG. 7 is a simplified circuit diagram for a machine where automatic tool attitude is provided.
FIGS. 8A and 8B are side elevation views showing some of the possible reach and sender cylinder locations when automatic tilt is provided.
FIG. 9 is a schematic diagram showing how by means of selector valves a knuckle boom could be made to selectively operate either in the conventional prior art mode or in the mode of the invention.
FIG. 10 is a perspective view showing that the reach cylinder (or a sender cylinder) can be pinned side by side with other cylinders. In this case it is shown between two hoist cylinders which are hydraulically connected together to act as one.
FIG. 11 is a schematic diagram showing hydraulic connections using a manifold block instead of tees.
FIG. 12 is a side elevation view showing a typical desired boom travel path.
DETAILED DESCRIPTION
FIG. 1A shows a typical prior art configuration of a feller buncher for tree harvesting, in a retracted or “close reach” position. FIG. 1B shows it in an extended or “far reach” position. There is a machine base 1 supported above vehicle tracks 2 . An operator's cab 3 is mounted on the machine base, and a diesel engine 4 is cantilevered on the back of the machine base. The knuckle boom assembly comprises a hoist boom 6 , and a stick boom 7 . The hoist boom is pivotally mounted relative to the machine base, for example at a hoist-base pivot pin 8 on a mounting bracket 9 secured to the machine base. The stick boom is pivotally connected to the distal end of the hoist boom at a hoist-stick pivot pin 15 . The hoist boom is actuated by at least one hydraulic hoist cylinder 10 connected between the machine base and the hoist boom, at an effective angle relative to the hoist boom. The stick boom is actuated by at least one stick cylinder 11 connected between the hoist boom and the stick boom, at an effective angle relative to the stick boom. A tool, such as a feller-buncher head 12 (not shown in detail), is carried at the distal end of the stick boom. Commonly, the tool must also be kept level, and is therefore pivotally mounted about a horizontal axis at a tool-stick pivot pin 13 at the distal end of the stick boom. A tilt cylinder 14 is connected between the stick boom and the tool to control the angle of the tool relative to the stick boom. In FIGS. 1A and 1B, the tilt cylinder is shown pinned above the boom stick and acting on the head through a crank and link set (to achieve a larger tilt angle range). It is not significant to the invention whether such a crank linkage is used or not, or whether the cylinder is above the stick boom, or below it as shown for example in FIG. 3 A.
The invention generally has or can have the same components as in the prior art, but also has an additional hydraulic cylinder and different connection lines. It is helpful to compare the circuit drawings for the invention with typical prior art circuit drawings, to understand the differences in the hydraulic conduit connections which cause the improvement in operation.
FIGS. 1A and 1B show how knuckle boom geometry is typically arranged in the prior art, and how the cylinders must alternately contract and extend to achieve reaching and tucking action. FIG. 2 is a schematic diagram of typical oil flow connections in the prior art. Each of the three cylinders has its two ports connected individually by separate hydraulic conduits to the two work ports on respective directional control valves. Thus the hoist cylinder 10 is operated by a hoist control lever 20 through a hoist directional control valve 21 . The hydraulic conduit line 101 connects one of the work ports on valve 21 to the rod end port of the hoist cylinder, and conduit 102 connects the other work port of valve 21 to the base end port of the hoist cylinder 10 .
Similarly, the stick cylinder 11 is operated by a stick control 22 through a stick directional control valve 23 and conduit lines 103 and 104 . Finally, the tilt cylinder 14 is operated by a tilt control 24 through a tilt directional control valve 25 and conduit lines 105 and 106 .
Thus each control and valve operates its own cylinder and no other. Since all three cylinders must operate simultaneously and at the appropriate matching speeds to get horizontal tool head movement while keeping the tool vertical, considerable training and skill are required for an operator to be highly productive; the operator must learn to control three movements simultaneously.
These drawings of the prior art assist in visualizing that throughout the horizontal travel of the tool the base ends of both the stick and the boom cylinders remain pressurized. The weight of the hoist boom 6 , stick boom 7 , head 12 and tree 5 all are supported against pivoting about the hoist-base pivot pin 8 by the hoist cylinder 10 acting as a strut, with oil in its base end and conduit 102 being under pressure. The oil in the base end of the stick cylinder 11 and in conduit 103 is similarly pressurized by the weights of the stick boom 7 , the head 12 and the tree 5 . Laws of trigonometry for efficient design and full use of components cause these two base end pressures on most machines manufactured, even in the prior art, to be nearly equal to each other for most of the distance of horizontal tool travel, even though they are never connected together. When a directional valve is manually activated to extend one of these cylinders the pump supplies pressurized oil to the base, while the rod end oil is dumped to the hydraulic oil reservoir. When the valve is used to retract a cylinder, the base end oil is dumped to the reservoir while pumped oil is used to fill the rod end.
In the invention, as shown in FIGS. 3A and 3B, the hoist cylinder 10 and the stick cylinder 11 remain pinned into the knuckle boom much as in the prior art, but the hydraulic conduit connections are changed as can be seen in FIGS. 4 and 5. An additional cylinder, called a “reach” cylinder 16 , is pinned into the knuckle boom geometry, between the hoist boom and the stick boom, to alter and hold the angle between them. The tilt cylinder 14 and its circuit in this preferred embodiment are unchanged from the prior art in FIG. 2 .
FIG. 4 is a simplified schematic showing how the hydraulic connections are made to reduce reach energy consumption. Although the bank of valves need not be physically changed, the hoist valve 21 of the prior art becomes the “lift” valve 27 of the invention. The stick valve 23 becomes the reach valve 29 . The tilt valve 25 and the hoist, stick and tilt cylinders 10 , 11 and 14 remain substantially unchanged. Conduits 107 and 108 (corresponding to conduits 101 and 102 of FIG. 2) still connect the ports of the hoist cylinder 10 to the work ports of valve 21 . However, the stick cylinder 11 is not connected at all to valve 29 (corresponding to valve 23 in FIG. 2 ), but instead is connected by means of conduit 114 to conduit 108 , which in effect unites the base end volume of the hoist cylinder 10 with the base end volume of the stick cylinder 11 . That is, the hoist cylinder and stick cylinder base ends are piped together and to a valve work port with hydraulic conduit, so that they share a common load-supporting pressurized volume or “slug” of oil behind their pistons. With a routine calculation in selecting appropriate rod and piston diameter sizes, as is known in the art, conduits 107 and 113 can be used to similarly provide a hydraulic connection to the rod end ports of the hoist cylinder 10 and stick cylinder 11 . Alternatively, the rod end ports can be connected for connection via a valve to either the reservoir or the supply, i.e in the preferred embodiment they are connected together as is the case with the base ends, but that is not essential, and some significant benefit from the invention can be achieved without such a connection; it is the load-supporting hydraulic oil, i.e. the oil in the base ends of the hoist and stick cylinders, which is more important. Even though during normal operations no load is supported by the rod-end oil and it might expediently be connected to the reservoir 31 , it is preferred to be able to pressurize it so that the boom is also usable for pushing down with its tool end in certain operating and maintenance situations.
Thus the lift valve 27 merely controls the volume of the hydraulic oil slug which is free to shuttle between the base ends of the hoist and stick cylinders (and between the rod ends of those cylinders, if connected so that this is applicable to them as well). Examining this situation, one can see that, ignoring friction, there is nothing in this hoist and stick cylinder arrangement which prevents free in and out reaching motion of the knuckle boom. All that happens as the boom is retracted or extended is that the slug of oil flows back and forth freely between the respective cylinders. Thus as the boom extends from the position of FIG. 3A to the position of FIG. 3B, hydraulic oil leaves the base end of the hoist boom so that it retracts, and shuttles to the base end of the stick boom so that it extends. At the same time, of course, hydraulic oil leaves the rod end of the stick boom, and shuttles to the rod end of the hoist boom.
Of course, this free reaching of the boom cannot be allowed, so this is where the “reach” cylinder 16 comes into play. By means of a directional valve 29 the reach cylinder 16 is used to adjust and set the stick-to-hoist boom angle, and thus control the reach. The reach cylinder does not primarily support the loads, as that is accomplished by the slug in the hoist and stick cylinders; the reach cylinder only alters the angle between the stick boom and the hoist boom.
As mentioned above, the tilt mechanism of the prior art can be retained, as in the preferred embodiment, and indeed normally would be retained. However, FIG. 5 is a schematic representation showing the components and hydraulic connections of the simplest embodiment of the invention, in which there is no tilt control, which may be acceptable for some applications of the invention. FIG. 5 illustrates how both the stick and hoist cylinders are made to stroke simultaneously with one control movement, i.e. operation of control lever 26 .
When both valves 27 and 29 are in their center positions (as valve 27 is drawn), the pumps supply no oil to the cylinders, nor can any oil escape from the cylinders to the reservoir 31 . The weights of the tool 17 , the hoist boom 6 , stick boom 7 , stick cylinder 11 and reach cylinder 16 all tend to pivot the entire boom assembly down around hoist-base pivot pin 8 . The hoist cylinder 10 resists this rotation with a force from oil pressure in its base end sufficient to match the loading moments.
At hoist-stick pivot pin 15 only the stick boom 7 and the tool 17 cause a loading moment and force, which must be shared by the stick cylinder and the reach cylinder. How this loading is shared by these two cylinders is an important part of this invention.
Because conduit 114 connects the base end ports of the hoist cylinder 10 and the stick cylinder 11 , the pressure provided by the hoist cylinder 10 to the base of the stick cylinder 11 is whatever is needed for the hoist cylinder 10 to support the entire boom, as just described. This hoist pressure acting in the stick cylinder 11 provides a moment about hoist-stick pivot pin 15 , which opposes the downward moment of weights of the stick boom 7 and tool 17 . If this stick cylinder moment is less than the loading, then reach cylinder 16 (being locked with trapped hydraulic oil) develops enough base end pressure to produce a force that makes up the moment difference so that the stick and its tool do not pivot down. If the stick cylinder moment with its hoist-dictated pressure is more than needed at the hoist-stick pivot pin 15 to hold up the stick boom and the tool, then the reach cylinder will develop a rod end pressure to resist the excess.
To gain the energy-saving benefits of the invention, those implementing the invention will select the cylinder sizes and their acting geometry, using ordinary knowledge in the industry, so that when the system is operated by stroking the reach cylinder, the pressure that the hoist cylinder sends to the stick cylinder is right for it to support the moments about the stick pivot, with little assistance from the reach cylinder for much of the reach range. The volume of oil flowing from the stick cylinder to the hoist cylinder (when retracting reach) remains pressurized so that the loads can be supported in a new reach position without having dumped nor added pumped oil. In the prior art of FIGS. 1A and 1B, by contrast, stick cylinder 11 oil is dumped to the reservoir and new oil is pumped to extend hoist cylinder 10 .
If the cylinder sizes and geometry are calculated such that the reach cylinder exerts a significant amount of force to assist the stick cylinder or to hold it back, and the boom point travel is not nearly horizontal with single control lever action, then the energy saving will be somewhat reduced. This should not be considered a failure of the invention because some knuckle boom applications might be preferred to work that way, accepting the energy saving still obtained by exchanging at least some of the working oil by means of conduit 114 instead of dumping and pumping all of the oil.
To achieve maximum energy savings during reaching it is necessary to lay out the boom geometry and cylinder strokes and diameters so that the volume of oil in the base end of the hoist cylinder plus the volume in the base of the stick cylinder plus the volume in conduits 108 and 114 remains nearly constant as the felling head is moved, for example from the position in FIG. 3A to that in FIG. 3 B. Since existing wood harvesting knuckle booms are usually already designed to do equal amounts of work with their sticks and hoists, this can easily be done by those skilled in the art.
Preferably, as shown in FIGS. 4 and 5, the rod ends of the stick and hoist cylinders are also connected directly together by means of conduit 113 and also to the other work port of valve 27 by means of conduit 107 . During reaching action another, smaller slug of oil will be shunted between the rod ends of those cylinders. As stated previously, even though during normal operations no load is supported by the rod-end oil, it is preferred to be able to pressurize it so that the boom is also usable for pushing down with its tool end in certain operating and maintenance situations.
In order to use this preferred rod-end connection arrangement those skilled in the art will calculate to ensure that the ratio of the piston rod diameter to the piston diameter is the same in both the hoist and stick cylinders. This will prevent unwanted oil pressure build up and cavitation in the rod-ends when the work ports in valve 27 are closed and the stick cylinder is being stroked by the reach cylinder. FIG. 6 illustrates that even if the ratio calculations are not made exact, the anti-cavitation and port-relief device 40 , found in most commercial directional valves, will prevent damage. Of course any oil forced out to the reservoir 31 via conduit 117 will be an unwanted heat generation so it is preferred to calculate and manufacture the diameter ratios to be very nearly equal.
As can be best visualized from FIG. 5, when it is necessary to depart from horizontal boom point travel and for example only raise the tool, the reach control 28 and its valve 29 are left in the neutral position so that reach cylinder 16 is prevented from stroking. Control lever 26 is then used to operate directional valve 27 . This valve sends additional pumped oil via conduit 108 to join the slug of oil which occupies conduit 114 and the base ends of both the hoist and stick cylinders. Since the stick cylinder is prevented from stroking by the locked reach cylinder, this additional oil enters the hoist cylinder base, extends its stroke and raises the boom. Similarly, removing oil from the hoist cylinder base with valve 27 can lower the tool. During actual working use some amount of reach is usually mixed with raising and lowering, i.e. a good approximation of perfect horizontal reach is the most that is likely to be obtained in practice. At such times both valves 27 and 29 are simultaneously activated to compensate for any minor deviations from the horizontal, if they cannot be tolerated, but the operator still has a distinct control of reaching with a single hand action.
The preceding paragraph describes lifting the tool if the reach cylinder is pinned in the stick location. This is the preferred arrangement because a desirable lifting arc is obtained about the hoist-base pivot pin 8 . If as shown for example in FIG. 8A the reach cylinder 16 is in the hoist location, the lifting action pivoting will be about the hoist-stick pivot pin 15 , which is not a good arc.
Some additional improvements and variations are described in the following:
FIG. 5 illustrates the simple case where the tool head attitude does not need to be held, as for example when a loader grapple or harvesting head is allowed to dangle or a tool gets its alignment by grasping a tree stem. Although a tilt control valve and cylinder are not needed, the invention can be advantageously applied to such felling, harvesting, delimbing and loading knuckle booms.
In most uses involving tools carried by knuckle booms, providing one-hand reach control is a very significant improvement. The operator's other hand, being freed from the task of helping to effect horizontal reach, can do a good job of adjusting the tilt attitude of the head as needed for delimbing or tree felling. This is the situation shown in FIGS. 3A, 3 B and 4 . However, in some cases where the tool is especially fragile or the feed attitude critical, it may be desirable to set up the circuit as shown in FIG. 7, where a “sender” cylinder 18 exchanges a slug of oil with the tilt cylinder 14 , thus providing a certain degree of automatic tilt control. Cylinder diameters and strokes can be calculated by those skilled in the art so that the tool has the desired tilt angle while the invention moves it on a desired locus. FIGS. 8A and 8B show one possible cylinder extension sequence and location arrangement for such a hydraulic circuit. Because the tilt and sender cylinders 14 and 18 do useful work without needing or dumping pumped oil, this action saves energy as compared to the prior art, but it is necessary that the cylinders both have their same ends pressurized when supporting the tool.
Another variation is useful in some work situations where a knuckle boom machine may be required, for example, to do mostly high piling of wood for periods of time where not much reaching is needed, and then at times turn to delimbing where much reaching is done. Optional selector valves 51 and 53 as shown schematically in FIG. 9 may be inserted into the hydraulic circuit, allowing the operator to switch back and forth between what is essentially a prior art configuration, and the configuration of the present invention as the work changes. Specific connections resulting from operation of the valves are not shown, since such connections would be clearly within the level of ordinary skill in the art, but essentially the result is switching between FIG. 2 type of prior art routing, and the routing of the invention. The valves could be ganged together, or preferably they could be kept separate to allow operators to select any one of four modes: tilt and reach on, tilt and reach off, tilt off-reach on, or tilt on-reach off. It is also known that with more complicated controls than depicted by the manual levers 50 and 52 , or even with electronic programming, the selector switchover could be automatic within a cycle. However for the rough machine usage conditions in tree harvesting, it is best to obtain the substantial fuel savings and improved tool control of this invention without adding additional technical complexity. Knuckle boom machines set up with a sophisticated capability to shift into or out of the efficient reach mode when needed for certain types of work would require this aspect of the invention.
It should be noted that while FIGS. 3A, 3 B, 5 , 8 A and 8 B show the reach cylinder 16 pinned to the hoist boom and to the stick boom just above the stick cylinder II as a way to achieve balanced bearing forces at the pin 15 , it is sometimes more practical to pin these two cylinders side by side on exactly the same geometry, and design the bearings to be adequate for the resulting forces as one cylinder pushes with a different force than the other. The schematic drawings in FIGS. 4, 5 and 9 , for example, apply for either reach cylinder pinning arrangement.
FIG. 10 illustrates another possible variation in which twin hoist cylinders are pinned side by side and the reach cylinder (or a sender cylinder) is in between them, which is also good for balancing pin bearing loads. When the reach cylinder is designed into the hoist location rather than the stick location, the schematic drawings of the hydraulic connections remain the same and the same energy benefits are obtained during horizontal action, so it clearly is part of the invention. However, this is not a preferred design because when only lifting of the tool is desired, operating the lifting valve only produces stick action and not boom and stick lifting.
When twin cylinders 10 are used instead of a single cylinder they are treated as a single cylinder in this invention and the schematic of their connections is as in FIG. 9 . In this schematic the reach cylinder 16 is in the stick location and a sender cylinder 18 is in the hoist location between the twin hoist cylinders. For automatic tilt in this configuration, it should be appreciated that the tilt cylinder 14 must be above the stick boom as in FIG. 10, rather than below it, so that the sender and tilt cylinders counteract each other rather than add to each other.
FIGS. 2, 4 , 5 and 7 show hydraulic conduit lines between the ports of components as single piece runs. For example, conduit 107 is shown from one of the hoist valve ports to the hoist cylinder rod end, where there is a tee for a hydraulic connection to both the cylinder and conduit (hose) 113 . In practice the hose runs may not be that simple—the tee effect may not be at the cylinder but within the selector valve of FIG. 9 or in the manifold block of FIG. 11 . It should therefore be appreciated that the illustrations are schematic only, and the practical implementation may vary from case to case, as will be clearly understood by those who are knowledgeable in the field of the invention.
FIG. 6 shows two hydraulic pumps, 30 and 32 , instead of a single pump as in the other schematics. It is known that more pumps, even as many as one for each cylinder, will theoretically reduce energy waste. But in practice these particular machine functions are most often done with only one pump to simplify the mechanical drives and hydraulic conduits.
It should be understood that, while these descriptions may appear to infer that a perfectly horizontal reach travel with a perfectly vertical head is a strict requirement, that is almost never so. An operator often needs to superimpose some lift and tilt adjustments to accommodate terrain, tree and various other conditions. Machines with marginal stability at long reach might be better with a slight upward incline to the boom end path to compensate for the vehicle tipping forward in soft ground. Other operations with peculiar piling needs may want the head to rise as it is pulled in towards the carrier. At times it could be desired to tilt an accumulating felling head slightly rearward or a delimber slightly forward when the boom end is withdrawn with trees in the head. Such variations can often be designed into knuckle boom geometry when using the reach and lift control of this invention. FIG. 12 shows a typical acceptable boom point travel path, for example.
The energy savings provided by this invention are very substantial, and accordingly machine size and power provided is reduced significantly, or the power saved in reaching is used in speed to gain productivity. | The two boom members and hydraulic cylinders of a knuckle boom tree harvesting machine are so arranged and proportioned that with a single control movement during reaching and retracting actions the working tool head is made to travel in an approximately horizontal path. The cylinders and control valve are so connected that during horizontal reaching action load-supporting pressurized oil from a collapsing cylinder is not required to be dumped to the reservoir in the conventional heat generating manner, but is rather shunted directly to an extending cylinder where it continues to do useful load support work. Energy waste to hydraulic oil heat and fuel consumption is significantly reduced. Although these advances have been particularly developed for disc saw felling and stroke delimbing of trees they can also be applied to other knuckle boom applications where horizontal reaching is a major function. | 5 |
BACKGROUND
1. Field of the Invention
This invention relates to the general field of telemetry systems for monitoring temperature, more specifically to radiotelemetry devices monitoring skin temperature of feverish children in home settings.
2. Prior Art
Fever is a common and normal reaction to a number of ailments, primarily viral and bacterial infections. It is generally accepted that a mild level of hyperthermia actually helps fight infections. However, excessive fever is a clear source of discomfort for adults and children, and may create complications of its own, such as dehydration and febrile convulsions in infants. Fever often tends to get higher at night. In some cases the pharmacological effects of an antipyretic drug taper off during the night, so that a supplemental dose is necessary to keep a high fever in check.
As fever by itself rarely justifies hospitalization, it is managed at home, typically by the parents of a child with an otorhino-pharyngeal infection. Taking care of a febrile infant at night and at home is an emotionally straining and a tiring task for a parent, especially if the fever spans several days. First, it is difficult to take the "core" temperature (oral, axillar, rectal, or even aural) of a sleeping and febrile infant, without risking waking up the child. This may deprive the child of precious rest needed to help fight the infection. As a result, temperature is often only estimated by manually feeling the child's forehead. Second, the parents often spend sleepless nights, by being urged periodically to "check" on their child, and worrying about its well-being in-between.
The radio pacifier of U.S. Pat. No. 5,033,864 is an example of the quest for a way to monitor the temperature of children. However, in case of fever, a child may breathe fast and shallowly through the mouth and, depending on its state of hydration, provide erroneously cool temperature readings. A feverish child may not keep the pacifier in its mouth during the whole night. Also, in case of temperature within the normal range, the device does not transmit to save power; if for any reason it fails during such a quiescent mode, the failure would not be detected at the receiver end. Finally, pacifiers have themselves been implicated in the recurrence of infections.
A non-invasive method of monitoring fever is available by instrumentally monitoring skin temperature. Instruments specifically designed to measure skin temperature have existed since at least 1926 (U.S. Pat. No. 1,175,262). Normally the skin temperature is only indirectly linked to core temperature, but as a part of temperature regulation during a fever, the nervous system creates an active vasodilatation in the skin for use as a thermal radiator (Houdas & Ring, 1982). In case of fever, the skin will reach a temperature very close to that of the core temperature. The resulting elevation of skin temperature is easy to measure, but more difficult to communicate reliably and safely to the parents. Monitoring devices that use external wiring present real risks of electrocution and strangulation, and are therefore not an option for semi-unsupervised children in home settings.
The simplest approach for measuring skin temperature is the use of temperature-sensitive liquid crystals, in the form of commercially available patches to be affixed on the skin, generally on the forehead (U.S. Pat. Nos. 3,661,142; 4,747,413). These patches change color or display as a function of skin temperature. However, this method requires periodic inspection and sufficient ambient light to read them. The parents may indeed be reassured by mild temperature readings, but at the cost of repeated visual checks during the night.
A more elaborate approach for measuring skin temperature is the use of a computerized thermometer clipped to the rim of a garment facing the abdomen, marketed under the name of Temp-A-Sure(TM) (ELCON 1995). This accurate thermometer and data logger measures and displays numerically skin temperature every 5 minutes, and rings an alarm of short beeps for 15 seconds when it exceeds 37.8° C. (100° F.). However, there are problems in its operation:
Because it contains many components, the device is bulky, being 24 mm (nearly 1") thick. If the child is lying on it, it applies significant pressure on the skin, locally reducing its blood flow, and therefore its temperature, thus generating "false negatives". It can also detach itself more easily from the garment during the motions of a feverish and agitated half-sleeping child.
The alarm triggers for temperatures in excess of the fixed and relatively low value of 37.8° C. (100° F.). However, a child is likely to wear the device because of being feverish, that is often with an already elevated temperature baseline, so the alarm could be tripped repeatedly and unnecessarily during the night as "false positives". Furthermore, as the alarm is produced by the device itself, it would also disrupt the sleep of the child.
Monitoring temperature from another room of the dwelling requires the use of some intercom to hear the alarm. This adds one link and one more opportunity for failure to the chain of information transfer. Without intercom, a parent must remain in the same room as the sick child.
The method is not fail-safe, as the parents have no means of being warned by the alarm if the battery went dead, the device got damaged, detached itself from the garment, or if an intercom did not pick up alarm beeps muffled by some bed cover. It is this kind of "what if" knowledge which adds greatly to the normal anguish of the parents of a sick child.
A similar problem is encountered in diabetic patients who are prescribed drugs to lower their blood glucose levels. For a variety of reasons, these drugs can sometimes act too effectively and create a dangerous hypoglycemia that can lead to "insulin shock" and even death. Diabetic patients learn to recognize early symptoms of hypoglycemia, typically including cold sweats, and generally ingest sugars to counteract the overzealous effect of the drugs. However, when sleeping in their private homes, these patients may not be aware of any telltale symptoms and may then drift into a coma, unbeknownst to themselves or their family. Some wearable devices of the Prior Art (U.S. Pat. Nos. 4,178,916; 4,509,531) detect the lowering of skin temperature which is one symptom of hypoglycemia, and they trigger an alarm to alert patient or family.
Given its importance in animal and medical studies, temperature was one of the earliest, and is still, one of the most common parameters transmitted in wireless bio-telemetry systems comprising a transmitter and a receiver. For wildlife surveys, there are many commercially available transmitters (for example in the 148-220 or 450-470 MHz bands), used for animal tracking. Some of these produce a train of pulses whose interpulse interval, generally about 1 second, is a function of temperature (SIRTRACK 1998). However, because of their power output, type of modulation, or frequency, most of these transmitters would not comply with the rules and regulations of the national entity that regulates the allocation and use of radio frequencies, if used to transmit temperature data within a private household. In the United States of America, such entity is the Federal Communication Commission (FCC), publishing mostly in the Code of Federal Regulations (CFR). Furthermore, wildlife biotelemetry systems, especially receivers, are quite expensive.
Biomedical telemetry devices are commonly used in hospitals (for example in the 512-566 MHz band) to transmit many types of medical parameters, including temperature. However, their use is prohibited outside of hospitals (47 CFR 15.209g2). Other telemetry systems require either licensing by the user or emergency conditions, which would not comprise monitoring a simple fever at home (47 CFR 90.238h). Similarly, the simple skin temperature telemetry system described by Higgins et al. (1978) employs a squegging or blocking oscillator transmitter which would create significant and unacceptable interference because of its broadband characteristics, if it were not low-powered and limited to a broadcast range of a few feet. Many radio telemetry systems of the prior art do not address at all the problems of created and received interference.
The radio telemetry monitoring of infant skin temperature is not new, and can be considered to be in the public domain (for example U.S. Pat. No. 4,747,413). The temperature-sensing transmitter can be manufactured for a relatively low cost, and as a consequence, some transmitters of physiological data are even designed to be disposable (U.S. Pat. No. 3,943,918). These and the above-described radio transmitters require dedicated devices for receiving their radio waves, filtering and processing the signal, decoding the temperature information, displaying the temperature, and triggering alarms when this temperature exceeds some threshold. As a result, these receivers comprise many parts and are relatively complicated, that is, can be excessively expensive for their intended function. A high cost is justifiable for radio monitoring of EKG in case of a life-threatening heart condition, for example, but it is generally not justifiable for monitoring a simple fever. In general, no parent will purchase an expensive telemetry system to monitor the episodic fevers of a child, unless this child is subjected to repeated infections. This has hampered the marketing of temperature biotelemetry systems for the general public.
In a different domain, many alarm clocks are already associated with radio receivers. There are many designs of clock-radios or radio alarm clocks that receive commercial FM or AM broadcasts, generally with the option of being turned on automatically by the alarm system of the clock. Some alarms can be triggered by radio, for example upon reception of a special signal from the Emergency Alert System. Also, some clocks reset themselves automatically and precisely with a built-in radio receiver tuned to the signals from land-based or satellite transmitters broadcasting "atomic clock" time. Finally, alarm clock devices are used in some medication dispensers, beeping an alarm or even opening some pill container when it is time to take another dose of a medication.
SUMMARY OF THE INVENTION
A temperature radio telemetry and alarm system that is safe, fail-safe, simple, accurate, interference-resistant, operable without license, but of relatively low cost by being combined with an ubiquitously needed object such as a bedside alarm clock, an alarm clock radio, or a computer running an alarm clock subroutine. The telemetry and alarm clock of the present invention makes temperature telemetry affordable for any household. When skin temperature is the telemetered variable, its main application in private home settings is primarily the monitoring of fevers in children, or that of hypoglycemia symptoms in diabetic patients.
OBJECTS AND ADVANTAGES
It is the general object of the invention to provide a performant, robust, and safe, yet in expensive temperature monitoring system which avoids the disadvantages of prior temperature biotelemetry systems while affording additional functional advantages.
Although the telemetry system of the present invention consists of two physical components, a temperature sensitive radio transmitter, and a dual-function telemetry radio receiver combined with an alarm clock, its main advantage is reduced cost per individual function, as will be apparent below. The temperature transmitter itself generally consists of very few and ubiquitous parts apart from an inexpensive transmitter module ($5.60 even in unitary quantity). As a result, the transmitter can be manufactured inexpensively, and can even be envisioned as disposable. The naturally more complex receiver is integrated with an alarm clock, instead of being a dedicated stand-alone device. As can be seen in the Table I, a typical alarm clock already comprises most of the components necessary for the temperature alarm telemetry of the present invention. That is, for the relatively low cost of adding a telemetry receiver module and the associated signal processing circuitry to an alarm clock, one obtains a device with two functions, with an average lower cost per function than if each were stand-alone devices.
TABLE I______________________________________ Bedside Temperature Alarm Clock Alarm Telemetry______________________________________compact bedside enclosure YES desirablecircuitry keeping time YES YESdisplay of time numerals YES --display of temperature numerals -- YESset-up buttons or switches YES YESback-up fail-safe battery often YESloudspeaker or buzzer YES YEStelemetry radio receiver -- YESsignal processing circuitry -- YES______________________________________
Moreover, the combination of the two functions is not only economical, but mutually complementary as well, during the monitoring of a fever. The same device can be used to alarm the parent of an abnormal temperature, and to alarm the parent of the time of night when it is necessary to administrate a medication, for example. Some antipyretic, anti-inflammatory, and other drugs have a short pharmacokinetic life in the bloodstream; evenly spaced dose administration may help prevent the fever from flaring up. A parent prone to worry may also use the alarm clock function to be woken up at a predetermined time during the night to check on the child in person. Naturally, the telemetry alarm clock can also be used as a plain alarm clock to wake up the parent normally every morning, with the temperature telemetry functions in stand-by. In other words, the parents will use the alarm clock or radio alarm normally for weeks on end, until need arise to monitor the temperature of their child, time at which they will activate the telemetry system.
A very significant advantage of the telemetry system of the present invention is its fail-safe operation for monitoring fevers. If the skin temperature transmitter is made inoperative by some impact damage, by a fluid leak, by a broken antenna, by a low-voltage or dead battery, or any other cause interrupting the transmission of temperature data, the condition is detected at the receiver end, and an alarm triggered. The same occurs if too much radio interference is present, or if the quality of the radio transmission drops, such as with a folded antenna. At the receiver end, a back-up battery ensures that the alarm is operational should the household electrical power be interrupted, for any reason. Also, the user-adjustable temperature alarm setting is possible only within a predefined range to ensure high fever detection, should that alarm be set erroneously. The knowledge that the operation of the system is fail-safe contributes significantly to the quality of sleep of the parents.
A further advantage of the system is that it is child-safe. It is wireless, meaning that the risk of strangulation and electrocution is eliminated. The temperature transmitter is generally flat with rounded and smooth edges, and does not exert physical discomfort while providing good quality data collection. Its antenna, if of the wire type, is too short to present a strangling hazard. Its battery is purposely too large a diameter so as to reduce the choking hazard, should it be accidentally released from its holder and put in the mouth before parents are warned by the loss of transmission alarm. The transmitter may be coated with an hypo-allergic finish. The radio-frequency irradiation of very short pulses of less than 1 mW, every half-minute or so, is an insignificant biohazard, several orders of magnitude less than by using a walkie-talkie or a cellular phone.
A significant advantage of the temperature monitoring system of the present invention lies in its option of using computer port plug-in receiver embodiments. Practically all computers, including the portable, laptop, or even palmtop types, possess some form of parallel or serial port, or both. Computers already possess the above-said attributes of an alarm clock (Table I). Such computers are found in a large and rapidly growing number of households and can run alarm clock programs concurrently with those processing temperature information. Owing mostly to its low part count and simple design, the cost of a plug-in temperature receiver is significantly cheaper than that of a stand-alone device, and cheaper than a combined temperature receiver and alarm clock.
A real advantage of the telemetry system of the present invention is the legality of its operation, a topic often shunned by manufacturers of telemetry devices. The system of the present invention is compliant with the rules and regulations of the FCC for license-free operation in private home settings. A first condition for such operation is that the "device may not cause harmful interference" (47 CFR 15.19a3). The practical range of the transmitter is in the order of 30 m (100 feet), which is within the boundaries of most houses or apartments, especially considering absorption by the peripheral walls of the dwelling. Also, the transmission of a short pulse separated by long periods of about 30 seconds would not interfere with the operation of a neighbor's garage door opener operating on the same frequency, for example. A second condition for operation is that the "device must accept any interference received, including interference that may cause undesired operation" (47 CFR 15.19a3). Unlike hospital telemetry systems, the device of the present invention generally shares frequency with many other transmitters, such as remote controls, garage door openers, wireless alarms, satellite pagers, or other telemetry systems. However, a special technique of data smoothing eliminates out-of-bounds readings. As a result, the system of the present invention is relatively immune to interference, including either false negatives or false positives.
BRIEF DESCRIPTION OF THE DRAWINGS
1A First transmitter schematics
1B Second transmitter schematics
2A Transmitter general arrangement
2B Parallel port receiver view
2C Serial port receiver view
3A Parallel port receiver schematics
3B Serial port receiver schematics
4A Bedside alarm clock & receiver synoptics
4B Bedside alarm clock & receiver view
5 Flow-chart of receiver--clock program
6A Raw data signal period plot
6B Smoothed temperature data plot
LIST OF REFERENCE NUMERALS
10 temperature transmitter
10A first variant of 10
10B second variant of 10
11 astable multivibrator
12 timing capacitor
13 temperature sensor
14 one-shot monostable
15 active low thermal switch
16 transmitter RF module
17 transmitting antenna
18 transmitter battery
19 manual on-off switch
20 active high thermal switch
21 single NOR gate
22 magnetic reed switch
23 Printed Circuit Board
24 transmitter battery holder
25 securing hole
30 computer port receiver
30A parallel variant of 30
30B serial variant of 30
31 parallel port connector
32 computer parallel port
33 household computer
34 receiver RF module
35 receiving antenna
36 antenna cable
37 low dropout diodes
38 optional battery
39 battery connector
40 voltage regulator
41 reversal protection diode
42 regulator protection diode
43 current limiting resistor
44 parallel adapter housing
45 securing suction cup
46 securing clip
50 serial port connector
51 protecting diodes
52 op-amp comparator
53 low-dropout regulator
54 N.C. jack switch
55 external power jack
56 serial adapter housing
60 alarm receiver & clock
61 microcontroller
62 household plug
63 AC/DC converter
64 back-up battery
65 real time module
66 manual input device
67 visual display
68 sound-producing unit
69 alarm receiver enclosure
70 transmitter receptacle
71 receptacle cover
DESCRIPTION
The description proceeds by that of two variants A and B of a temperature transmitter 10, then by that of two variants A and B of a temperature receiver 30 to be plugged in a port of a computer running an alarm clock program, and finally by that of a stand-alone temperature receiver and alarm clock 60. The term "alarm clock" is defined herein as any device that gives the time of day, has a settable alarm time, and can sound an alarm when the time of day reaches the set alarm time. The alarm clock can be not only a typical bedside digital type, but an alarm clock program or subroutine running on a computer.
Description of the temperature transmitters
Referring to FIG. 1A, the electronic schematics for a first temperature transmitter 10A are described. An astable multivibrator 11 such as a CMOS 555 timer generates a train of pulses function of the constant value of a timing capacitor 12, preferably of the tantalum type, and of a temperature sensor 13, here a Negative Temperature Coefficient (NTC) thermistor, which is to be in contact with the skin of a subject. Residual resistance between pins 7 and 6 & 2 is sufficient to give a 5 ms width to the negative pulses produced as output on pin 3. At 25° C. (77° F.), the period of such output pulses is relatively long, of the order of 70 seconds (calculations will be detailed in the Operation section). A single-shot monostable 14, such as a second CMOS 555 timer, produces a positive pulse each time it receives a pulse from astable 11. With component values depicted in FIG. 1A, the duration of such positive pulses is about 20 ms. This mode of transmission is well within the FCC limitations (47 CFR 15.231e) which state that "the duration of each transmission shall not be greater than one second and the silent period between transmissions shall be at least 30 times the duration of the transmission but in no case less than 10 seconds". Such long-period transmissions allow more legal power to be used than in continuous transmissions. Should it be required by the FCC, a tiny temperature switch such as a MAXIM 6501 (open drain, low when hot) disables the pulse production ability of monostable 14 when its temperature exceeds some fixed value above that of highest fevers, such as 55° C. (131° F.), at which the 10 second limit may be reached. Finally, a miniature Radio-Frequency (RF) transmitter module 16, such as a LINX TXM-418-LC, transmits the pulses via antenna 17, here on 418 MHz. A lithium battery 18 of relatively large size, such as the ubiquitous coin battery 23 mm (0.9") diameter, provides electrical power for transmitter 10A, upon actuation of a manual miniature on-off switch 19. With low consumption electronic components, the battery can continuously power the transmitter for several weeks.
Referring to FIG. 1B, the electronic schematics for a second and preferred temperature transmitter 10B are described. Transmitter 10B is different from transmitter 10A in that a single CMOS 555 performs the functions of astable 11 and of monostable 14 (in FIG. 1A). Should it be required by the FCC, a tiny temperature switch 20, such as a MAXIM 6502 (push-pull, high when hot), is combined with the pulses produced by astable 11 through a NOR gate 21, such as a FAIRCHILD TinyLogic NC7S02. Positive pulses outputted by gate 21, about 18.7 ms duration with the components shown, are fed to transmitter module 16 as described previously. A sealed reed type switch 22 turns the transmitter off in the presence of an appropriate magnetic field.
The general arrangement of temperature transmitter 10 (either version 10A or 10B) is shown in FIG. 2A. Most of the transmitter electronic parts are soldered as surface mount components onto the top coppered surface of a single side printed circuit board (PCB) 23 as shown. Prominent among such components are a battery holder 24 to hold battery 18 (23 mm diameter), followed by radio transmitter module 16 (13×9.5×3.8 mm), and the relatively large capacity timing capacitor 12. Apart from battery compartment 24 and eventually an on-off switch (not shown), the whole top surface is covered with a suitable waterproof protective coating (not shown). Temperature sensor 13 (not visible) is positioned approximately at the center of the bottom copperless surface of PCB 23, with its leads reaching the coppered traces on the top surface through holes in PCB 23. The relatively wide area surrounding sensor 13 helps limit its own pressure on the skin when the bottom surface of PCB 23 is applied onto the subject. The overall dimensions of temperature transmitter 10 are less than 50 mm by 30 mm, and less than 6 mm thick, excluding antenna 17. If temperature transmitter 10B is marketed as a disposable device, the whole unit, battery included, may be coated with a waterproof hypoallergic finish. Lithium batteries generally have a shelf life of 10 years. Holes 25 may be used for securing the transmitter to a garment such as a diaper with clips, pins, wires, ties, or Velcro(R) material.
Description of temperature receiver embodiments
Several types of temperature telemetry receivers are described, first a plug-in version 30 for the port of a computer running an alarm clock program, in two variants 30A and 30B shown in FIGS. 2B and 2C, then a stand-alone alarm clock and temperature telemetry receiver 60.
Parallel port version
Referring to FIG. 3A, the electronic schematics for plug-in parallel port temperature receiver 30A are described. Receiver 30A is to be plugged via a connector 31 (type DB25M shown) into a parallel port 32 (type DB25F shown) commonly found on a computer 33 to interface with printers and other ancillary equipment, with said computer running a custom alarm clock program (detailed below). A low-power RF receiver module 34, such as a LINX RXM-418-LC, receives the electromagnetic signal transmitted by a temperature transmitter (FIGS. 1A-B, 2A), via an antenna 35 and an antenna cable 36, and outputs either a logic high or low voltage in accordance with that signal. Receiver module 34 is powered by setting and maintaining all 8 bits of TTL output byte high in parallel port 32, and combining them together through low-dropout diodes 37 such as germanium diodes. In case parallel port 32 is unable to provide sufficient voltage and/or amperage to receiver module 34, electrical power may be supplied by a battery 38 (typical 9V shown), plugged into a battery holder 39 Battery voltage is fed to a voltage regulator 40 through a diode 41 protecting said regulator against accidental battery polarity reversals. Output of regulator 40 is protected from that of parallel port 32 by a diode 42. Regulator 40 may already comprise built-in diodes 41 and 42. Regulator 40 may be set or chosen to maintain a voltage higher than required by module 34 to compensate for the voltage drop in diode 42. Module 34 sends the received temperature signal to parallel port 32 and computer 33 via one of the "printer status" pins (such as ACKnowledge, BuSY, PaperEnd, SELect, or ERRor), eventually through a current limiting resistor 43.
Referring back to FIG. 2B, the general arrangement of parallel port receiver 30A is shown. The few electronic parts depicted in FIG. 3A fit easily within a hood or housing 44 of connector 31, except for battery holder 39 and antenna cable 36 as shown. Antenna securing devices such as a suction cup 45 or a clip 46 or both (as shown) allow positioning of antenna 35 for best reception. To limit possible TTL voltage drop in extension cables, receiver 30A benefits from being plugged directly into port 32 of computer 33.
Serial port version
Referring to FIG. 3B, the electronic schematics for a plug-in serial port temperature receiver 30B are described. Receiver 30B is to be plugged via a connector 50 (DB9F shown) into a RS-232 serial port commonly found on a computer (not shown), with said computer running a custom alarm clock program (detailed below). The pin-out is detailed in FIG. 3B for a DB9 interface, but other physical interfaces (DB-25 or other) are usable as long as the RS-232 protocol is respected in the following.
A DTR (Data Terminal Ready) pin is set by software to a positive voltage, of the order of +10 Volts, through a protecting diode 51. This voltage is applied to the positive supply of an operational amplifier such as a "741" configured as a voltage comparator 52. A RTS (Request To Send) pin is set by software to a negative voltage, of the order of -10 Volts. A TD (Transmit Data) pin asserts a negative voltage, also of the order of -10 Volts in the absence of any serial data transmission, which will always be the case in this embodiment. These two negative voltages are combined via supplemental protecting diodes 51 and applied to the negative supply of comparator 52, to the ground pin of a low-power receiver module 34, and to that of a low-dropout voltage regulator 53. A SG (Signal Ground) pin is at a positive level relative to the aforementioned negative voltage and is applied to the input of regulator 53 via a Normally Closed switch 54 in an external power jack 55. In case the serial port is unable to provide sufficient voltage and/or amperage to regulator 53, an external power supply such as a battery (not shown) can provide the necessary power via a polarized plug connected to jack 55. In that case, switch 54 will open and isolate the SG pin from the circuit. The output of regulator 53 powers receiver module 34 and a voltage dividing resistance network used as reference by comparator 52. The radio temperature signal obtained by receiver module 34 via antenna 35 is fed to comparator 52, which outputs it to a CTS (Clear To Send) pin, to be read by the computer. As shown, upon reception of a signal high from receiver module 34, the comparator will output a positive voltage of approximately the same value as provided by DTR, and upon a signal low a negative one of approximately the same value as provided by RTS and TD.
Referring back to FIG. 2C, the general arrangement of serial port receiver 30B is shown. The electronic parts depicted in FIG. 3B fit within an adapter housing 56 for connector 50, except for a semi-flexible antenna 35 and jack 55 as shown. As the relatively large RS-232 voltages allow it, extension cables can be used between computer and receiver 30B, so that the latter may be positioned for best reception.
Bedside Digital Alarm Clock (preferred embodiment)
Referring to FIG. 4A, the synoptics for a stand-alone temperature telemetry receiver and alarm clock 60 are described. A digital microcontroller 61 is at the hub of the device. It is functionally connected to a plurality of items listed hereinbelow, possesses some memory, and can run computer programs. A plug 62 for a household electrical outlet and an AC/DC converter 63 normally provides power to alarm receiver & clock 60. Should household electrical power fail, a back-up battery 64, either of the primary or of the rechargeable type, provides enough power for all the functions of alarm receiver & clock 60 for at least the duration of one night. A real-time clock module 65 comprising an oscillator or resonator, for example a Pocket Watch (SOLUTIONS CUBED 1997), keeps the time of day and can communicate with microcontroller 61. Some microcontrollers already comprise onboard timers that can perform the same function, and use the same digital clocking system both for their own digital operation and for time-keeping purposes. An input device group 66 comprising buttons, switches, keys, touch-screen sensors, or dip-switches allows the user to set the time of day, to set the alarm time, to set the high temperature alarm, to set the low temperature alarm, to change the status of device 60, and to stop eventual alarms. As described in the plug-in embodiments, receiver module 34 receives the radio signal transmitted by a temperature telemetry transmitter through antenna 35, and sends it to microcontroller 61, which decodes it into an actual temperature (see Operation below). A visual display 67 such as LCD or LED numeric or alphanumeric displays or screens, shows simultaneously or sequentially the time of day and the telemetered temperature, and can show alarm settings and current status conditions. A sound-producing unit 68, such as a vibrator, loudspeaker, bell, or buzzer can be activated by microcontroller 61. Telemetry receiver and alarm clock 60 can also be equipped with an external alarm relay or generate a carrier current signal via plug 62 to trigger secondary remote alarms (not shown).
The general arrangement of telemetry receiver & alarm clock 60 is shown in FIG. 4B. Practically all units depicted in FIG. 4A fit within a bedside enclosure 69, as shown. Appended or embedded in enclosure 69 is a receptacle 70 destined to hold temperature telemetry transmitter 10 when not in use, under an openable cover 71. Two events occur when transmitter 10B (FIG. 1B) is placed in storage in compartment 70. First a magnet (not shown) within enclosure 69 opens the magnetically actuated reed switch 22 of the transmitter to turn the temperature transmitter off. Second, a contact switch (not shown) also within enclosure 69, informs microprocessor 61 that it does not need to run the temperature alarm algorithm of its program, and in this case temperature and alarm clock 60 performs like a standard alarm clock. Telemetry receiver and alarm clock 60 can be further combined in the same enclosure with an AM/FM broadcast receiver as in typical a clock radio (not shown) to share even more common components. Receptacle 70 may also comprise an automatic electrical connection to recharge battery 18, if the latter is of a rechargeable type, when transmitter 10 is docked in the receptacle.
OPERATION
All of the above-listed components 61 to 68 of a stand-alone telemetry receiver and alarm clock 60 can be already found in a typical portable computer 33 equipped with a plug-in telemetry receiver 30. There is a conceptual similitude between microprocessor and microcontroller, computer battery and back-up battery, clock module and system timer (for example 18.2 Hz on PCs), keys and buttons or switches, screen and digital display, and loudspeaker and buzzer. As a consequence, the operation which will be described in detail for the stand-alone embodiment of the present invention will essentially be the same, and will not be repeated, for the computer port plug-in embodiments. Also, the operation will be described for skin temperature elevation caused by fever in children but applies with minor modifications to skin temperature drops caused by hypoglycemia in diabetics. For example, a transmitter to detect fever is best placed proximally, one to detect hypoglycemia distally.
As with any bio-medical device, each transmitter 10 is to be tested thoroughly prior to release to the general public. During that Quality Control phase, even with high accuracy transmitters (SIRTRACK 1998), the transmitter temperature pulse duration and period are characterized, and the receiver program is eventually calibrated so as to obtain an accuracy of a fraction of a degree Celsius or Fahrenheit. The pulse duration selected herein is about 20 ms long, so as to be longer than 1 or 2 ms long pulses used in remote controls, and shorter than pager beepers. Furthermore, prescanning of the intended frequency of operation can reveal best pulse durations to use for a given frequency (47 CFR 15.17).
For most days and weeks, telemetry receiver and alarm clock 60 is used as a plain alarm clock. However, upon a suspected or an actual fever in a infant, in the typical situation presented earlier, a parent simply removes temperature transmitter 10 from its storage 70. This automatically turns on the transmitter, and activates the temperature monitoring functions of the microcontroller program The alarm sounds briefly to check that it is operational. The parent eventually sets the time alarm at which some medication may be required during the night. The parent then secures transmitter 10 onto the skin of the child, with garment clips, biocompatible glue, tape, or other means, and needs only to remain in the vicinity of the alarm clock receiver for the duration of the night to be safely informed of the child's temperature condition. The receiver can be located in a different room than that of the child's, in particular the parents' bedroom.
Referring to FIG. 5, the flow-chart of the main loop of program run by microcontroller 61 is described. From top to bottom, the first task is performing the basic alarm clock function. If the time of day exceeds set alarm time, alarm is triggered and sounds until the user stops it. If the temperature monitoring is not activated, the program loops again from there (shortest loop). Otherwise, the second task is the detection of a valid signal, defined herein as a pulse of appropriate duration, as sent by temperature transmitter. Detection is based on waiting for the appropriate transitions of the output of receiver module. Such transitions can be detected by polling, which is accurate enough given the long time the program generally spends performing abbreviated loops. They can also be detected by using interrupts, which are available on many microcontrollers as well as on computer ports. If a low to high transition is detected, a pulse duration variable is reset to zero. If subsequently a high to low transition is detected, a complete pulse has then been detected. If the duration of that pulse fits within preset limits, either real time limits if millisecond resolution is available, or simply the number of times the program loops were run, the signal is said to be valid. However, a valid signal does not necessarily come from the temperature transmitter, as will be seen now.
Still referring to FIG. 5, the third task is the rejection of spurious data, both the false positives, that is pulses of unknown origin but happening to be of the correct duration, and the false negatives, that is valid pulses temporarily masked by interference or accidentally blanked out by some other transmission on the same frequency. To do so, a running median of (2N+1) periods is used (Tukey 1977), with N generally varying between 1 and 4 depending on the local interference level. This relatively uncommon method for smoothing data here lends itself ideally to filtering out irrelevant periods. Temperature changes slowly enough that several consecutive measures are somewhat redundant and quite a few can be discarded. This is unlike running average or cumulative sum methods (U.S. Pat. Nos. 4,475,158; 5,764,542), which furthermore require time-consuming floating-point calculations. The period of the signal is calculated and entered in an odd-number First-In First-Out queue circular array A copy of this array is sorted and the median value is retained as the period encoding the temperature measured by the transmitter.
Finally, the fourth task is the calculation of temperature. In FIGS. 1A-B, the resistance R (in Ohms) of thermistor 13 as a function of temperature pulse period P (in s) and capacitance C (in F) of timing capacitor 12 is of the form R=(P-Constant)/(0.693*C). Next, the temperature T (in Kelvin) of thermistor 13 is given by the Steinhart-Hart equation (1/T)=a+b*Ln(R)+c* Ln(R)!3, with a-b-c depending on the particular thermistor used. This formula can be greatly simplified for microcontrollers without floating-point computing ability when only a narrow but biologically significant temperature range is to be accurate. The temperature is finally converted in Celsius or Fahrenheit units. If the temperature is above a high threshold (high fever) or below a low threshold (data transmission problem), an alarm is triggered and sounds until the user stops it. The pitch or pattern of the alarm can vary with the intensity of the fever, and with the type of alarm involved (time, fever, or contact lost). If the alarm sounds through a loudspeaker, the latter can also be used to communicate the temperature aurally to the parent, via synthetic or recorded voice. A loudspeaker can furthermore provide prerecorded advice on how to deal with a high fever, in accordance with recommended medical practice.
Referring to FIGS. 6A and 6B, a whole night of skin temperature data, recorded in real-life conditions, are plotted against time, including local time. The subject was a 19 month old girl on the trailing edge of a rhinopharyngitis, who was feverless at bedtime. A temperature transmitter of the type of FIGS. 1A/2A was attached to the inner part of a diaper facing a parasagittal area of the abdomen. A receiver of the type of FIGS. 2B/3A was plugged in the parallel port of a 8 MHz INTEL 8088-based portable computer. The temperature radio signal was transmitted from the child in her own bedroom, through two walls, to the plug-in receiver placed on a piece of furniture in the parents bedroom. The recording was made on the second floor of a wooden house in the center of a city of 100,000 inhabitants. The data presented in FIGS. 6A-B happen to illustrate in a single night most of the events that can occur during the skin temperature monitoring of the present invention.
The periods of all consecutive temperature pulses, i.e. the raw data, are shown in FIG. 6A. Most periods are about 42 s, longer than the 10 s FCC limit discussed above. A significant number of periods occur at multiples of this value (84, 126, etc.), corresponding to pulses that were missed by the receiver (false negatives), for any reason. It is likely that most of the early ones were obliterated by transmissions by other transmitters on the same frequency, a kind of interference that generally peaks during evening hours. However, there are very few, if any, periods resulting from extra pulses (false positives), presumably because 20 ms duration pulses are uncommon, for reasons explained above.
The resulting skin temperature profile is shown in FIG. 6B, using a 9 bin wide running median to smooth the raw period data. Temperature accuracy is better than 0.3° F. between 96° and 106° F., but it can be seen that even an accuracy of 1° F. would be sufficient for a successful operation. The first temperature drop at Hour #1 (9 pm) resulted from a diaper change and transferring the transmitter from one diaper to another. This occurred during a first skin temperature rise up to nearly 101° F., which did trip the alarm, which was set at 100° F. A second and spectacular fever flare of 105.4° F. (40.7° C.) occurred shortly after Hour #2 (10 pm). In this instance active vasodilatation brings the skin temperature very close to the core temperature, and illustrates the suitability of the method to detect fever. The temperature drop at Hour #3 (11 pm) is a loss of transmission artifact probably due to the child having moved in a position creating a poor geometrical relationship between transmitter and receiver antennas (extinction). Any low temperature alarm would easily detect that anomaly. Shortly before Hour #7 (3 am), the child woke up and cried, at which time the parents brought her in their bedroom for the rest of the night. The room transfer caused a number of false negatives. At Hour #9 (5 am) an unusually shaped temperature drop, easily detectable by a low temperature alarm of 95° F., suggests that a gap occurred between top of diaper--and transmitter attached to it--and skin. If not set tight at the beginning of the night, diapers tend to get loose with time and movement; a transmitter pasted to the skin with tape would not show this type of incident. Finally, the child woke up at 7:30 am and the transmitter was removed from contact with the skin.
It is worth noting that any event is detected with a delay of half a time width of the running median, about 3 minutes in the data shown. This is of little consequence in monitoring fevers, given their normally slow time course. Also, the higher the temperature, the shorter the periods, and the shorter the delay. With the computer plug-in receiver embodiments, temperature profiles such as FIG. 6B can easily be shown in "real time" on the computer screen concurrently with numeric values and alarm clock settings, so as to inform parents at a glance about the skin temperature history of their child. The data may also be saved to a storage medium such as a diskette to be replayed in detail for a physician, should it be necessary, for diagnostic or therapeutic purposes.
CONCLUSION, RAMIFICATIONS, AND SCOPE
Thus the reader will see that the temperature telemetry and alarm clock of the present invention provides a safe, reliable, yet economical device that can dramatically ease the monitoring of fever or diabetes in home settings. While the above description and operation contains many specificities, these should not be construed as limitations on the scope of the invention, but rather as an exemplification of a few embodiments thereof. Many other variations are possible, and will now be listed.
It will be apparent to a Health Professional that the temperature transmitter of the present invention can be positioned in other skin locations than the described abdominal area, such as thoracic, neck, axillar, or wrist areas. It will also be apparent that the described transmitter of skin temperature can be exchanged for one with other temperature objectives than fever monitoring or insulin shock detection. For example, an ovulation detector transmitter used for contraception or fertility purposes (McCreesh et al. 1996) can naturally be used with the telemetry receiver and alarm clock of the present invention, albeit with a different time scale. It will be apparent to a Physiologist or Veterinarian that the telemetry of the present invention may be used with any homeotherm in which skin vasomotricity can regulate temperature.
It will be apparent to a Chemistry Engineer that the temperature telemetry and alarm clock of the present invention can be used both to monitor the temperature of an ongoing chemical or physical process and to modify or terminate that process at a predetermined time. Generally, the receiver and alarm clock of the present invention can be used with any transmitter broadcasting period-encoded or interpulse-encoded signals.
It will be apparent to a Medical Sensors Engineer that astable 11 in transmitters 10A-B (FIGS. 1A-B) can be replaced by any other electronic device similarly producing a relatively long-period pulse as a function of temperature. It will also be apparent to an Electronics Engineer that monostable 14 in transmitter 10A (FIG. 1A) can be replaced by any encoder producing a more complex pattern than plain single pulses, with appropriate decoding on the receiving end, should it be required because of an excessive number of "false positives". However, this did not appear to be necessary in field trials.
It will be apparent to a Radio Engineer that the wire antennas described herein can be replaced alternatively by base-load, whip, coil, loop, split-ring, dipole, or rigid or flexible PCB trace antennas. Also, antenna output limiting resistors that may be required for FCC compliance are not shown in the Figures.
It will be apparent to a Computer Engineer that the typical parallel and serial port receivers described can be adapted to practically any computer port, including game, keyboard, mouse, accessory, infrared, docking, and the like.
Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents. | A temperature radio telemetry system combined with an alarm clock, intended for home settings. The alarm clock can be a digital alarm clock, or a radio alarm clock, or a computer running an alarm clock subroutine, devices nearly ubiquitous in private homes. The telemetry receiver is integrated with the alarm clock in a bedside enclosure, or is plugged in the parallel or serial port of the computer. The telemetry system principally detects the skin temperature elevation in infants and children with fever, especially at night, and subsequently triggers an alarm for the parents. The system can also detect the peripheral skin temperature drop in diabetic patients with early symptoms of hypoglycemia, or the small temperature rise associated with ovulation. The telemetry link has several fail-safe attributes, is operable without a license, and resists to interference by using a running median data smoothing method. The transmitter is simple, inexpensive, and child-safe. The receiver shares many common parts and functions with the alarm clock or the computer, and therefore becomes inexpensive enough to be affordable by any household. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to control systems and methods.
In particular, the present invention relates to control systems and methods which utilize magnetically retentive bodies each of which has a given magnetic orientation for reacting magnetically to provide between at least two of these bodies a predetermined positional interrelationship for achieving a predetermined effect.
At the present time there is a requirement in a number of different fields for various types of controls which can only be achieved with conventional methods and structures in a complex, expensive manner. Thus, for example, in order to index a given element to a number of different positions, only relatively complex, expensive systems and methods are available. Also, in connection with controlling the flow of fluids, it is necessary at the present time to utilize relatively complex expensive systems. With respect to fluid flow, control systems and methods are required not only for starting and stopping the flow of a fluid but also for providing different types of flow such as, for example, filtered and unfiltered fluid flow. The presently known methods and systems for achieving such results are easily subject to faulty operation, require a relatively complicated design, and can be changed from one type of operation to another type of operation accidentally.
Although the present invention is applicable to a number of widely differing fields, it is in particular applicable to the reversible prevention of conception by placing in each vas deferens of a male adult a device which can be selectively set either to permit sperm to flow freely so as to enhance the possibility of conception or to prevent sperm from flowing in numbers sufficient to achieve conception. Devices of this type are shown, for example, in U.S. Pat. Nos. 3,991,743 and 4,013,063. The features disclosed in these patents are entirely satisfactory, and the present invention in one of its aspects provides a further development of the features of these patents.
SUMMARY OF THE INVENTION
It is accordingly a primary object of the present invention to provide methods and systems capable of achieving controls in a simple, effective, inexpensive, and fully reliable manner.
It is in particular an object of the present invention to provide monostable methods and systems according to which it becomes possible to provide effective controls under conditions where at least two different effects are required but do not exist as possible conditions simultaneously and therefore cannot be inadvertently created as often happens with bistable systems which do provide for at least two conditions simultaneously. For the purposes of clarity, a bistable system is defined as follows:
A bistable control means is a control means which provides an existing control condition "A" and an existing control condition "B", said bistable control means being capable of randomly being positioned at either control condition "A" or control condition "B" by a random disturbance once said random disturbance is removed.
Reference is made to FIG. 19 in which a control member 152 is positioned at recess A along control surface 151. As a result of a random disturbance of the system of FIG. 19, the control member 152 can be positioned at recess B as shown in phantom lines when the random disturbance is removed.
A monostable control means is a control means which provides a single existing control condition, said monostable control means being self-restoring to said single control condition when a random disturbance is applied and subsequently removed.
A monostable system is shown in FIG. 20. As a result of a random disturbance, the control member 152 can be displaced from position A along surface 153, said control member 152 being self restoring to condition A when the external disturbance is removed.
A similar monostable control system is shown in FIG. 21 to provide a monostable position "B" of control member 152 along control surface 154.
It is an object of the present insertion to provide methods and systems of remotely eliminating the monostable system of FIG. 20 and replace it with the monostable system of 21 for all conditions encountered in service, thereby eliminating the effects of a random disturbance or inadvertent operation of the system.
Thus, it is an object of the present invention to provide methods and systems according to which it becomes possible to effectively achieve controls such as turning a valve on and off according to a predetermined program, mechanically moving a component according to a predetermined program, providing different types of fluid flow such as filtered and unfiltered fluid flow and in particular this latter type of operation in connection with reversible prevention of conception.
According to the method of the invention, at least two magnetically retentive bodies, each of which has a given magnetic domain orientation, provide as a result of the natural magnetic interaction therebetween a first monostable relationship which achieves a first effect. At least one of these magnetic domain orientations is changed by the temporary application of a polarizing magnetic field and then at least one of these bodies is released to move as a result of magnetic interaction with the other body to a position with respect thereto providing a second monostable relationship between the bodies, and this second monostable relationship is utilized for achieving a second effect.
The structure of the invention includes at least two magnetically retentive bodies, each of which has a given magnetic orientation, and a support means which supports at least one of these bodies for movement with respect to the other, as a result of natural magnetic interaction therewith, to a position where these bodies provide a first monostable relationship for achieving a first effect. By way of a magnetic field of sufficient strength to reorient at least one of the magnetic domains to form a new permanent magnet (herein referred to as a polarizing magnetic field), a polarizing magnetic field is directed through the bodies for changing at least one of the magentic domain orientations, and upon termination of the polarizing magnetic field, one of the bodies moves with respect to the other to provide therebetween a second monostable relationship capable of achieving a second effect. It is noted that a polarizing magnetic field is generally of the order of 15,000 oersteds applied for a few milliseconds and such a polarizing magnetic field cannot practically be provided by a permanent magnet or for a longer period of time without incurring extremely high forces and energy levels.
Whereas the system is most advantageous to providing a positional relationship between components of a given assembly, it is applicable to force balance mechanisms wherein none of the components are permitted to move, but interactive forces produced between the members provides useful force or torque relationships.
BRIEF DESCRIPTION OF DRAWINGS
The invention is illustrated by way of example in the accompanying drawings which form part of this application and in which;
FIG. 1 is a fragmentary longitudinal sectional elevation schematically illustrating the principle of operation of the method and system of the present invention;
FIG. 2 is a transverse section of the structure of FIG. 1 taken along line 2--2 of FIG. 1 in the direction of the arrows;
FIG. 3 is a schematic illustration of application of a magnetic field to the structure of FIG. 1;
FIG. 4 is a side elevation schematically illustrating further details of the application of one type of polarizing magnetic field in the arrangement shown in FIG. 3;
FIG. 5 schematically illustrates the result of the change of the magnetic domain caused by the polarizing magnetic field as illustrated in FIGS. 3 and 4 after the polarizing magnetic field is removed.
FIG. 6 is a fragmentary schematic partly sectional elevation showing one type of application of the method and system of FIGS. 1-5;
FIG. 7 schematically illustrates how a polarizing magnetic field is applied to the arrangement shown in FIG. 6;
FIG. 8 illustrates a position occupied by the components of FIG. 6 after application and removal of the magnetic field;
FIG. 9 is a schematic sectional elevation illustrating how the principles of the invention can be applied to a valve;
FIG. 10 schematically illustrates how a polarizing magnetic field is applied for changing the magnetic domain of at least one component of the valve of FIG. 9, with FIG. 9 showing in phantom lines how the magnetic field creating means of FIG. 10 is positioned with respect to the structure of FIG. 9;
FIG. 11 while also showing the polarizing magnetic field creating means in phantom lines illustrates schematically the position which the valve of FIG. 9 assumes after application and removal of a polarizing magnetic field;
FIG. 12 schematically illustrates in a sectional elevation a further embodiment of a structure utilizing the method and system of the invention with a polarizing magnetic field creating means being indicated in phantom lines in FIG. 12;
FIG. 13 is a schematic top plan view of the structure of FIG. 12;
FIG. 14 is a schematic sectional elevation showing the position assumed by components of FIG. 12 after application and removal of a polarizing magnetic field in accordance with the invention, with FIG. 14 also showing the polarizing magnetic field creating means in phantom lines;
FIGS. 15 and 16 are schematic longitudinal sectional elevations of a method and system of the invention utilized for achieving non-filtered and filtered fluid flow;
FIG. 17 is a sectional elevation of a device to be situated in a vas deferens for reversible prevention of conception while utilizing the method and system of the invention; and
FIG. 18 shows another embodiment of a movable magnetically retentive body which may be utilized in the structure of FIG. 17.
FIGS. 19-21 illustrate bistable and monostable systems.
FIG. 22 illustrates remotely detectable detent positions.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring to FIG. 1, there is schematically illustrated therein a support means which includes, as a part thereof, a non-magnetic tubular housing 20. Within this housing 20 are situated a pair of magnetically retentive bodies 22 and 24. Magnetically retentive bodies are bodies which will retain a given magnetic domain although this domain can be changed by situating the body in a polarizing field of sufficient strength. However, once the magnetic retentive body has a given magnetic domain it will retain this domain until the latter is changed as by way of a sufficient strength polarizing field. In the illustrated example these bodies are in the form of solid cylinders. The magnetically retentive material of the bodies 22 and 24 may be materials such as alloys of platinum-cobalt or iron-cobalt-vanadium. As is well known, such magnetically retentive bodies are capable of being magnetically oriented in a predetermined manner while at the same time the magnetic domain orientation can be changed for isotropic materials and is difficult to change for anisotropic materials. In the particular example shown in FIG. 1 the magnetically retentive body 22 has a magnetic orientation according to which the south pole of the body 22 is situated at the upper part thereof, as viewed in FIG. 1, and the north pole is situated at the lower part thereof. On the other hand, the body 24 has a magnetic orientation according to which the north pole is situated at the upper part thereof and the south pole is situated at the lower part thereof, as is apparent from FIGS. 1 and 2.
In the particular example illustrated in FIG. 1, the support means which includes the tubular housing 20 maintains the body 22 stationary, as by way of a schematically illustrated set screw 26. On the other hand, the support means includes a shaft 28 fixed coaxially to the body 22 and projecting therefrom through an axial bore passing through the body 24 so that the latter is supported for free rotation, being maintained on the shaft 28 against axial movement with respect thereto by way of suitable collars 30. This body 24 is freely turnable within the tubular housing 20 so that it naturally assumes by magnetic interaction with the fixed body 22 the angular position illustrated where the north pole of body 24 is aligned with the south pole of the body 22 while the south pole of the body 24 is aligned with the north pole of the body 22. Simply in order to indicate the angular position of body 24 with respect to body 22, body 24 has a projection 32 which it will be noted is situated at the upper part of the body 24 when the latter provides with the body 22 the positional relationship between these bodies 22 and 24 illustrated in FIG. 1. This positional relationship between the bodies 22 and 24 may be utilized to achieve any one of a number of different effects, as will be apparent from the description which follows.
In order to change the particular positional relationship of the bodies 22 and 24 shown in FIG. 1, at least one of the magnetic orientations is changed. For this purpose, as shown schematically in FIG. 3, a polarizing magnetic field creating means 34 is positioned close enough to the schematically illustrated bodies 22 and 24 for directing therethrough, in a direction normal to the common axis thereof, a polarizing magnetic field 36 which is schematically illustrated in dotted lines and which creates an upper north pole and a lower south pole so that in the illustrated example the magnetic orientation of body 22 remains unchanged while the magnetic orientation of body 24 is changed to be the same as that of the body 22. As is shown in FIG. 4, the polarizing magnetic field creating means 34 includes any suitable support structure 37, shown in phantom lines, carrying a pair of coils 38 which by way of the support structure 37 can be situated with respect to the bodies 22 and 24 in the position indicated in FIGS. 3 and 4. The positions indicated by FIG. 3 exist only during the pulsation of the polarizing magnetic field. The coils 38 are connected in series to a source of current 40, and the illustrated circuit be opened and closed by way of a switch 42. It will be understood that the source of power 40 and the switch 42 can be situated at a location remote from the bodies 22 and 24 while through flexible conductors the support structure 37 can be connected to the source of power and the switch while carrying the coils 38 at locations spaced from each other in the manner shown in FIGS. 3 and 4 to enable these coils to be positioned with respect to the bodies 22 and 24 in the manner illustrated. Thus, upon closing of the switch 42 the magnetic field 36 will be created for changing the magnetic orientation of the body 24 in the illustrated example. The switch 42 is only schematically illustrated. The switch 42 is closed only momentarily for a relatively short interval which will provide the field 36 in the form of a pulsation which will substantially instantaneously change the magnetic orientation of the magnetically retentive body 24.
As soon as the polarizing magnetic field 36 terminates, the body 24 is released from the influence of the magnetic field while still retaining its changed magnetic orientation, so that upon termination of the magnetic field 36 the body 24 immediately turns through 180° around the shaft 28, assuming now the position schematically indicated in FIG. 5 where the body 24 has been displaced angularly through 180° with respect to the body 22, as compared with the positional relationship between these bodies shown in FIG. 1. The termination of the magnetic field 36 releases the body 24 so that as a result of natural magnetic interaction with the fixed body 22 it is possible for the body 24 to assume automatically the angular position shown in FIG. 5 where a second positional relationship is provided between the bodies 22 and 24, and it will be seen that the projection 32 is now situated at the lower part of the body 24. This second positional relationship shown in FIG. 5 is utilized in any one of a number of different ways to achieve a second effect, as will be apparent from the description which follows.
It will be noted that with the above method and system of the invention, the changed magnetic orientation of body 24 provided by way of the polarizing magnetic field 36, as shown in FIG. 3, rotates body 24 to the initial relative orientation with body 22 as indicated in FIG. 1. Thus, upon termination of the polarizing magnetic field 36, the body 24 immediately turns through 180° to restore the body 24 to its initial magnetic relationship with body 22, even though the body 24 now has with respect to the body 22 a positional relationship different from that shown in FIG. 1. Thus, the method and systems of the invention as shown in FIGS. 1-5 and described above is a monostable control method and system in the sense that predetermined relative positions are always provided unless an external force such as a torque is applied, and upon elimination of this external torque, the system is self-restoring to the initial control condition according to which the same physical orientations are restored after the torque has been eliminated.
It is noted that if both 22 and 24 are made of isotropic materials the plane of the polarizing magnetic field could be at an angle with respect to the plane of FIG. 3 and body 24 would still rotate 180° with respect to body 22 if both bodies are subject to the polarizing magnetic field. This fact is very important for practical systems which exist at an unknown angular orientation within a sealed housing.
It is possible under certain special conditions to utilize the method and system of the invention with one anisotropic body in which the magnetic poles can only extend in a certain direction and therefore the plane of magnetization cannot be changed. Thus by utilizing one anisotropic material for body 22 and one isotropic material for body 24 is is not essential to provide an arrangement as shown in FIG. 3 where the polarizing field is in the plane of the drawing. If, for example, the magnetic field creating means 34 is oriented in the position displaced by 90° from the position thereof shown in FIG. 4, then the magnetic field 36 would provide north and south poles which are in a horizontal plane on body 24, rather than a vertical plane as illustrated, and under these conditions when the magnetic field 36 terminates the body 24 would turn only through 90°.
Furthermore, it is not essential to change the magnetic orientation of the movable body. Thus the magnetic field creating means 34 could be reversed so that it would provide an upper south pole and a lower north pole, thus maintaining the magnetic orientation of the movable body 24 unchanged while reversing the polarity of the stationary body, and under these conditions also when the magnetic field terminates the movable body 24 would turn through 180°.
Many variations are possible by using two isotropic materials, or one isotropic material and one anisotropic materials, and by varying the coverage of the field of the polarizing magnetic field.
One of the advantages achieved with the method and system of the invention results from the fact that the method and system of the invention are predictable. As a result of this characteristic, it is possible to maintain the polarizing magnetic field creating means 34 at a position such as that shown in FIG. 4, and the switch 42 can be opened and closed at regular predetermined intervals, with the result being that the body 24 will turn at given intervals through 180° without requiring any change in the position of the magnetic field creating means 34. Thus, because of this monostable feature of the invention it is possible to provide an exceedingly simple structure of achieving a series of movements of a member such as the member 24. The timing of these movements of course can easily be controlled by proper timing of the closing and opening of the switch 42. Of course, the polarizing magnetic field can be created by a capacitor discharge energy supply to supply a pulse of polarizing magnetic field.
FIGS. 6-8 schematically illustrate one possible application of the method and system of the invention. Thus, as is schematically illustrated in FIG. 6, a non-magnetic tubular housing 44 fixedly carries in its interior a magnetically retentive body 46 which is cylindrical but has oppositely inclined end faces, although if desired only the right end face of the body 46 need be inclined as illustrated. The support means of this embodiment includes in addition to the housing 44 an elongated shaft 48 fixed to and projecting axially from the body 46 which is fixed to the housing 44 as by a set screw 50. The shaft 48 extends through coaxial bores of a pair of magnetically retentive bodies 52 and 54 which may be identical with the body 46 except for the bores passing through the bodies 52 and 54. A spring 56 is coiled around the shaft 48 and urges the bodies 52 and 54 toward the body 46, a suitable nut 58 being threaded onto the shaft 44 for adjusting the compression of the spring 56. The body 54 fixedly carries a downwardly extending lug 60 which passes freely through an axially extending slot 62 formed in the housing 44, and this lug 60 is pivotally connected with an elongated pusher bar 64 capable of cooperating with the teeth 66 of a member 68 which is to be indexed.
The bodies 46 and 54 have identical magnetic orientations according to which, for example, they have as viewed in FIG. 6 upper south poles and lower north poles. Of course the intermediate body 52 will have an upper north pole and lower south pole as a result of its magnetic interaction with the bodies 46 and 54 both of which cannot rotate.
Assuming that the polarizing magnetic field creating means 34, which may be the same as that of FIG. 4, is applied to the system of FIG. 6 in the manner indicated in FIG. 7, then the switch 42 of the magnetic field creating means can be closed to change the magnetic orientation of the intermediate body 52, (or of all three bodies 46, 52, 54) and upon termination of the polarizing magnetic field this body 52 will immediately turn 180° to provide the positions of the components as illustrated in FIG. 8. Thus, the bodies 52 and 54 because of their oppositely inclined end faces move apart from each other and to the right from the body 46, causing the lug 60 to be displaced toward the right, and thus pulling the pusher bar 64 to the right so that its free end moves beyond the next tooth of the member 68. Thus, the magnetic field creating means 34 remains in the position shown in FIG. 7 and at the next pulse the body 52 will return to the position thereof shown in FIG. 6, with the spring 56 expanding so that the pusher bar 64 will now advance the member 68 through a given increment.
In this way, a method and system as shown in FIGS. 6-8 can be used for indexing the member 68 according to a predetermined program. This member 68 may be a turntable which turns sequentially to different operating stations, or it may be an endless chain which is moved by given increments to achieve predetermined controls. If desired the lug 60 can be used simply for opening and closing certain switches or for operating certain valves as this member 60 moves with the body 54. Thus a wide variety of controls can be achieved with a method and system of the invention as shown in FIGS. 6-8 and these controls can be actuated through a sealed barrier or vacuum.
FIGS. 9-11 illustrate how the method and system of the invention may be utilized for rotating another component. Thus, FIG. 9 shows a rotary ball valve member 70 situated in a spherical housing 72 which communicates with a supply pipe 74 and a discharge pipe 76. The valve is shown in FIG. 9 in its left position where the passage in the valve member 70 provides communication between the pipes 74 and 76. The valve member 70 is fixed to a valve stem 78 which in turn is fixed to a rotary magnetically retentive cylindrical body 80 corresponding to the body 24 of FIG. 1. This body 80 is situated over a similar fixed body 82 which corresponds to the stationary body 22 of FIG. 1, these bodies 80 and 82 being situated within a housing 84 which of course is non-magnetic in the same way as the valve housing 72. The body 82 is fixed to the housing 84 as by a set screw 86. A polarizing magnetic field creating means 34 cooperates with this structure of FIGS. 9-11 in the manner shown in phantom lines. Thus, when the switch 42 of the means 34 is closed the magnetic field referred to above will be provided, and upon termination of this polarizing magnetic field, when the switch 42 opens, the body 80 will turn 180° so as to displace the valve member 70 from the position of FIG. 9 to that of FIG. 11, and now the valve is directed to the right. Upon the next closing and opening of the switch 42 the valve 70 will of course be returned to the left position thereof shown in FIG. 9. Thus it is easily possible with the method and system of the invention to control fluid flow in the manner shown in FIGS. 9-11.
FIGS. 12-14 show a non-magnetic housing 88 which is of a rectangular configuration and which has its interior communicating with a pair of pipes 90 and 92 through which a fluid is adapted to flow. For example the pipe 90 is a supply pipe for supplying a liquid to the pipe 92 which is a discharge pipe. The housing 88 has in its interior a pair of magnetically retentive bodies 94 and 96 which may be identical and which are of a rectangular configuration, the body 94 being fixed while the body 96 is free to slide to the left and right as viewed in FIGS. 12-14.
If it is assumed that the bodies 94 and 96 have magnetic orientations according to which unlike poles are situated at the adjoining surfaces of the bodies 94 and 96, then of course these bodies attract each other, so that the body 96 by attraction to the body 94 remains in the position shown in FIGS. 12-13 where the pipes 90 and 92 do not communicate with each other.
As shown in phantom lines in FIG. 12, a magnetic field creating means 34a, which may be the same as the magnetic field creating means 34 except perhaps it has a different size, can be situated in the position indicated in FIG. 12, and when the switch of the magnetic field creating means is closed to create the magnetic field, this field will pass vertically through the bodies 94 and 96, as viewed in FIG. 12, to provide them with like poles at their adjoining surfaces. When this magnetic field is terminated, the bodies 94 and 96 will thus repel each other, so that now they will assume the position indicated in FIG. 14, and thus the valve is opened and the pipes 90 and 92 communicate with each other.
It will be seen that this system differs from those described above in that the magnetic relationship of the bodies 94 and 96 is changed to maintain the repulsion between the bodies 94 and 96 which maintains them in the position shown in FIG. 14.
Now when it is desired to return the parts to the position of FIG. 12, a magnetic field creating means 34b must be arranged as shown in phantom lines in FIG. 14, to provide a horizontal magnetic field, a viewed in FIG. 14, thus creating at the end faces of the bodies 94 and 96 which are directed toward each other and which are nearest to each other unlike poles, so that when this magnetic field is terminated the body 96 will be attracted back to the body 94, thus returning the parts to the position shown in FIG. 12.
It is possible with an arrangement as shown in FIGS. 12-14 to maintain one magnetic field creating means 34a in the position shown in FIG. 12 and the other magnetic field creating means 34b in the position shown in FIG. 14, and then the magnetic fields can be applied and terminated in a given sequence so as to cause repeated cyclical movement of the body 96 with respect to the body 94 in the manner described above, but it is apparent that this system is not as advantageous as a switch system using a single source of polarizing magnetic field.
FIGS. 15 and 16 illustrate how the method and system of the invention may be utilized to achieve on-off fluid flow. Thus, FiGS. 15 and 16 show a non-magnetic tubular housing 102 which may be similar to the tubular housing 44 of FIG. 6. In this housing 102 are situated three magnetically retentive bodies 104, 106, and 108, which are respectively similar to the bodies 46, 52 and 54 except that the bodies of FIGS. 15 and 16 are not of the wedge-shaped configuration of the bodies of FIGS. 6 and 8. Thus the bodies 104, 106, and 108 have flat end faces which are normal to the common axis of these bodies. The bodies 104 and 108 are fixed in the housing 102 while the body 106 is turnable therein about the common axis of the bodies, this common axis coinciding with the axis of the tubular housing 102. Moreover, the bodies 104, 106 and 108 are solid bodies which are impermeable to fluid flow.
The bodies 104 and 108 are formed with bores 110 and 112, respectively, passing therethrough in a direction parallel to the common axis of these bodies while being spaced from this common axis and being out of alignment with each other as illustrated. On the other hand, the body 106 is formed with a bore 114 passing diagonally therethrough.
In the position of the parts shown in FIG. 15, the bore 114 provides communication between the bores 110 and 112 so that fluid flow is provided, assuming that a fluid of any type flows thorugh the tubular housing 102. These bodies 104, 106 and 108 may be considered as having the same magnetic orientations as the bodies 46, 52 and 54 of FIG. 6.
When it is desired to stop the fluid flow, a polarizing magnetic field creating means 34 is applied in the same way as described above in connection with FIGS. 6-8, and when the polarizing magnetic field is terminated the body 106 will of course turn through 180° to assume the position shown in FIG. 16. Thus in the position shown in FIG. 16, the bore 114 no longer provides a communication between the bores 110 and 112, and thus fluid flow from one to the other of the bores 110 and 112 is prevented. Of course at the next application and termination of the polarizing magnetic field it is possible to return the body 106 to the position shown in FIG. 15, so that with the arrangement of FIGS. 15 and 16 it is easily possible to change from flow to no flow.
A particular application of the monostable method and system of FIGS. 15 and 16 is illustrated in FIG. 17. Thus, FIG. 17 shows a non-magnetic housing 116 which has at its upper end region as viewed in FIG. 17 a tubular portion fixedly receiving a magnetically retentive body 118, this body 118 being formed with a passage 120 extending therethrough as illustrated. This passage 120 is inclined away from the common axis of the housing 116 and the body 118 so as to terminate at the bottom end of the body 118, as viewed in FIG. 17, at a location spaced from the common axis of the housing 116 and body 118. The housing 116 has spaced from the body 118 a relatively thick end wall 122 which is formed with a passage 124 which is aligned with the inner end of the passage 120 as illustrated. At the outer lower end region of the housing 116, as viewed in FIG. 17, this passage 124 is inclined so as to be situated at the axis of the housing 116. This end wall 122 fixedly and fluid-tightly carries a cap 126 which is formed with an axial bore which receives in its interior in a fluid-tight fixed manner an end region of an elongated tube 128 which is adapted to be placed in a portion of a vas deferens.
In a similar manner the outer portion of the bore 120 of the magnetically retentive body 118 extends along the axis of the body 118 and fluid-tightly carries a tubular member 130 which is non-magnetic and which is fixed fluid-tightly at its interior to an outer end surface region of an elongated tube 132 which is adapted also to be situated in the interior of another portion of the vas deferens.
In the space between the end wall 122 and the magnetically retentive body 118, the housing 116 accommodates a filter body 134 which is also magnetically retentive. The filter body 134 is in a known way provided with a porosity which is sufficiently fine so that while the fluid in which sperm are suspended can pass through the filter body 134, sperm will be retained thereby. The filter body 134 is in the form of a circular disc which can freely turn about the common axis of the body 134 and the housing 116. This filter body 134 is formed with a bore 136 passing therethrough at the same distance from the common axis of the bodies 118 and 134 and housing 116 as the inner lower end of the passage 120, as viewed in FIG. 17. Thus in the position of the parts shown in FIG. 17, the passage 120 communicates with the passage 136 which in turn is coaxially aligned with the bore 124, so that is is possible for sperm suspended in the vas fluid to travel freely through the device shown in FIG. 17 when the components thereof have the position shown in FIG. 17.
The rotary filter body 134 is formed with a detent recess 138 receiving a low force spring detent 140 carried by the end wall 122 of the housing 116. While the spring detent cannot overcome the natural alignment of the monostable system, it has been found advantageous to minimize cumulative errors which can result from multiple sequential reversals as well as provide a detectable position signal as discussed below. This detent recess 138 is diametrically opposed to the bore 136 and situated at the same distance from the axis of the body 134 as the bore 136. Thus the spring detent 140 cooperates with the recess 138 to provide a precise determination of the position of the body 134. The magnetic orientations of the magnetically retentive bodies 118 and 134 may be as illustrated in FIG. 17. Also it is only the bodies 118 and 134 which need be made of a magnet material, the remaining structure of FIG. 17 being non-magnetic. The exterior surfaces of the structure shown in FIG. 17, including the housing 116, the tubular components 132, and the components 130 and 126 may be provided with a tissue ingrowth means 142, in the form of fine gold wire wrapped around and situated against the structure as illustrated, so that tissue in the body will grow into the interstices between the wire portions which form the ingrowth means 142 in order to provide a secure mounting of the device of FIG. 17 in the body. It may be assumed that the sperm-carrying vas fluid flows upwardly as viewed in FIG. 17 from the tube 128 through the bore 124 and the bore 136 of filter body 134 into the bore 120 and then along the tubular member 132.
Assuming that it is desired to place the structure of FIG. 17 in a conception-preventing position, then it is only necessary to apply a polarizing magnetic field through the bodies 118 and 134 in the manner described above in connection with FIG. 1, so that upon termination of this magnetic field body 134 will turn through 180° from the position shown in FIG. 17, and of course the spring detent 140 will now enter into a portion of the bore 136 in order to more precisely align the member 134. In this latter position of course the vas fluid must travel through the filter body 134 which has a porosity fine enough to retain sperm in numbers sufficient to prevent conception.
When it is desired to resume a condition where conception is desired rather than prevented, it is only necessary to apply again a polarizing magnetic field in the form of a pulse which will cause the body 134 to return to the position shown in FIG. 17.
This arrangement of FIG. 17 is of a particular advantage in connection with reversible prevention of conception since an individual provided with devices as shown in FIG. 17 need only visit a physician who can by manipulation tactically situate the device of FIG. 17 between the coils of a unit such as the polarizing magnetic field creating means 34, without requiring any cutting or other surgical procedure for this purpose. Then the magnetic field creating means is operated to create the polarizing magnetic field which will change the position of the body 134, so that in this simple way it is possible to change in the physician's office in a minimum of time and with a maximum of convenience between a condition preventing conception and a condition permitting conception.
FIG. 18 shows a variation of the body 134 of FIG. 17. Thus in FIG. 18 there is shown a magnetically retentive body 144 of the same size and shape as the body 134, this body 144 having a bore 146 which is identical with the bore 136. However, instead of a detent recess 138, the body 144 has a second bore 148 passing therethrough, and in this second bore there is tightly situated a filter plug 150 which has the same capability as the filter body 134 to permit flow of vas fluid therethrough while preventing travel of sperm therethrough in numbers sufficient for conception.
Thus, if the body 134 is replaced by the fluid impermeable body 144, then when the magnetic orientations position passage 146 in line with passage 120 there will be no obstruction to sperm flow and the spring-pressed detent will enter bore 148. On the other hand, when the magnetic forces situate the filter 150 in the path of flow, so that the fluid in which the sperm are suspended can flow through the filter while the sperm are prevented from flowing with this fluid in numbers sufficient for conception then detent 140 will enter bore 146.
Of course, a construction as shown in FIG. 18 may be utilized to replace the body 106 of FIGS. 15 and 16. Also, the use of a spring detent, although shown only in FIG. 17, a generally applicable to minimize a cumulative angular error caused by repetitive cycling and may be used with any of the above embodiments where a body is to be more precisely positioned repetitively. In effect, the magnetic forces create 99% of the alignment and the detent the remaining 1% of the alignment.
Of course it is to be understood that the construction shown in FIGS. 17 and 18 is illustrated at an enlarged scale inasmuch as the actual device which is implanted in the vas is exceedingly small with the bodies 134 and 144 having the construction of relatively small wafers.
It is thus apparent that by way of the simple, inexpensive methods and systems of the invention it is possible to achieve a wide variety of monostable controls in a reliable, convenient manner.
The arrangement of FIG. 22 illustrates a variation of the detent mechanism which is useful for remotely verifying the position of the moveable member 155 in a sealed system years after it has been magnetized to its monostable state at which time verification of the monostable state could be made in the event that medical records are unavailable. Application of a random disturbance, such as a cyclical vibration will automatically vibrate the detent pin 158 in the monostable detent hole. If this monostable position represents detent hole 156, the resultant vibration will be characterized by the small clearances provided between hole 156 and detent 158. If this monostable position represents detent oval hole 157, the resultant vibration will be characteristic of the large clearances provided and the different vibration characteristics can be detected. | In a control system and method which utilize at least two magnetically retentive bodies, each of which has a given magnetic domain orientation, preferably at least one of these bodies is supported by a supporting structure for movement or balance with respect to the other to assume due to its natural magnetic interaction with the other body a monostable position or force interaction providing between the bodies a first magnetic relationship which achieves a first effect which is monostable under the influence of random disturbances. A structure capable of temporarily creating a polarizing magnetic field of sufficient strength is utilized for changing at least one of the above magnetic domain orientations thereby eliminating the first magnetic relationship. After the polarizing magnetic field has been removed, due to the changed magnetic domain orientation one of the bodies can move with respect to the other, due to natural magnetic interaction therewith, to a second monostable magnetic interrelationship, and this latter second monostable positional or force interrelationship is utilized for achieving a second effect. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of Korean Patent Application No. 2000-55577 filed on Sep. 21, 2000, in the Korean Industrial Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to foot measurement systems and methods; and, more particularly, to foot measurement systems and methods to scan someone's foot from the bottom and/or oblique topside directions for generating pixel data for the foot shape, and then to calculate and obtain main foot-dimensions and other information required for last design (for example, shoes design) using the generated pixel data.
2. Description of the Related Art
Generally, there has been known a method for fabrication of shoes or appliances for foot-remedy, in which molds for human feet are made using plaster bandages and the shoes or appliances for foot-remedy are fabricated using the molds with synthetic resins having suitable properties. In a case of fabricating general shoes made to order, a shoes maker draws the bottom outline of orderer's foot in a condition of putting the orderer's foot on a sheet of paper and measures the main sizes for the foot with a ruler. Such tasks are required for extraction of orderer's foot shape. The shoes maker then makes a foot framework fixed to the measured foot sizes to fabricate shoes with using the foot framework.
However, there are some shortcomings in the fabrication of mold by the plaster bandage and the fabrication of the foot-remedy shoes or appliances based on the mold. Namely, it takes a long time for performing the task, which does not allow mass production and may allow only individual fabrication for a particular person so that other persons cannot use the fabricated foot-remedy appliances. Furthermore, in the case of using the touch type foot-dimension's measurement method, the person to be measured should maintain an immobile posture for a long time, otherwise precise measurement cannot be obtained. In spite of the inconvenience, the measured data are not reproducible.
The fabrication of general shoes made to order also has inconveniences that the shoes maker measures orderer 's foot sizes manually and that it takes a long time for the measurement. In spite of the inconveniences, the measurement cannot be precise so that the shoes maker cannot make the most suitable shoes to orderer's feet.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide foot measurement systems and methods to scan someone's foot from the bottom and/or oblique topside directions for generating pixel data for the foot shape, and then to calculate and obtain main foot-dimensions and other information required for last design (for example, shoes design) using the generated pixel data.
In accordance with an embodiment of the present invention, there is provided a foot measurement system comprising: foot data generating means for generating pixel data for foot shape and transmitting them to the exterior, said pixel data being obtained by emitting light to a foot placed on a substrate and analyzing information of the reflected light; and image treatment means for generating foot image through analyzing said pixel data transmitted from said foot data generating means with line-scan algorithm and/or stereo vision algorithm.
Wherein it is preferred that said foot data generating means comprises: an image generating part for generating said pixel data for foot shape through emitting light to said foot and analyzing said information of the reflected light; a foot data memory part for storing said generated pixel data; driving means for moving said image generating part; and a control part for controlling said image generating part, said foot data memory part and said driving part.
Said image generating part may comprise a light generating part (light source) below said substrate, for emitting light to the bottom of said measured foot; and an image sensor or sensors for detecting the light reflected from the bottom of said foot and generating said pixel data, and said driving means may be for moving said image generating part horizontally below said substrate. Said image generating part may also comprise a light generating part obliquely placed over said measured foot, for obliquely emitting light to the top and side surfaces of foot; and an image sensor or sensors for detecting the light reflected from the surface of foot and generating said pixel data, and said driving means may be for rotating said image generating part around said measured foot.
In accordance with another embodiment of the present invention, there is provided a foot measurement method comprising the steps of: emitting light to the bottom of foot and/or the top and side surface of foot and detecting the reflected light with a sensor or sensors; converting said reflected light detected with said sensor(s) into electronic signal and converting said electronic signal into pixel data including image information; generating three-dimensional image coordinates of foot from said pixel data with using a line scan method and/or a stereo vision method; and calculating at least one distance and coordinates for each part of foot from said three-dimensional image coordinates.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and features of the present invention will become apparent from the following description of preferred embodiments given in conjunction with the accompanying drawings, in which:
FIG. 1 shows a device configuration for depicting a foot measurement system according to an embodiment of the present invention.
FIG. 2 is a block diagram for depicting the configuration of a first foot data generating means for generating data for the bottom shape of foot with line-scan manner, in the foot measurement system according to an embodiment of the present invention depicted in FIG. 1 .
FIG. 3 is a block diagram for depicting the configuration of a second foot data generating means for generating data for the three-dimensional shape of the top and side surface of foot with stereo vision manner, in the foot measurement system according to an embodiment of the present invention depicted in FIG. 1 .
FIG. 4 is a drawing for describing a method for calculating foot shape information from the pixel data, in the foot measurement system according to an embodiment of the present invention.
FIG. 5 is a flow chart for describing the operation of a foot measurement method according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will be illustrated in detail by the following preferred embodiments with reference to the accompanying drawings. The embodiments below will explain line-scan manner to generate information for the bottom of foot by scanning the bottom of foot and stereo vision manner to generate information for the three-dimensional shape of top and side surface of foot by scanning the top and side surface of foot with laser line generator. However, the above-mentioned embodiments could be changed and modified by a person having ordinary skill in the art to which the invention pertains. Therefore, the idea and scope of the invention is not limited to the specific line-scan and stereo-vision manners described below, and might include the changes and modifications.
FIG. 1 shows a device configuration for depicting a foot measurement system according to an embodiment of the present invention. FIG. 2 is a block diagram for depicting the configuration of a first foot data generating means for generating data for the bottom shape of foot with line-scan manner, in the foot measurement system according to an embodiment of the present invention depicted in FIG. 1 . FIG. 3 is a block diagram for depicting the configuration of a second foot data generating means for generating data for the three-dimensional shape of the top and side surface of foot with stereo vision manner, in the foot measurement system according to an embodiment of the present invention depicted in FIG. 1 .
As shown in FIG. 1 , the foot measurement system according to the invention may include a first foot data generating means 10 , a second foot data generating means 100 , interface cable 20 , and a computer 30 . The computer 30 is to transmit an instructions signal of foot measurement via the interface cable 20 to the first and second foot data generating means 10 and 100 according to operation of a shoes maker, to receive pixel data for the bottom of foot and the three-dimensional shape of the top and side surface of foot generated from the first and second foot data generating means 10 and 100 , and then to generate information for the shape of foot using the transmitted pixel data for providing the shoes maker or designer with it.
The first foot data generating means 10 may emit light from a light source under a substrate, preferably, a glass substrate 12 formed for that a person to be measured places his or her foot on it to measure the shape of foot. The first foot data generating means 10 may then generate pixel data for the bottom of foot from the reflected light to transmit the pixel data via the interface cable 20 to the external. On the glass substrate 12 is formed an end line 11 , which can be used for matching the heel of the person to be measured to it when the person to be measured places his or her foot on the glass substrate 12 . When the end line 11 is detected with the light emitted from a bottom image generating part 40 , the first foot data generating means 10 becomes to terminate the generation of pixel data for the bottom of foot.
Referred to FIG. 2 , the first foot data generating means 10 may include the bottom image generating part 40 , a foot bottom data memory part 50 , a control part or control unit 60 , a roller driving part (not shown), and a roller 80 . The bottom image generating part 40 comprises a lens 42 , a light source or light generating part 44 and an image sensor 46 .
The bottom image generating part 40 may emit light from the light source or light generating part 44 under the glass substrate 12 to the foot placed on the substrate 12 , and detect the light reflected from the substrate 12 with the image sensor 46 to generate the pixel data for the bottom of foot. The light source or light generating part 44 may be allowed to emit white light or mixed light of Red (R), Green (G) and Blue (B) light to the bottom of the glass substrate 12 . The image sensor 46 can then collect the light reflected from the glass substrate 12 , through the lens 42 . The collected light is converted into electronic signal, and which is then converted into digital signal, the pixel data for the bottom of foot. Therefore, the image sensor 46 may include an A/D converter. The foot bottom data memory part 50 can store the pixel data for the bottom of foot transmitted from the image sensor 46 , according to the control signal inputted from the control part 60 , and transmit the stored pixel data into the computer 30 according to the instruction of the control part 60 .
The control part 60 can also output roller-driving signal for driving the roller 80 in response to the instructions signal for the measurement of foot shape transmitted via the interface cable 20 from the computer 30 . The roller 80 can then move the image generating part 40 along to the direction of the end line 11 in response to the roller-driving signal inputted from the control part 60 .
The second foot data generating means 100 may emit laser line to the top and side surface of foot, and detect the light reflected from the foot to be measured, thereby generating pixel data for the top and side surface of foot. Referred to FIGS. 2 and 3 , the second foot data generating means 100 may include a three-dimensional image generating part 140 , a three-dimensional foot data memory part 150 , a control part or control unit 160 , a CCD cart-movable rail 180 , and a CCD cart-driving motor 190 . The three-dimensional image generating part 140 may comprise a light source or light generating part 144 such as a laser line generator, a lens 142 , and a CCD image sensor 146 . Here, each of the control part 160 and the three-dimensional foot data memory part 150 may be integrated with the control part 60 and the foot bottom data memory part 50 , respectively, or they may be formed separately.
The light generating part 144 performs the function of laser line generator, which emits laser line to the top and side surface of foot to be measured. The CCD image sensor 146 may collect and capture the light reflected from the top and side surface of foot, through the lens 42 . The collected laser line may be then converted into electronic signal, and which may be converted into digital signal, the three-dimensional pixel data for the top and side surface of foot. Therefore, the image sensor 146 may include an A/D converter.
The three-dimensional foot data memory part 150 can store the information for the laser line position, namely the three-dimensional data for foot transmitted from the CCD image sensor 146 according to the control signal inputted from the control part 160 by the operation of computer 30 , and transmit the stored three-dimensional data for foot into the computer 30 .
The control part 160 may output a signal for driving the stepping motor 190 in response to the instructions signal for the measurement of three-dimensional foot shape transmitted from the computer 30 , so that the three-dimensional image generating part 140 can be moved 360 along the clockwise or counter clockwise direction on the CCD cart-movable rail 180 , which is placed on the circumference of the foot to be measured. It is preferred that the three-dimensional image generating part 140 should be moved 360 on the CCD cart-movable rail 180 to be returned to the original position. It is also preferred that the CCD cart-movable rail 180 and the three-dimensional image generating part 140 work together with a three-dimensional measurement software for the treatment of foot image. It is also preferred that the foot image measurement start time and end time of the image generating part 140 are synchronized with the rotating time of the rail 180 .
The computer 30 may receive the pixel data from the foot bottom data memory part 50 and/or the three-dimensional foot data memory part 150 , and perform the function as means for treating the line-scan and/or stereo-vision image to extract main foot dimensions. As shown in FIGS. 2 and 3 , the computer 30 may include outline information output means 32 and/or image treatment means 132 , which can take the pixel data for the bottom of foot during the bottom image generating part 40 are moving linearly, and/or the three-dimensional image data stored during the three-dimensional line image generating part 140 is rotating 360 along the clockwise or counter-clockwise, and perform the reconstruction and rendering of them into the image information for the bottom of foot and/or the top and side surface of foot. The three-dimensional image treatment means 132 depicted in FIG. 3 may be integrated with the outline information output means 32 depicted in FIG. 2 , or be formed separately.
Next, with referring to FIG. 4 will be illustrated an embodiment of method for calculating the image information of foot from the three-dimensional pixel data generated by the second foot data generating means 100 . FIG. 4 is a drawing for describing the use of optical triangle method as an example of principle for three-dimensional measurement. The optical triangle method is a technique for displacement measurement based on the principle of geometrical optics. A coordinate system of the optical triangle method exists within a plane, and two of optical axes are intersected with an angle of θ to the coordinate axis of z. In the principle for the measurement of three-dimensional shape using the optical triangle method applied to the invention, one of the two optical axes is a laser line for forming an optical point on the surface of a body to be measured, and the other is an optical axis of CCD image for collecting the light of image on the optical point. The optical point formed on the body to be measured becomes to move linearly along the laser line according to the relative position of the body to be measured. The optical point is projected on the image coordinates [α (width)×β (length)] of CCD array plane. The CCD then converts the intensity of light into electronic signal, and which is then converted into computer monitor coordinates [N (width)×M (length)] by image grabber. The computer monitor coordinates is extracted to be converted into image coordinates Q (x′,y′) of CCD array to calculate the distance S* from the body to be measured to the CCD with applying the optical triangle method. In order to obtain the tree-dimensional shape of the body to be measured, the CCD rotates 360 with a distance to the body along the circumference of the body, and measures the distance from the body to the CCD at a predetermined rotating angle. After that, the optical point is converted into body coordinates P (x,y,z), which have the center of the body to be measured as the origin of the coordinates.
Now, a more detailed description will be provided with referring to FIG. 4 . The light at a certain point P(x,y,z) of the coordinates of the body is projected on the CCD array image coordinates Q(x′,y′). The image coordinates become to move along the system of image coordinates x′ according to the change of distance from the body to be measured to the CCD. When the focus distance of CCD lens is defined to f, the relation of given body distance s and the image distance s′ is obtained by paraxial optics as the following mathematical formula (1).
1 s ′ = 1 f - 1 s or s ′ = s × f ( s - f ) ( 1 )
The body distance s* from the CCD for a certain point P on the surface of the body is obtained from the geometric relation as the following formula (2).
s*=s−p cos θ (2)
Here, p is a distance from the origin of the coordinates for the point P of the body. The distance q from the origin of the image coordinate system for the image coordinates Q is defined as in the following formula (3) based on the magnification relation of CCD lens.
q p × sin θ = s ′ s * ( 3 )
When the formula (2) is substituted into the formula (3), the relation between the distance p of the laser optical point moved on the track of body and the distance q of the image coordinates corresponded to the distance p is obtained as the following formula (4).
p = q × s ( s ′ × sin θ ) + ( q × cos θ ) ( 4 )
Here, the obtained p is a distance from the origin in the coordinate system of the body to the laser optical point emitted on the surface of body. The coordinate P(x,y,z) of the body may be obtained using this value. When the CCD cart rotates to an angle of φ along the circumference of the body to be measured by the operation of stepping motor, the body coordinate P(x,y,z) obtained by the formula (4) rotates to the angle of φ. Therefore, the model coordinates P M (x m ,y m ,z m ) may be generated by compensating the coordinates with the rotated angle (φ) in the use of the formula (5).
[ x m y m z m ] = [ cos φ 0 - sin φ 0 1 0 sin φ 0 cos φ ] [ x y z ] ( 5 )
Examples for the information of foot calculated by the outline information input means 32 and image treatment means 132 using the pixel data for the bottom of foot and the three-dimensional image of foot may include the followings: Ball Girth; Foot Length, which is a distance from the end point of foot (heel) to the longest toe end; Instep Length, which is a distance from the end point of foot to the inside middle foot point; Fibular Instep Length, which is a distance from the end point of foot to the outside middle foot point; Anterior Foot Length, which is a distance from the longest toe end to the inside middle foot point; Foot Breadth, which is a distance from the inside middle foot point to the outside middle foot point; Heel Breadth, which is a vertical distance to Foot Length on the location distant to the degree of 16% of Foot Length from the end point of foot; Ball Breadth, which is a vertical distance to Foot Length from the inside middle foot point to the outside middle foot point, namely, is a vertical component of Foot Breadth to Foot Length; Ball Flex Angle, which is a foot boundary angle made by the fore and rear parts of foot at a time of walking; Medial Angle, which is a foot boundary angle distinct and made by the anatomical fore and rear parts of foot; Lateral Angle, which is an angle formed between the side of foot and the centerline of foot; Toe V Angel, which is an angle formed between the little toe and the centerline of foot; Toe I Angle, which is an angle formed between the big toe and the centerline of foot; and Little Toe Angle.
A serial port is equipped in the first and second foot data generating means 10 and 100 of the foot measurement system according to the invention, in order to perform communication with the computer 30 . The interface cable 20 , which is a serial port cable, is connected between the serial port and the computer 30 . Therefore, when a shoes maker inputs instructions signal for the measurement of three-dimensional foot shape through the computer 30 , the signal to start the measurement of foot shape may be transmitted to the first and second foot data generating means 10 and 100 through the interface cable 20 , and the light generating parts 44 and 144 may then be driven to emit light mixed with R, G and B and line laser light onto the surface of foot placed on the substrate 12 . The light and laser line projected onto the foot is captured by the image sensors 46 and 146 , and are converted into electronic signals including the image information for the shape of foot, which are stored in the foot data memory parts 50 and 150 . The image information for the shape of foot may then be transmitted to the computer 30 and immediately converted into the final foot information required for the fabrication of shoes and the like. Therefore, the foot measure system according to the invention can measure the foot shape of a person to be measured and provide design data useful to last designers for the fabrication of shoes.
FIG. 5 is a flow chart for describing the operation of a foot measurement method according to an embodiment of the present invention.
As shown in FIG. 5 , first, a foot to be measured is placed on the substrate 12 of the first and second foot data generating means 10 and 100 , and instructions signal for the measurement of foot shape is transmitted from the computer 30 to the control parts 60 and 160 . The control parts 60 and 160 then drive the roller 80 and the motor 190 to move the light generating parts 44 and 144 to a predetermined distance and angle (S 100 ).
At this time, the light generating parts 44 and 144 emit light to the bottom of foot and the top and side surface of foot, respectively, and the image sensors 46 and 146 detect the images of light reflected through the lenses 42 and 142 , respectively (S 120 ). Briefly, the image generating parts 10 and 100 emit laser line light on the foot to be measured at each of predetermined distances and angles, collect the reflected light through the lenses 32 and 142 , and detect the collected light with the sensors 46 and 146 such as CCD array. The lights projected to the sensors 46 and 146 are converted into electronic signals, which are converted into pixel data of foot by image grabber, and which are transmitted to the computer 30 via the interface cable 20 connecting the image generating parts 10 and 100 to the computer 30 (S 140 ).
Then, the outline information output means 30 and the image treatment means 132 embedded in the computer 30 calculates the information for generating three-dimensional image coordinates for foot with using the pixel data for the three-dimensional image of foot transmitted via the interface cable 20 (S 160 ). The three-dimensional image information generated by this procedure is inspected of whether it is valid or not (S 180 ). The validity for the information is determined based on the expected distance from the foot to be measured. At this time, invalid information is discarded and only valid information is taken.
Next, three-dimensional image coordinates are generated with the line-scan method and/or stereo-vision method using the valid information to calculate distances and coordinates for each parts of foot (S 200 ). At this time, it is preferred that the information for the entire foot shape should be produced from a specific number of obtained valid values in the use of interpolation. It is also preferred that a model table consisted of the information for facets to construct a three-dimensional shape of foot and attribute values for the facets should be made using each of the obtained information.
After the coordinates and distances for each parts of foot are calculated, the motor 190 and the roller 80 are driven to determine whether the end line is detected by the image sensor 46 and the image sensor 146 is rotated 360 along the rail 180 , and to perform the procedure for obtaining data for the next locations repeatedly (S 220 ). When all of the information for the bottom surface and the top and side surface of foot are collected during such a procedure, the outline information output means 32 and the three-dimensional treatment means 132 generate the three-dimensional information for the bottom of foot and the top and side surface of foot so as to be used as data for a foot shape in last design (s 240 ).
In the above, there is described a method for measuring a foot shape, in which after data is obtained at a certain location of the specific sensors 46 and 146 , the foot shape is calculated and then the locations of sensors 46 and 146 move to the next location. However, after all of data are obtained at all of the locations of sensors 46 and 146 , the foot shape may be calculated to obtain the required information.
As described above, the present invention is to solve the shortcomings in the prior art that the person to be measured should be maintained at an unnatural state of immobile posture for a long time in order to perform a measurement of foot shape and that the data obtained by the measurement are not reproducible. Further, the present invention can obtain three-dimensional data for a foot shape within a short time by using a computer.
The present invention relates to a three dimensional foot shape measurement system, which is processed by a method for emitting laser line to the foot to be measured, or emitting R, G and B LED, and a method for driving a image CCD using stereo-vision manner in order to measure three-dimensional data for foot for a short time. Therefore, the present invention is economically profitable in the view of facility for transportation and treatment of the foot measurement system, and in the view of the prices of the sensors.
The present invention can also obtain within a short time, the data such as Ball Girth, Ball Breadth, Ball Flex Angle, Medial Angle, Lateral Angle, Toe V Angle, and Toe I Angle, which cannot be obtained by the contact type of measurement system or device used in the prior art.
The present invention can also conveniently measure foot sizes and three-dimensional foot image data of any customers by equipping the measurement system according to the present invention in a store, and provide shoes suitable to the customers by making the shoes in the use of the measured foot shape data.
While the present invention has been described with respect to a certain preferred embodiment only, other modifications and variations may be made without departing from the spirit and scope of the present invention as set forth in the following claims. | There are disclosed foot measurement systems and methods to scan someone's foot from the bottom and/or oblique topside directions for generating pixel data for the foot shape, and then to calculate and obtain main foot-dimensions and other information required for last design (for example, shoes design) using the generated pixel data. The foot measurement system comprises foot data generating means for generating pixel data for foot shape and transmitting them to the exterior, the pixel data being obtained by emitting light to a foot placed on a substrate and analyzing information of the reflected light; and image treatment means for generating foot image through analyzing the pixel data transmitted from the foot data generating means with line-scan algorithm and/or stereo vision algorithm. | 0 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to novel mannobiose derivatives useful as a component modifying pharmaceutical preparations, such as liposomes, having a specific affinity for Kupffer cells of liver.
(2) Prior Art
Recently, organ- or cell-directed preparations have been reported in the pharmaceutical and medical fields. For example, several proposals have been made regarding a technique that a drug is selectively delivered to an objective internal organ or cells by administering the drug encapsulated in liposomes.
One such proposal is found in a report by Szoka, et al. (Biochem. Biophys. Res. Comm., 110, 140-146 (1983)) relating to a liposomal preparation of which target is macrophage cells such as Kupffer cells of the liver.
In this prior art, a fatty acid diester of dimannosylglceride is mixed with liposomal lipid membrane to give the liposomes an affinity for macrophage cells, but the above diester compound is a natural substance isolated from a luteus coccus, so it is difficult to produce the compound industrially. Further, as examples of research using a synthetic substance as a liposome lipid membrane-modifying substance for targeting macrophage cells, typically Kupffer cells of liver, a report by Bachhawat et al. (Biochim. cells of liver, a report by Shen et al. (Biochim. Biophys. Acta, 632, 562-572 (1980)), a report by Shen et. al. (Biochim. Biophys. Acta, 674, 19-29 (1981)), are shown. In the former, a substance obtained by coupling (i) p-aminophenyl-D-mannoside obtained by reduction of p-nitrophenyl-D-mannoside, (ii) phosphatidylethanolamine which is too expensive to obtain as a pure product among natural phospholipids and (iii) glutaraldehyde is used. In the latter report, a compound obtained by linking a hexyl group (--(CH 2 ) 6 --) to a hydroxyl group at the 3-position of cholesterol and further linking the resulting hexyl group to the C1-position of D-mannose through thio group (--S--) is used. Thus, in both methods, compounds having a complicated structure are used and are not useful in view of industrial production, safety after administration to living bodies or the like.
As is seen from the foregoing, though liposomal preparations of which target is macrophage cells, typically Kupffer cells of the liver, have been prepared, the objective efficiency for the targetting and industrial production have not been attained.
SUMMARY OF THE INVENTION
The primary object of this invention is to provide novel substances capable of giving liposome an effective and specific affinity for Kupffer cells of liver, and capable of being produced industrially.
The objective compound of this invention is represented by the general formula [I]: ##STR3## wherein groups of R 1 to R 5 each represents --OH, --OR 6 , --NHR 6 , (R 6 represents an acyl group) or a group represented by the following formula (a), (b), (c), (d) or (e), provided that one of R 1 to R 5 represents --OR 6 or --NHR 6 , one of the other 4 groups of R 1 to R 5 represents one of the groups represented by the formulae (a) to (e), and the remaining 3 groups of R 1 to R 5 represent --OH: ##STR4## wherein represents α or β bond. Liposomes containing a mannobiose derivative of the general formula [I] in its membrane have satisfactorily a specific affinity for the objective cells.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The group represented by the formula (a) is preferable among the groups represented by the formulae (a) to (e), and among the compounds represented by the formula [I], the compound represented by formula [I] wherein R 3 , R 4 or R 5 is the group represented by the formula (a) are preferable.
An acyl group having 12 to 30 carbon atoms may preferably be used as the acyl group in the definition of R 6 , and examples thereof include straight or branched, or saturated or unsaturated acyl groups such as dodecanoyl, tridecanoyl, tetradecanoyl, pentadecanoyl, hexadecanoyl, heptadecanoyl, octadecanoyl, nonadecanoyl, eicosanoyl, heneicosanoyl, docosanoyl, tricosanoyl, tetracosanoyl, hexacosanoyl, triacontanoyl, 9-hexadecenoyl, 9-octadecenoyl, 9,12-octadecadienoyl, 9,12,15-octadecatrienoyl, 11-eicosenoyl, 11,14-eicosadienoyl, 11,14,17-eicosatrienoyl, 4,8,12,16-eicosatetraenoyl, 13-docosenoyl, 4,8,12,15,19-docosapentaenoyl, 15-tetracosenoyl, 2-decanylhexadecanoyl, 2-tetradecylhexadecanoyl, 2-tetradecylhexadecenoyl and 2tetradecenylhexadecanoyl. Eicosanoyl is preferable among them.
Further, the position to which --NHR 6 or --OR 6 is linked in the formula [I] is not specifically limited, but it is generally desirable that R 1 represents --NHR 6 or --OR 6 .
Methods for preparing the mannobiose derivatives represented by the formula [I]are described below.
Compounds of the formula [I] wherein one of R 1 to R 5 represents --OR 6 and compounds of the formula [I] wherein one of R 1 to R 5 represents --NHR 6 are prepared by different methods. Each method is described in detail below.
(1) When one of R 1 to R 5 represents --OR 6 :
Mannobiose, wherein 2 mannoses are linked together, can be used as starting material. Examples of mannobiose include mannopyrasylmannopyranose, etc. such as α-1,6-mannobiose obtained from yeasts, α-1,3-mannobiose obtained from a kind of mushroom and β-1,4-mannobiose. The objective compound can be obtained by reacting one of the above mannobioses with R 6 COX (wherein X means a halogen atom) or (R 6 CO) 2 O in an aqueous solvent or a nonaqueous solvent.
When the above reaction is carried out in an aqueous solvent, R 6 COX or (R 6 CO) 2 O may be added into an aqueous solution containing about 20 to 90% of mannobiose while the pH of the solution is maintained at about 9.0 with an alkali such as sodium hydroxide or potassium hydroxide. R 6 COX or (R 6 CO) 2 O is usually used in an amount of 0.1 to 1 times the molar amount of mannobiose. The reaction is usually carried out at 0 to 60° C., preferably 40 to 50° C. for about 1 to 5 hours.
When the above reaction is carried out in a nonaqueous solvent, R 6 COX or (R 6 CO)hd 2O may be reacted with the mannobiose in the presence of a base in a mixture of (1) a solvent such as acetone, dioxane, chlorobenzene, toluene, ethyl acetate or methylene chloride and (2) a solvent such as hexamethylphosphoric triamide (hereinafter referred to as HMPA) or dimethylsulfoxide. A mixture of toluene and HMPA is preferable among them. The above base includes an organic base such as pyridine, 4-dimethylaminopyridine, or triethylamine and an inorganic base such as sodium hydroxide, pottasium hydroxide, sodium carbonate, potassium carbonate or sodium bicarbonate, preferably pyridine. R 6 COX or (R 6 CO) 2 O is usually used in an amount of 0.2 to 4.0 times, preferably 1.0 to 2.0 times, the molar amount of mannobiose. The base is usually used in an equimolar cr molar excess amount to the amount of R 6 COX or (R 6 CO) 2 O. The reaction is usually carried out at 60 to 100° C., preferably at 70 to 90° C. for 2 to 6 hours.
When the product is a mixture of mannobiose monofatty acid esters wherein linking positions of the fatty acid ester are different, it can be used without separating to prepare the objective liposome preparation. Usually, the mixture is separated by separating method such as column chromatography to obtain a mannobiose monofatty acid ester in the form of single component.
The method of Roulleau et al. (Tetrahedron Letters 24, 719-722 (1983)) may be used in order to selectively link an acyl group to the hydroxyl group at the 1-position of the reducing end mannose of mannobiose to form an ester bond. That is, a mannobiose monofatty acid ester wherein the acyl group, is linked to the hydroxyl group at the C1-position of the reducing end mannose of mannobiose may be prepared by reacting (i) a reactive acylating agent such as an amide compound obtained by reaction of a desired R 6 COOH with thiazolidinethione or an ester compound obtained by reaction of the R 6 COOH with p-nitropherol, mercaptobenzothiazole, 8-hydroxyguinoline or the like, for example N-eicosanoylthiazolidinethione, p-nitrophenyl eicosanoate, mercaptobenzothiazolyl eicosanoate, 8-eicosanoyl-oxyquinoline or the like, with (ii) a mannobiose (excluding α-D-mannopyranosyl-α-D-mannopyranoside and α-D-mannopyranosyl-β-D-mannopyranoside) in the presence of a base. Examples of the base used in the reaction include potassium hydride, sodium hydride, etc., preferably sodium hydride. Amount of the base is, preferably 0.8 to 1.2 times the molar amount of the acylating agent. Preferred examples of a reaction solvent include pyridine, methylpyrrolidone, dimethylsulfoxide, hexamethylphosphoric triamide, etc. The amount of the reaction solvent is not particularly limited, may be 5 to 50 times the amount of mannobiose. Further, the amount of the acylating agent may be 0.1 to 1.0 times, preferably 0.2 to 0.5 times the molar amount of mannobiose. When the acylating agent is ar amide compound obtained by reaction of R 6 COOH with thiazolidinethione or an ester compound obtained by reaction of R 6 COOH with mercaptobenzothiazole, 8-hydroxyquinoline or the like, the reaction may be carried out at 10 to 60° C., preferably 20 to 40° C. for about 1 to 5 hours. When the acylating agent is an ester compound obtained by reaction of R 6 COOH with p-nitrophenol, the reaction may be carried out at 40 to 90 ° C., preferably 60 to 80° C. for 1 to 5 hours.
(2) When one of R 1 to R 5 is --NHR 6 :
Hydroxyl groups of mannobiose as a starting compound are protected by proper protective groups such as a benzylidene group and an acetyl group, and then a hydroxyl group is replaced by an amino group at a desired position of the resulting compound according to a known method. The resulting compound is reacted with R 6 COOH in the presence of a condensing agent in a proper organic solvent to link the acyl group to the amino group. Examples of the solvent include tetrahydrofuran, dimethylformamide, dichloromethane, ethyl acetate, methanol, ethanol, benzene, and a mixture thereof, and the like. The amount of the solvent is not particularly limited, and may be 10 to 100 times the weight of the starting compound. Examples of the condensingagent include N,N'-dicyclohexylcarbodiimide (DCC), N-ethyl-5-phenylisoxazolium-3'-sulfonate, diphenylketene-p-tolylimine, 1-ethoxycarbonyl-2-ethoxy-1,2-dihydroquinoline (EEDQ), N-isobutyloxycarbonyl-2-isobutyloxy-1,2-dihydroquinoline (IIDQ), diethylphosphorocyanidate (DEPC), and so on. The amount of the condensing agent may properly be selected and varied, and for example, may be 1 to 3 moles per 1 mole of the starting compound. Further, the amount of R 6 COOH may be 1 to 3 moles per 1 mole of the starting compound. The reaction may be carried out at -10 to 50° C., preferably at 0 to 30° C. for 2 to 72 hours.
The resulting compound may be treated with an alkali such as sodium alkoxide (e.g., sodium methoxide), ammonia or triethylamine in a polar solvent such as, methanol or ethanol or in a mixture thereof, or a mixture of the above solvent and chloroform to prepare a desired compound. The reaction may be carried out at 0 to 40° C. for 1 to 10 hours.
After the reaction, the objective compound may, if necessary, be separated and purified by utilizing known separating and purifying methods such as removal of solvent, crystallization and column chromatography.
A compound wherein the hydroxyl group at the C1-position of the reducing end mannose of mannobiose is replaced by an acylamino group may be prepared in the following manner. Hydroxyl groups of mannobiose are protected with acetyl groups, and the acetyloxy group at the C1-position of the reducing end mannose of mannobiose is replaced by a bromine atom. The resulting compound is then reacted with an azide salt to replace the bromine atom by an azido group, followed by reduction to obtain a mannobiosylamine wherein the hydroxyl group at the C1-position of the reducing end mannose of mannobiose is replaced by an amino group. An acyl group is linked to the amino group using the above active ester method, and then the protective groups bonding to the hydroxyl groups other than that of the desired position are removed using an alkali such as sodium methoxide to prepare the objective N-acyl-mannobiosylamine wherein the hydroxyl group at the C1-position of the reducing end mannose of mannobiose is replaced by an acylamino group.
Further, a compound wherein the hydroxyl group at the C2-position of the reducing mannose or the nonreducing end mannose of mannobiose is replaced by an acylamino group may be prepared as follows. That is, mannosamine and mannose are condensed using a known condensing reaction, and the resulting mannopyranosyl-mannosamine or 2-deoxy-2-amino-mannopyranosylmannopyranose is reacted with R 6 COOH using the above active ester method to obtain the objective compound.
Next, a method for preparing a liposome which contains a compound of the invention in liposomal membrane is described below.
An aqueous dispersion of liposomes is prepared using membrane components such as a phospholipid (e.g., phosphatidylcholine, sphingomyelin or phosphatidylethanolamine), a glycolipid, a dialkyl (double-chain) amphiphiles according to a known method (Annual Review of Biophysics and Bioengineering, 9, 467-508 (1980)). The liposomes may further contain a membrane stabilizer such as a sterol (e.g., chlesterol or chlestanol), a charged modifier such as a dialkyl phosphate, a diacylphosphatidic acid or stearylamine, and an antioxidant such as α-tocopherol in the membrane. An aqueous solution of a compound of the formula [I] is added to the thus prepared aqueous dispersion of liposomes, and the mixture is allowed to stand for a certain time, preferably under warming to or above the phase transition temperature of the membrane, or above 40° C., and then allowed to cool to prepare objective liposomes. The liposomes may also be prepared by mixing a compound of the formula [I] with membrane components, and treating the mixture according to a known method to prepare the liposomes.
In order to give the liposome an affinity for the aforesaid Kupffer cells of liver, it is preferable that the ratio of the compound of the invention to the total lipid membrane components is about 1/40 mole ratio or more in a preparation step thereof.
Liposomes containing a compound of the invention in its membrane have a specific affinity for not only Kupffer cells of the liver but also macrophages, monocytes, spleen cells, lymphocytes and aleolar macrophages. Therefore, the compounds of the invention are important as a component modifying liposomes.
Further, the compounds of the invention may give such affinity not only to the liposomes but also to micells and microemulsions.
The invention is further described below according to examples, but should not be interpreted to be limited thereto.
EXAMPLE 1
400 mg of 2-O-α-D-mannopyranosyl-D-mannopyranose was dissolved in 1 ml of water, and an aqueous 10% sodium hydroxide solution was added thereto to adjust the pH to 9.0. Then, 277 mg of arachidyl chloride prepared from arachidic acid and thionyl chloride was added by portions at 50° C. while the reaction pH was maintained at 9.0 with an aqueous 10% sodium hydroxide solution, and stirred at the same temperature for one hour.
After the reaction, the formed precipitate was collected by filtration and recrystallized from methanol. The resulting crystalline substance was twice purified by silica gel column chromatography (Solvent system; chloroform/methanol =30/1 to 5/1) to obtain a mixture of monoeicosanoic acid esters of 2-O-α-D-mannopyranosyl-D-mannopyranose.
Yield ; 50 mg,
TLC ; Rf value 0.5 or less (mixture) . (CHCl 3 /MeOH=2/1).
Elementary analysis as C 32 H 60 O 12 (Molecular weight 636.49);,. Calculated(%), C 60.38, H 9.43, 0 30.15, Found(%), C 60.75, H 10.05, 0 29.20.
IR(KBr); 2845, 2910, 1465 (CH), 1730 (--CO--O--)
1 H-NMR (90 MHz, CDCl 3 /TMS); δ0.7-1.40 (39H, Eicosanoyl), 2.8-4.0 (21H, Mannobiose ring protons),
EXAMPLE 2
400 mg of 4-0-8-D-manncpyranosyl-D-mannopyranose was dissolved in 8 ml of hexamethylphosphoric triamide (HMPA), and 8 ml of pyridine was added. Then, 730 mg of arachidyl chloride separately prepared from arachidic acid and thionyl chloride was dissolved in 1.5 ml of toluene, and added to the above reaction solution at 30° C. or less, and stirred at 80 to 85° C. for about 4 hours to conduct the reaction.
After the reaction, the reaction solution was concentrated under reduced pressure, and the resulting syrup was twice purified by silica gel column chromatography (solvent system; chloroform/acetone=30/1 to 5/1) to obtain a mixture of monoeicosanoic acid esters of 4-O-β-D-mannopyranosyl-D-mannopyranose (4 components).
Yield ; 447 mg
TLC ; Rf value 0.5 or less (4 components mixture) (CHCl 3 /MeOH=2/1)
IR(KBr); 2845, 2910, 1465 (CH), 1730 (--CO--O--)
Elementary analysis as C 32 H 60 O 12 (Molecular weight 636.49), Calculated(%), C 60.38, H 9.43, 0 30.15, Found(%), C 60.50, H 9.94, 0 29.56 .
1 H-NMR (90 MHz, CDCl 3 /TMS); δ0.7-1.40 (39H, Eicosanoyl), 2.8-4.0 (21H, Mannobiose ring protons)
EXAMPLE 3
300 mg of the mixture obtained in Example 2 was fractionated by silica gel chromatography (Solvent system; chloroform/methanol 10/1 to 7/1), followed by powdering from chloroform/methanol (1/1) and ether to obtain 4-O-(6-O-eicosanoyl-β-D-mannopyranosyl)-D-mannopyranose wherein eicosanoic acid is linked to the hydroxyl group at the C 6 '-position by ester bond.
Yield ; 126 mg.
Decomposition point; 152-158° C..
TLC ; Rf=0.50 (CHCl 3 /MeOH=2/1).
IR(KBr); 2845, 2910, 1465 (CH), 1730 (--CO---O-).
Elementary analysis as C 32 H 60 O 12 (Molecular weight 636.49); Calculated(%), C 60.38, H 9.43, 0 30.15, Found(%), C 60.28, H 9.82, 0 29.90 .
1 H-NMR (90 MHz, DMSO-d 6 /TMS);δ0.7-1.40 (39H, Eicosanoyl), 2.8-4.0 (21H, Mannobiose ring protons).
13 C-NMR (90 MHz, DMSO-d6/TMS); δ173.0, 100.9, 100.8, 938, 77.9, 74.2, 73.2, 71.0, 70.6, 70.4, 69.0, 66.9, 63.7, 60.6.
EXAMPLE 4
After elution of 4-O-(6-O-eicosanoyl-δ-D-mannopyranosyl)-D-mannopyranose of Example 3, elution was further continued with chloroform/methanol (5/1 to 1/1) to obtain a mixture of 6-O-eicosanoyl-4-O-δ-1-mannopyranosyl-D-mannopyranose, 4-O-(3-O-eicosanoyl-δ-D-mannopyranosyl)-D-mannopyranose and 2-O-eicosanoyl-4-O-δ-D-mannopyranosyl-D-mannopyranose wherein an eicosanoic acid is linked to the hydroxyl group at the C 6 -, C 3 '- and C 2 -positions, respectively.
Yield ; 108 mg.
Decomposition point; 148-152° C.
TLC ; Rf=0.12 (3 components) (CHCl 3 /MeOH=2/1).
IR(KBr); 2845, 2910, 1465 (CH), 1730 (--CO--0--)
Elementary analysis as C 32 H 60 O 12 (Molecular weight 636.49);, Calculated(%), C 60.38, H 9.43, O 30.15, Found(%), C 60.67, H 9 73, O 29.60.
1 H-NMR (90 MHz, DMSO-d6/TMS); δ0.7-1.40 (39H, Eicosanoyl), 2.8-4.0 (Mannobiose ring protons).
13 C-NMR (90 MHz, DMSO-d 6 /TMS); δ173.0, 172.9, 172.8, 103.1, 102.6, 96.4, 81.4, 79.1, 77.4, 74.3, 73.6, 73.3, 71.1, 70.7, 70.5, 70.3, 69.1, 67.5, 67.0, 65.1, 63.9, 63.7, 61.1, 61.0.
EXAMPLE 5
300 mg of 4-O-δ-D-mannopyranosyl-D-mannopyranose was dissolved in 6 ml of HMPA, and 6 ml of pyridine was added thereto. Separately, 365 mg of myristoyl chloride prepared from myristic acid and thionyl chloride was dissolved in 1 ml of toluene, and the solution was added to the above reaction solution at 30° C. or less, and the mixture was subjected to reaction at 80 to 85° C. for 4 hours with stirring. After the reaction, the reaction solution was concentrated under reduced pressure, and the resulting syrup was twice purified by silica gel chromatography (Solvent system; chloroform/methanol=30/1 to 5/1) to obtain a mixture of monomyristic acid esters of 4-O-δ-D-mannopyranosyl-D-mannopyranose.
Yield ; 237 mg.
TLC ; Rf value 0.48 or less (mixture), (CHCl 3 /MeOH=2/1).
IR(KBr); 2845, 2910, 1465 (CH), 1730 (--CO--O--).
Elementary analysis as C 26 H 48 O 12 (Molecular weight 552.43); Calculated(%), C 56.52, H 8.69, 0 34.73 Found(%) , C 56.74, H 9.97, 0 33.29.
1 H-NMR (90 MHz, CDCl 3 /TMS); δ0.7-1.40 (27H, Myristoyl), 2.8-4.0 (Mannobiose ring protons).
EXAMPLE 6
150 mg of the mixture of monomyristic acid esters of mannobiose obtained in Example 5 was further twice fractionated by silica gel chromatography (Solvent system; chloroform/methanol=5/1 to 3/1) to obtain 6-O-myristoyl-4-O-δ-D-mannopyranosyl-D-mannopyranose wherein myristic acid is linked to the hydroxyl group at the C 6 -position by ester bond.
Yield ; 32 mg.
TLC ; Rf value 0.15 (CHCl 3 /MeOH=2/1).
IR(KBr); 2845, 2910, 1465 (CH), 1730 (--CO--O--).
Elementary analysis as C 26 H 48 O 12 (Molecular weight 552.43); Calculated(%), C 56.52, H 8.69, 0 34.73, Found(%), C 56.22, H 9.01, 0 34.77.
1 H-NMR (90 MHz, CDCl 3 /TMS); δ0.7-1.40 (27H, Myristoyl), 2.8-4.0 (Mannobiose ring protons).
13 C-NMR (90 MHz, DMSO-d 6 /TMS); δ173.1, 100.9, 95.8, 92.4, 77.7, 77.4, 73.6, 70.7, 70.6, 70.1, 69.1, 67.0, 63.5, 61.4.
EXAMPLE 7
The procedure in Example 5 was repeated using 449 mg of stearoyl chloride in place of 365 mg of myristoyl chloride to obtain a mixture of monostearic acid esters of 4-O-δ-D-mannopyranosyl-D-mannopyranose.
Yield ; 267 mg.
TLC ; Rf value 0.51 or less (mixture) (CHCl 3 /MeOH=2/1).
IR(KBr); 2845, 2910, 1465 (CH), 1730 (--CO--O--).
Elementary analysis as C 30 H 56 O 12 (Molecular weight 608.47); Calculated(%), C 59.21, H 9.20, O 31.53, Found(%), C 59.11, H 9.11, O 31.78.
1 H-NMR (90 MHz, CDCl 3 /TMS); δ0.7-1.4 (35H, Stearoyl), 2.8-4.0 (Mannobiose ring protons).
EXAMPLE 8
The procedure of Example 5 was repeated using 530 mg of behenoyl chloride in place of 365 mg of myristoyl chloride to obtain a mixture of monobehenic acid esters of 4-O-δ-D-mannopyranosyl-D-mannopyranose.
Yield ; 262 mg.
TLC ; Rf value 0.51 or less (mixture) (CHCl 3 /MeOH=2/1).
IR(KBr); 2845, 2910, 1465 (CH), 1730 (--CO--O--).
Elementary analysis as C 34 H 64 O 12 (Molecular weight 664.51); Calculated(%), C 61.45, H 9.63, 0 28.88, Found(%), C 61.30, H 9.99, 0 28.71.
1 H-NMR (90 MHz, CDCl 3 /TMS); δ0.7-1.41 (43H, Behenoyl), 2.8-4.0 (21H, Mannobiose ring protons).
REFERENCE EXAMPLE 1
4-O-(2,3,4,6-Tetra-O-acetyl-δ-D-mannopyranosyl)-2,3,6-tri-O-acetyl-D-mannopyranosylamine (hereinafter referred to as compound A).
16 ml of pyridine and 10 ml of acetic anhydride were added to 2 g of 4-O-δ-D-mannopyranosyl-D-mannopyranose, and stirred at room temperature overnight. The product was treated in a conventional manner to obtain 3.98 g of 4-O-(2,3,4,6-tetra-O-acetyl-δ-D-manncpyranosyl)-1,2,3,6-tetra-O- acetyl-D-mannopyranose as white powder. This compound was dissolved in 20 ml of dichloromethane, and 20 ml of a hydrogen bromide-saturated acetic acid solution (30%, w/v) was added thereto under ice cooling, followed by stirring at 0° C. for 15 hours. The reaction solution was poured into ice water and extractad with chloroform. The extract was washed successively with ice water and with ice-cooled aqueous sodium bicarbonate, and dried over anhydrous magnesium sulfate. The solution is concentrated to obtain 3.97 g of 4-O-(2,3,4,6-tetra-O-acetyl-δ-D-mannopyranosyl)-2,3,6-tri-O-acetyl-D-mannopyranosyl bromide. Then, 3.97 g of this compound was dissolved in 80 ml of dimethylformamide, and 8.0 g of sodium azide was added, followed by stirring overnight. The reaction mixture was poured into ice water and extracted with chloroform. The extract was washed successively with ice water, 5% aqueous hydrochloric acid and ice-cooled aqueous sodium bicarbonate, and dried to obtain 3.84 g of crude 4-O-(2,3,4,6-tetra-O-acetyl-δ-D-mannopyranosyl)-2,3,6-tri-O-acetyl-D-mannopyranosyl azide. This compound was purified by silica gel chromatography (Solvent system; chloroform/acetone=30/1) to obtain 2.98 g of 4-O-(2,3,4,6-tetra-O-acetyl-δ-D-mannopyranosyl)-2,3,6-tri-O-acetyl-D-mannopyranosyl azide. Then, 2.88 g of this azide compound was dissolved in 140 ml of methanol and subjected to a catalytic reduction in the presence of 300 mg of platinum dioxide for 2.0 hours. The catalyst was removed by filtration using Celite, and the filtrate was concentrated to obtain 2.57 g of amorphous entitled compound A.
TLC; Rf value 0.3 (chloroform:ethanol=19:1).
REFERENCE EXAMPLE 2
N-Eicosanoyl-4-O-(2,3,4,δ -tetra-O-acetyl- 67 -D-mannopyranosyl)-2,3,6-tri-O-acetyl-D-mannopyranosylamine.
580 mg of compound A obtained in Reference example 1 was dissolved in 25 ml of ethanol, and a solution of 627 mg of arachidic acid dissolved in 30 ml of benzene was added. Then, 494 mg of N-ethoxycarbonyl-2-ethoxy-1,2-dihidroquinoline (EEDQ) was further added thereto, followed by stirring at room temperature for 48 hours. The reaction solution was cooled, the precipitated unreacted arachidic acid was removed by filtration, and the filtrate was concentrated. The resulting residue was purified by silica gel chromatography (Solvent system; chloroform:acetone (30:1)) to obtain the entitled compound as white powder.
Yield ; 696 mg.
TLC ; Rf value =0.45 (chloroform:acetone =6:1).
1 H-NMR (90 MHz, CDCl 3 /TMS); 6 0.81-1.60 (39H, Eicosanoyl), 1.97-2.20 (21H, all S, OAc x 7) 6.22 (d, 1H, J NH , 1 =9Hz, NH).
IR(KBr); 3300 (NH), 1750 (OAc), 1660 (amido I), 1540 (amido II).
Elementary analysis as C 46 H 75 O 18 N (Molecular weight 930.10); Calculated, C 59.40, H 8.13, N 1.51% Found, C 59.60, H 8.25, N 1.39%.
EXAMPLE 9
N-Eicosanoyl-4-O-δ-D-mannopyranosyl-δ-D-mannopyranosylamine 550 mg of the compound obtained in Reference example 2 was dissolved 40 ml of chloroform and 80 ml of methanol, and 40 mg of sodium methylate was added, followed by stirring at room temperature for 6 hours. The resulting precipitate was separated by filtration and thoroughly washed with methanol and ether to obtain the entitled compound.
Yield ; 240 mg.
mp ; 194-200° C.
1 H-NMR (90 MHz DMSO-d 6 /TMS); 0.80-1.50 (39H, Eicosanoyl), 4.60 (d, 1H, J NH , 1 =10Hz, NH).
IR(KBr); 3400-3300 (OH, NH), 1650 (amido I), 1530 (amido II).
Elementary analysis as C 32 H 61 O 11 (Molecular weight 635.83); Calculated, C 60.45, H 9.67, N 2.20% Found, C 60.25, H 9.57, N 2.15%.
REFERENCE EXAMPLE 3
N-Lauroyl-4-O-(2,3,4,6-tetra-O-acetyl-δ-D-mannopyranosyl)-2,3,6-tri-O-acetyl-D-manncpyranosylamine
Compound A (390 mg) was treated in the same manner as in Reference example 2 except that 627 mg of arachidic acid was replaced by 270 mg of lauric acid to obtain the entitled compound.
Yield ; 465 mg.
TLC ; Rf value =0.44 (chloroform:acetone=6:1).
1 H-NMR (90 MHz, CDCl 3 /TMS); 0.80-1.60 (23H, Laurcyl) 1.97-2.21 (21H, all S, OAc x 7) 6.22 (d, 1H, J NH , 1 =9Hz, NH).
IR(KBr); 3300 (NH), 1750 (OAc), 1660 (amido I), 1540 (amido II).
Elementary analysis as C 38 H 59 O 18 (Molecular weight 817.87); Calculated, C 55.81, H 7.27, N 1.71% Found, C 55.60, H 7.38, N 1.58%.
EXAMPLE 10
N-Lauroyl-4-O-δ-D-mannopyranosyl-D-mannopyranosylamine
360 mg of the compound as obtained in Reference example 3 was dissolved in 25 ml of anhydrous methanol, 25 mg of sodium methylate was added, and then the same procedure as in Example 9 was conducted to obtain the entitled compound.
Yield ; 158 mg.
1 H-NMR (90 MHz, DMSO-d 6 /TMS); δ0.80-1.50 (23H, Lauroyl) 4.60 (d, 1H, J NH , 1 =10Hz, NH).
IR(KBr); 3400-3300 (OH, NH), 1650 (amido I), 1530 (amido II).
Elementary analysis as C 24 H 45 O 11 N (Molecular weight 523.61); Calculated, C 55.05, H 8.66, N 2.68% ., Found, C 54.82, H 8.72, N 2.67%.
REFERENCE EXAMPLE 4
N-Myristoyl-4-O-(2,3,4,6-tetra-O-acetyl-δ-D-mannopyranosyl)-2,3,6-tri-O-acetyl-D-xannopyranosylamine
Compound A (390 mg) was treated in the same manner as in Reference example 2 except that 627 mg of arachidic acid was replaced by 315 mg of myristic acid to obtain the entitled compound.
Yield ; 458 mg.
TLC ; Rf value =0.43 (chloroform:acetone=6:1).
1 H-NMR (90 MHz, CDCl 3 /TMS); δ0.80-1.60 (27H, Myristoyl); 1.97-2.22 (21H, all S, OAc x 7) ; 6.22 (d, 1H, J NH , 1 =9Hz, NH).
IR(KBr); 3300 (NH), 1750 (OAc), 1665 (amido I), 1540 (amido II).
Elementary analysis as C 40 H 63 O 18 N (Molecular weight 845.93); Calculated, C 56.79, H 7.51, N 1.66% Found, C 56.38, H 7.71, N 1.58%.
EXAMPLE 11
N-Myristoyl-4-O-δ-D-mannopyranosyl-D-mannopyranosylamine
360 mg of the compound obtained in Reference example 4 was dissolved in 25 ml of anhydrous methanol, 25 mg of sodium methylate was added, and then the same procedure as in Example 9 was conducted to obtain the entitled compound.
Yield ; 175 mg.
1 H-NMR (90 MHz, DMSO-d 6 /TMS); δ0.80-1.50 (27H, Myristoyl) 4.60 (d, 1H, J NH , 1 =10Hz, NH).
IR(KBr); 3400-3300 (OH, NH), 1650 (amido I), 1530 (amido II).
Elementary analysis as C 26 H 49 O 11 N (Molecular weight 551.67); Calculated, C 56.61, H 8.95, N 2.54% Found, C 56.88, H 8.77, N 2.48%.
REFERENCE EXAMPLE 5
N-Palmitoyl-4-O-(2,3,4,6-tetra-O-acetyl-δ-D-mannopyranosyl)-2,3,6-tri-O-acetyl-D-xannopyranosylamine
Compound A (390 mg) was treated in the same manner as in Reference example 2 except that 627 mg of arachidic acid was replaced by 364 mg of palmitic acid to obtain the entitled compound.
Yield ; 480 mg.
TLC ; Rf value =0.45 (chloroform:acetone =6:1).
1 H-NMR (90 MHz, CDCl 3 /TMS); δ0.80-1.60 (31H, Palmitoyl), 1.97-2.22 (21H, all S, OAc x 7), 6.22 (d, 1H, J NH , 1 =9Hz, NH).
IR(KBr); 3300 (NH), 1750 (OAc), 1660 (amido I), 1540 (amido II).
Elementary analysis as C 42 H 67 O 18 N (Molecular weight 873.98); Calculated, C 57.72, H 7.73, N 1.60% Found, C 57.82, H 7.32, N 1.68%.
EXAMPLE 12
N-Palmitoyl-4-O-(δ-D-mannopyranosyl)-D-mannopyranosylamine
360 mg of the compound obtained in Reference example 5 was dissolved in 25 ml of anhydrous methanol, 25 mg of sodium methylate was added, and a procedure similar to that in Example 9 was conducted to obtain the entitled compound.
Yield ; 160 mg.
1 H-NMR (90 MHz, DMSO-d 6 /TMS); δ0.80-1.52 (31H, Palmitoyl) 4.60 (d, 1H, J NH , 1 =10Hz, NH).
IR(KBr); 3400-3300 (OH, NH), 1650 (amido I), 1530 (amido II).
Elementary analysis as C 28 H 53 O 11 N (Molecular weight 579.72); Calculated, C 58.01, H 9.21, N 2.42% Found, C 58.18, H 9.50, N 2.32%.
REFERENCE EXAMPLE 6
N-Stearoyl-4-O-(2,3,4,6-tetra-O-acetyl-δ-D-mannopyranosyl)-2,3,6-tri-O-acetyl-D-mannopyranosylamine
Compound A (390 mg) was treated in the same manner as in Reference example 2 except that 672 mg of arachidic acid was replaced by 383 mg of stearic acid to obtain the entitled compound.
Yield ; 472 mg.
TLC ; Rf value=0.45 (chloroform:acetone=6:1).
1 H-NMR (90 MHz, CDCl 3 /TMS); δ0.80-1.60 (35H, Stearoyl) ; 1.97-2.22 (21H, all S, OAc x 7) 6.22 (d, 1H, J NH , 1 =9Hz, NH).
IR(Br); 3300 (NH), 1750 (OAc), 1660 (amido I), 1540 (amido II).
Elementary analysis as C 44 H 71 O 18 N (Molecular weight 902.04); Calculated, C 58.59, H 7.93, N 1.55% Found, C 58.63, H 8.02, N 1.70%.
EXAMPLE 13
N-Stearoyl-4-O-δ-D-mannopyranosyl-D-mannopyranosylamine
360 mg of the compound as obtained in Reference example 6 was dissolved in 25 ml of anhydrous methanol, 25 mg of sodium methylate was added, and then the same procedure as in Example 9 was conducted to obtain the entitled compound.
Yield ; 192 mg.
1 H-NMR (90 MHz, DMSO-d 6 /TMS); δ0.80-1.50 (35H, Stearoyl) 4.60 (d, 1H, J NH , 1 =10Hz, NH).
IR(KBr); 3400-3300 (OH, NH), 1650 (amido I), 1530 (amido II).
Elementary analysis as C 30 H 57 O 11 N (Molecular weight 607.78); Calculated, C 59.29, H 9.45, N 2.30% Found, C 59.42, H 9.58, N 2.58%.
REFERENCE EXAMPLE 7
N-Oleoyl-3-O-(2,3,4,6-tetra-O-benzoyl-δ-D-mannopyranosyl)-2,4,6-tri-O-benzoyl-1-deoxy-1-N-oleoyl-D-mannopyranosylamine
3-O-α-D-mannopyranosyl-D-mannopyranose (500 mg) was treated in the same manner as in Reference example 1 except 10 ml of acetic acid was replaced by 3.2 ml of benzoyl chloride to obtain 410 mg of 3-O-(2,3,4,6-tetra-O-benzoyl-α-D-mannopyranosyl)-2,4,6-tri-O-benzoyl-D-mannopyranosylamine.
Then, 410 mg of the amine compound was treated in the same manner as in Reference example 2 except that 627 mg of arachidic acid was replaced by 403 mg of oleic acid to obtain the entitled compound.
Yield ; 380 mg.
TLC ; Rf value=0.43 (chloroform:acetone=6:1);
1 H-NMR (90 MHz, CDCl 3 /TMS); δ0.80-1.60 (33H, Oleoyl) 6.22 (d, 1H, J NH , 1 =9Hz, NH) 7.2-8.3 (35H, Bz x 7).
IR(KBr); 3300 (NH), 1750 (OBz), 1660 (amido I), 1540 (amido II).
Elementary analysis as C 81 H 89 O 18 N (Molecular weight 1364.59); Calculated, C 71.30, H 6.57, N 1.03% Found, C 71.12, H 6.87, N 0.98%.
EXAMPLE 14
N-Oleoyl-3-O-α-D-mannopyranosyl-D-mannopyranosylamine
The compound (360 mg) as obtained in Reference example 7 was dissolved in 25 ml of anhydrous methanol, 25 mg of sodium methylate was added, and then the same procedure as in Example 9 was conducted to obtain the entitled compound.
Yield ; 102 mg.
1 H-NMR (90 MHz, DMSO-d 6 /TMS); δ0.80-1.50 (33H, Oleoyl) 4.60 (d, 1H, J NH , 1 =10Hz, NH).
IR(KBr); 3400-3300 (OH, NH), 1650 (amido I), 1535 (amido II).
Elementary analysis as C 30 H 55 O 11 N (Molecular weight 605.76); Calculated, C 59.48, H 9.15, N 2.31% Found, C 59.62, H 9.43, N 2.22%.
EXAMPLE 15
(1) Preparation of liposomes I (containing a compound of the invention)
First, 8.8 μmol of yolk phosphatidylcholine, 5.6 μmol of cholesterol, 0.8 μmol of dicetyl phosphate, and 0.8 μmol or 1.6 mol of one of the mannobiose derivatives of the invention as shown below were dissolved in a mixture of chloroform and methanol (volume ratio 2:1) in a test tube with warming. Then, the organic solvents were removed by a nitrogen gas stream to form a lipid film on the glass wall of the test tube. Then, 3.2 ml of phosphate-buffered physiological saline (pH 7.4, hereinafter abbreviated as PBS) was added thereto, and the mixture was shaken and then subjected to mild ultrasonication to prepare a liposome suspension. The suspension was warmed to 40 to 45° C. and entruded through a polycarbonate membrane filter having a pore size of 0.2 μm to prepare a suspension of liposomes having a particle size of 0.2 μm or less. Then, 1 ml of the suspension was subjected to gel filtration chromatography (Column: Sepharose CL-4B, 1.5 cmφ×15 cm, eluting solution: PBS (pH 7.4)) to further obtain 6.5 ml of a fraction as a liposome fraction which was eluted in the void volume. The lipid in this liposome fraction was quantitatively determined by an enzymatic method using the choline group of yolk phosphatidylcholine as a marker, and the liposome fraction was diluted with PBS (pH 7.4) so that the concentration of total lipids therein became 0.5 μmol/ml. The obtained liposomes and the used mannobiose derivatives is shown below.
______________________________________Liposome No. Mannobiose derivative Used amount______________________________________I-1 Compound of Example 3 1.6 μmolI-2 Compound of Example 4 0.8 μmolI-3 Compound of Example 4 1.6 μmolI-4 Compound of Example 9 0.8 μmolI-5 Compound of Example 9 1.6 μmol______________________________________
(2) Preparation of liposomes II (control)
The same treatment as in the above item (1) was conducted except that 8.8 u mol of yolk phosphatidylcholine, 5.6 μmol of cholesterol and 0.8 μmol of dicetyl phosphate were dissolved in a mixture of chloroform and methanol and the amount of PBS (pH 7.4) to be added to the lipid film was 2.88 ml to obtain 6.2 ml of liposome fraction after gel filtration per 1 ml of the liposome suspension. The whole fraction was diluted so that the total lipid concentration therein became 0.5 μmol/ml.
(3) Preparation of liposomes III (containing a compound of the invention)
72.4 μmol of L-α-dimyristoyl-phosphatidylcholine, 72.4 μmol of cholesterol, 7.2 μmol of dicetyl phosphate, and 8 or 16 μmol of one of the mannobiose derivatives of the invention as shown below were dissolved in a mixed solvent of chloroform and methanol (volume ratio 2:1) in a test tube with warming. The organic solvent was removed by a nitrogen gas stream to form a lipid film on the glass wall. Then, 6 ml of a solution of 1 mM inulin in PBS (pH 7.4) containing 240 μCi of 3H-inulin was added thereto, and the mixture was shaken and further subjected to mild ultrasonication to prepare a liposome suspension. The suspension was warmed to 40 to 45° C., and extruded through a polycarbonate membrane filter having a pore size of 0.2 μm to prepare a suspension of liposomes having a particle size of 0.2 μm or less. Then, the suspension was subjected to ultracentrifugation (150,000xg, 1 hour, twice), and the supernatant was removed, whereby inulin which had not been encapsulated in the liposomes was removed. PBS (pH 7.4) was added to the residue to obtain a liposome suspension having a total volume of 5.3 ml. Lipid was quantitatively determined by an enzymatic method using a choline group of L-α-dimyristoylphosphatidylcholine as a marker, whereby it was clarified that the suspension contained 10 μmol of lipids as the total lipids per 0.5 ml thereof. The obtained liposomes the used mannobioses and radioactivity are shown below.
______________________________________Liposome Mannobiose Used RadioactivityNo. derivative amount (μCi/0.5 ml)______________________________________III-1 Example 3 16 μmol 0.82III-2 Example 4 16 μmol 0.95III-3 Example 9 8 μmol 0.88III-4 Example 9 16 μmol 0.98______________________________________
(4) Preparation of liposomes IV (control)
The same treatment as in the above item (3) was conducted except that 76.2 μmol of L-α-dimyristoylphosphatidylcholine, 76.2 μmol of cholesterol and 7.6 μmol of dicetyl phosphate were dissolved in chloroform to obtain a liposome suspension of a total volume of 5.0 ml. The suspension contained 10 μmol of lipids as the total lipids per 0.5 ml thereof, and 1.29 μCi of inulin was encapsulated in the liposomes.
(5) Preparation of 1 H-inulin solution (control)
The above PBS (pH 7.4) solution (6 ml) of 1 mM inulin containing 240 μCi of 3H-inulin was diluted 20 times with PBS (pH 7.4) to prepare a solution containing 1 μCi of inulin per 0.5 ml of the diluted solution.
(6) Preparation of liposomes V (control)
The treatment similar to that in the above item (4) was conducted using the same formulation as in the above item (4) to obtain a suspension of liposomes having a total volume of 5.3 ml. The suspension contained 10 μmol of lipids as the total lipids per 0.5 ml thereof, and 1.08 μCi of inulin was encapsulated in the liposomes.
(7) Preparation of liposomes VI (containing a compound of the invention)
The same treatment as in the preparation of liposomes III-2 or III-4 in the above item (3) was conducted using the same formulation as therein tc obtain a liposome suspension having a total volume of 4.8 ml. Each of the obtained suspensions contained 10 μmol of lipids as the total lipids per 0.5 ml thereof, and 0.83 or 0.91 μCi of inulin was encapsulated in the liposomes.
TEST 1
A PBS (pH 7.4) solution containing 200 μg/ml of lectin having a sugar specificity to D-mannose (derived from Vicia fava, manufactured by Sigma Co.) was prepared. One of the liposome suspensions as obtained in the item (1) (Nos. I-1 to I-5) and the item (2) and the lectin solution were mixed in the ratio of 1:1, mildly shaken and poured into a measuring cell for a spectrophotometer, and absorbance at the wavelength of 450 nm was determined for 30 minutes.
In case of the liposome suspensions formulated with the mannobiose derivatives of the invention prepared in the above item (1), aggregation of liposome was observed by increase of absorbance together with passage of time, and the extent was I-1 ≦I-2 <I-3 =I-4 <I-5. On the other hand, aggregation was not particularly observed in the control liposome (prepared in the above item (2)).
From the foregoing it was confirmed that in the liposomes of the item (1), the mannobiose derivatives of the invention are incorporated into the liposomal membranes and the mannose residues are exposed on the liposomal membrane surfaces, respectively.
TEST 2
The liposome suspensions as obtained in the above item (3) (Nos. III-1 to III-4) and the above item (4) and the 3H-inulin solution as obtained in the above item (5) were intravenously administered to SD strain male rats (body weight 140 to 160 g) at the hind limb in an amount of 0.5 ml portions per 100 g of the body weight, respectively. Thirty minutes later each of the animals was exsanguinated from the carotid artery, the abdomen was opened to excise the liver, lung, kidney and spleen. A part or the whole of each of these organs was homogenized in PBS and determined for radioactivity by a liquid scintillation method to obtain a recovery (%) from each organ based on the dose. The radioactivity recoveries in the serum were calculated estimating the whole blood weight of a rat as 6.5% of the body weight and the serum volume as 50% of the whole blood volume. The results are shown in Table 1. In Table 1, each value represents the average value ± standard error, and each figure in parentheses shows the number of rats. These values are those at 30 minutes after the intravenous injection.
As is apparent from Table 1, distribution of the liposomes containing a mannobiose derivative of the invention to the liver is significantly larger than that of the liposome IV as a control, and it has been confirmed that affinity to the liver is increased in proportion as the containing amount of mannobiose derivative of the invention is increased.
TABLE 1__________________________________________________________________________Recovery % .sup.3 H-inulin Liposome Liposome Liposome Liposome Liposome solutionOrgan III-1 III-2 III-3 III-4 IV (control) (control)__________________________________________________________________________Liver 26.6 ± 1.6* 34.5 ± 1.7** 28.3 ± 4.1* 42.1 ± 3.2** 19.4 ± 2.6 1.6 ± 0.2 (3) (3) (3) (3) (4) (3)Lung 0.50 ± 0.06 0.31 ± 0.09 0.53 ± 0.11 0.62 ± 0.20 0.49 ± 0.07 0.19 ± 0.08 (3) (3) (3) (3) (4) (3)Kidney 0.99 ± 0.17 0.98 ± 0.20 0.85 ± 0.33 0.77 ± 0.13 0.84 ± 0.26 3.64 ± 4.24 (3) (3) (3) (3) (4) (3)Spleen 4.7 ± 0.8 4.0 ± 0.5 6.8 ± 1.0 7.1 ± 0.7 6.2 ± 1.3 0.07 ± 0.0 (3) (3) (3) (3) (4) (3)Serum 11.9 ± 1.9 8.0 ± 1.3 9.0 ± 1.5 11.3 ± 0.8 9.9 ± 0.9 2.6 ± 1.1 (3) (3) (3) (3) (4) (3)__________________________________________________________________________ *Being significant in 5% level of significance as compared with the control liposome (liposome IV) **Being significant in 1% level of significance as compared with the control liposome (liposome IV)
TEST 3
By using the liposome suspensions of the above Nos. III-2 to III-4 and the liposome suspension as obtained in the item (6) respectively, inhibition effect by mannan which has D-mannose at the end thereof on affinity to Kupffer cells of the liver was examined. That is, one minute before administration of the liposome suspensions to rats in the same condition as in Test 2, PBS solution of mannan was pre-administered intravenously to the hind limb (the hind limb of the opposite side of liposome injection side), and thereafter the same procedure as in Test 2 was conducted. Dose of mannan was 13.3 mg per 100 g of rat body weight. The results, namely inhibition effects of mannan on distribution of the liposomes to the liver are shown in Table 2. Each value in the table represents the average value ± standard error, and each figure in the parentheses shows the number of rats. These values are those at 30 minutes after the intravenous injection.
As s apparent from Table 2, distribution of the liposomes each containing a mannobiose derivative of the invention to the liver was significantly inhibited by mannan. On the other hand, the control liposome (liposome V) was not affected by mannan.
From the foregoing, it has been confirmed that the liposomes each containing a mannobiose derivative of the invention have an excellent affinity for the Kupffer cells of the liver.
TABLE 2______________________________________ Recovery (%) Liposome Liposome Liposome III-2 III-4 V (control)______________________________________Non-treated 34.5 ± 1.7** 42.1 ± 3.2** 19.6 ± 2.0 (3) (3) (3)Pre-administration 22.8 ± 2.9*** 24.3 ± 2.1*** 17.3 ± 3.5of mannan (3) (3) (3)______________________________________ **Being significant in 1% level of significance as compared with the control liposome (liposome V). ***Being significant in 1% level of significance as compared with nontreated group.
TEST 4
The liposome suspension as obtained in the above item (7) was intravenously injected into the hind limb of SD strain male rats (body weight 140 to 160 g) in an amount of 0.5 ml per 100 g of the body weight. Thirty minutes later, Nembutal was intraperitoneally administered and the abdomen was opened. Just thereafter, the liver was perfused with a pre-perfusing buffer, a collagenase solution and a Hanks' solution for cell-washing according to the method of Berry-Friend and Seglen to prepare a free liver cells suspension. The suspension was centrifuged under cooling to obtain a fraction containing the liver parenchymal cells and a fraction containing the liver non-parenchymal cells rich in the Kupffer cells of the liver.
Determination of radioactivity of both fractions revealed that 95% or more of radioactivity was recovered from the fraction containing the non-parenchymal cells rich in the Kupffer cells of liver and almost no radioactivity from the fraction containing the liver parenchymal cells.
From the above test, it has been confirmed that the mannobiose derivatives of the invention are useful as a component modifying pharmaceutical preparations, such as liposomes, having a specific affinity for Kupffer cells of liver. | Novel mannobiose derivative represented by the general formula [I]: ##STR1## wherein groups of R 1 to R 5 each represents --OH, --OR 6 , --NHR 6 , (R 6 represents an acyl group) or a group represented by the following formula (a), (b), (c), (d) or (e), provided that one of R 1 to R 5 represents --OR 6 or --NHR 6 , one of the other 4 groups of R 1 to R 5 represents one of the groups represented by the formulae (a) to (e), and the remaining 3 groups of R 1 to R 5 represent --OH: ##STR2## wherein represents α or β bond are provided by the invention.
These compounds give liposomes a specific affinity for Kupffer cells of liver, and can be produced industrially. | 8 |
COPYRIGHT NOTICE
© 2003 General Electric Company. A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. 37 CFR § 1.71(d).
TECHNICAL FIELD
The invention pertains to video cameras and related equipment and, more specifically, is directed to interfacing a video camera to transmit video signals over various signal transmission media.
BACKGROUND OF THE INVENTION
Closed-circuit television or CCTV is widely used for video security/surveillance, video distribution, distance learning and other applications. Frequently, remote CCTV cameras, for example those mounted in a warehouse or overlooking a parking lot, are wired to a monitoring station which may comprise one or more monitors for watching the video (and sometimes audio) stream, and/or recording equipment (DVR—digital video recording—for example) for capturing and storing the surveillance signals.
Various transmission methods and media are known for transmitting the video signals (which may include audio signals) from the camera to a remote monitor and/or recording system. The different transmission protocols and media offer choices to enable a user to trade off cost, interference immunity, signal loss (i.e., maximum distance), etc. Known transmission media include: coaxial cable (most commonly used), fiber-optic, radio frequency (RF), internet protocol (IP) (which may employ computer network wiring such at CAT-5), wireless, twisted-pair (UTP), etc. UTP would include ordinary telephone wiring, for example of the type terminated with RJ-11 or RJ-45 connectors.
Each of these media requires its own electrical/mechanical connectors. Examples of such connectors include BNC; RJ-11; RJ-45; Fiber-type; RCA etc. and terminals for twisted pair (UTP), coaxial cable, and others. Wireless systems or course have no physical connection between the transmitter and receiver nodes, but they require connections to input signals to the transmitter and, conversely, to output signals from the receiver device. The appropriate connector for a particular application may or may not be built into the camera at the time of manufacture.
In addition, various transmitters, receivers and transceivers are known for conveying video signals. These may be passive (non-amplified) or active, the latter enabling transmission over greater distances. For example, a typical known passive video transmitter will transmit full-motion video up to 1,000 feet over UTP, while the same transmitter used in conjunction with an amplified receiver is reported to operate up to 3,000 feet.
In general, a video surveillance camera has a video output connector or jack, or perhaps two different ones, built into the product. We will refer to such a connector as the “native” connector; the one already on the camera as purchased. A BNC connector is a common native connector. This works fine for connection to transmitters or cables that have a BNC input jack, but is incompatible with other connectors such as RJ-11 or RCA which may be needed for the transmission media (wiring) at hand. Installation of the camera in such applications requires the installer to deploy some kind of adapter, and to install the adapter between the camera and the transmission medium. Installing the adapter requires both electrical connection and mechanical mounting. This kind of activity adds to the time and expense of video camera installation, especially as it may be required at every camera throughout a large facility. Examples are shown in drawing FIGS. 1A and 1B further described below.
The need remains therefore for a fast, simple and convenient way to interface a video camera to a transmission media that requires a connection different from the “native” connector or connector(s) built into the camera at manufacture.
SUMMARY OF THE INVENTION
One aspect of the invention is directed to the concept of an interface adapter for mounting to a video camera, primarily for transmitting video signals originating in the camera to another location. The adapter can also provide other functions such as power distribution. Installation of the camera is simplified in many cases because the adapter provides the appropriate connector(s) for the application at hand. The video camera has at least one built-in or “native” connector typically on the back panel, to output the video signals. An adapter according to the invention includes input means arranged for electrical connection to the native connector to receive the video signals originating in the camera while the adapter is connected to the camera. The adapter further provides output means for conveying the video signals from the adapter to a transmission medium; for example, twisted pair, fiber optic or other cabling, or wireless transmission.
Accordingly, the output means is electrically coupled to the input means to receive the video signals originating in the camera. By the term “coupled” we mean a direct electrical connection, or an indirect connection that involves a transmitter, filter, amplifier, A/D converter or other electronic circuitry that takes the video signals generated by the camera as its input. In a presently preferred embodiment, the output means includes a terminal block or other connector to provide mechanical and electrical connection to a corresponding wired transmission medium such as UTP. The output means generally includes at least one of a twisted-pair connector, a BNC connector, an RCA connector, a USB connector or other analog or digital data connection. The output means can be wireless, in which case the electronic circuitry mentioned above would comprise a wireless transmitter. The output means could be fiber optic. These are merely examples and not listed by way of limitation. Multiple output connectors can be provided on one adapter. For example, a first connector can be provided for signal transmission and a second connector for temporary connection to a monitor for testing.
Preferably, the adapter is built into a substantially rigid housing that is generally shaped so as to cover at least a portion of the back panel of the camera that includes the native connector. The interface adapter assembly also should be mechanically compatible with the camera so as to enable removably connecting the adapter to the camera without modifying the camera. For example, the screw holes typically used to attach the back panel to the camera could be used to receive screws for mounting the adapter.
As a matter of design choice, the adapter can have any desired size or shape, but preferably it generally conforms to the configuration of the target camera. In other words, the adapter should look like a part of, or extension of, the camera when installed. This can be done, for example, by sizing the adapter to overlay a portion of the camera, with smooth transitions, while minimizing protrusions extending from the camera. So, for example, an external surface of the adapter housing would preferably parallel an external surface of the camera housing. These design principles will become more apparent in view of the various examples shown in the drawing figures and described in detail below.
Additional aspects and advantages of this invention will be apparent from the following detailed description of preferred embodiments, which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified diagram illustrating a prior art video system for transmitting video signals from a video camera to a remote location.
FIG. 2 is a perspective view of a video camera and cable connections (exploded) representative of the prior art.
FIG. 3 is a perspective view of a video camera with attached interface adapter and cabling in accordance with a first embodiment of the present invention for fiber optic transmission.
FIG. 4 is an exploded view of the apparatus of FIG. 3 .
FIG. 5 is a perspective view of the interface adapter of FIGS. 3-4 .
FIG. 6 is another perspective view of the apparatus of FIG. 3 .
FIG. 7 is a perspective view of an alternative embodiment of an interface adapter for fiber optic transmission.
FIG. 8A is a perspective, exploded view of a second embodiment interface adapter for UTP transmission.
FIG. 8B is a perspective view of the adapter of FIG. 8A assembled.
FIG. 9 is a side view, exploded, of a video camera and interface adapter of FIGS. 8A and 8B .
FIG. 10A illustrates another embodiment of an interface adapter in accordance with the present invention.
FIG. 10B illustrates another embodiment of an interface adapter in accordance with the present invention.
FIG. 11A is a perspective view of a video camera and attached interface adapter in accordance with another embodiment of the invention.
FIG. 11B is an alternative perspective view of the apparatus of FIG. 11 A.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 is a simplified diagram illustrating a prior art video system. Here, a video camera 100 has a video output connector (not detailed) to provide video output signals. A cable 102 is connected between the video output connector on the camera and a transmitter device 104 . An example of such a transmitter is model NV-314A available from Network Video Technologies (“NVT”), Redwood City, Calif. In a typical installation, the transceiver 104 is mounted near the camera. The transceiver provides appropriate interfacing for transmitting the video output signals over an unshielded twisted pair of wires (“UTP”) 106 with low signal loss. The transmitter can be passive (unpowered) or powered, in the latter case providing for transmission over greater distances, e.g., up to 3,000 ft. Although UTP cable is itself inexpensive and easy to use, providing connectors such as RJ-45 on the ends of the cable increases installation costs.
A second transceiver 108 , compatible with or even identical to the first transceiver 104 , is provided at the far end (away from the camera) for interfacing the UTP 106 to a coax cable 110 which, in turn, is connected to a video monitor 112 and/or other equipment such as a video motion detector. (Video signals, in this example and in general, can include audio content as well.)
FIG. 2 is a perspective view of a video camera 10 seen generally from the rear. Camera 10 has a back panel 12 on which one or more connectors are fixed for establishing electrical connections to the camera. While the number and types of connectors varies, FIG. 2 illustrates a common configuration that includes a first BNC connector 14 and a second BNC connector 16 , each used for transmitting video signals from the camera to a remote location such as a security monitoring station or recorder. It is also known to send control signals “up-the-coax” i.e., to the camera over the same cable, for controlling camera functions remotely. We refer hereinafter to connectors that are built into the camera (like 14 , 16 ) as “native” connectors.
In FIG. 2 , a first cable 20 (for example, a coax cable) has a male BNC type connector 22 for mating to native connector 16 on the camera back panel 12 . Another cable 24 has a connector 26 for mating to a corresponding connector 30 on the back panel 12 to power the camera, usually supplying 12 or 24 VDC from an external power supply. Typically, coax cable 20 is connected to a transceiver, just as coax cable 102 is connected to transceiver 104 in FIG. 1A , described above.
Referring now to FIG. 3 , we introduce a new video camera interface adapter assembly. In one embodiment, illustrated in FIG. 3 , the interface adapter 32 is removably attached to the camera 10 generally overlying the back panel 12 . The peripheral edge of the adapter facing the camera ( 17 in FIG. 4 ) is sized and shaped to generally conform to the periphery of the back of the camera so as to appear, when installed (as in this figure), to be a part or extension of the camera. The interface adapter assembly 32 in this embodiment includes a terminal block 34 and a fiber optic connector 36 . Power supply wiring 40 is shown installed into the terminal block 34 to power a fiber optic transmitter (or transceiver) in the adapter (not shown). FIG. 6 shows the apparatus of FIG. 3 from the right rear perspective.
FIG. 4 shows the apparatus of FIG. 3 in exploded view. The adapter 32 is removably attached to the camera with screws 42 or the like so that the adapter generally covers the back panel 12 . The screws 42 pass through holes in the adapter and are received in mounting holes 43 normally provided in the camera back panel. The adapter in this embodiment forms ah aperture 44 arranged so that the camera power connector 30 is exposed and available for connection to cable 24 via mating connector 26 . The adapter in this configuration thus does not affect the camera power connection.
The interface adapter ( 32 being just one example) can have any of various configurations. To illustrate, FIGS. 3 , 4 , 5 , 6 and 7 show an adapter 32 with a terminal block 34 and fiber optic connector 36 , as noted above. In such configurations, power is supplied to the terminal block to power the fiber optic circuits. FIGS. 8A , 8 B and 9 illustrate an alternative adapter 46 which has only a terminal block 34 for UTP output connection. FIG. 10A is a perspective view of an alternative adapter assembly 48 that includes a USB-type external connector 50 which could be used for a digital data connection. Multiple output connections can be implemented in a single adapter, again simplifying installation for many applications.
FIG. 10B illustrates another embodiment; an adapter assembly 52 that employs a wireless transceiver (not shown) for communicating video signals. Indicator lights 80 (LEDs) can be provided to indicate a present status of the wireless transceiver (for example, power and signal acquisition). Wireless transceiver circuits, for example IEEE 802.11 series, “WiFi” or Bluetooth, are known and commercially available from various vendors. Next we describe a UTP embodiment 46 in greater detail.
Adapter 46 is attachable to a camera as described earlier with regard to the adapter 32 . Referring to FIG. 8A , adapter 46 comprises a housing 56 formed of any sturdy, rigid material such as a molded polymeric material. The housing provides mounting screw holes, for attaching the adapter to the camera, although other attaching means can be used as a matter of design choice. Preferably, the housing is sized and arranged to generally conform to the configuration of the back and/or any one or more sides of the camera to which it will be attached. For example, at least a portion of the perimeter edge 57 of the housing should fit closely along the camera perimeter so as to give the combination a unitary, tidy appearance when the adapter is installed. In one anticipated commercial embodiment called PlusPacks™, the adapter assembly extends only about 3.2 cm beyond the back panel, yet it eliminates the need for an external transmitter and associated wiring to convert BNC analog video to twisted pair output.
Referring now to FIGS. 8A and 8B , adapter 46 in a presently preferred embodiment further comprises a circuit board 58 mountable inside the housing 56 , for example using screws. Referring now also to FIG. 9 , the circuit board 58 includes the terminal block 34 securely mounted on the underside 60 of the circuit board, and located on the board so that the terminal block 34 extends through an aperture 62 provided in the housing 56 when the board 58 is mounted in the housing, as indicated by dashed lines in FIG. 8 A and FIG. 9 . In this embodiment, the terminal block is used to connect a pair of wires for UTP video signal transmission.
A connector 64 is securely mounted the top side 68 of circuit board 58 . (The designations “underside” and “top side” here are arbitrary.) Connector 64 is located and aligned for mating engagement with a native connector on the camera back panel when the board 58 is mounted in the housing 56 and the adapter 46 is connected to the camera. FIG. 9 shows in side view how the connector 64 is aligned for engagement with native connector 16 on the camera. In one embodiment, connector 64 is a “push-in BNC” connector. It is compatible for “push-in” engagement with a standard BNC female connector ( 16 ) without the usual “push-and-turn” operation. Connector 64 thus couples video output signals from the camera to the adapter circuit board 58 when in use.
The interface adapter 46 in this example further includes a transmitter module 70 also mounted on the top side 68 of circuit board 58 although its location is a matter of design choice. Transmitter 70 provides suitable interfacing for transmitting video signals over wires connected to the terminal block 34 , e.g., UTP transmission. Accordingly, the circuit board 58 includes conductors (traces) for electrically connecting the push-in BNC 64 to the transmitter 70 input terminals (not shown), and traces 72 (see FIG. 8A ) for connecting the transmitter output terminals to the terminal block 34 . Transmitters of this type are commercially available, one example being model NV-M11 from NVT. For other designs, the appropriate transmitter or transceiver, if any, or other circuitry such as a filter or amplifier, will be determined by the output transmission media, transmission distance, environment, and the like.
In the fiber optic embodiment of FIGS. 3 and 4 , the adapter 32 is outwardly similar to adapter 46 as described, with the addition of the fiber optic output connector 36 . And in that case, the terminal block is used to supply power rather than UTP output connections. The fiber connector 36 can be deployed by mounting it on the underside 60 of a circuit board-similar to board 58 , and providing a suitable aperture 74 in the adapter housing, as best seen in FIG. 5 . Circuit board 58 in that embodiment would further include traces for connecting the push-in BNC 64 to the fiber optic transmitter signal input terminals (not shown), and for connecting the transmitter output terminals to the output connector 36 . Alternatively, a second push-in BNC connector (not shown) could be mounted on the top side of the board and aligned for engaging a second native connector 14 (see FIG. 9 ). Other types of connectors, for example, RCA, or S-video connectors or adapters can be deployed on the circuit board as appropriate to the native connector(s) of the target video camera.
Furthermore, any set of one or more desired output connectors can be implemented in the adapter; the appended illustrations shown only a few examples. In the example of FIG. 10A , a USB connector 50 would be mounted on the underside 60 of the circuit board of FIG. 9 , in lieu of the terminal block, and necessary interface electronics provided. In the example of FIG. 10B , a wireless transceiver is provided, as noted. It too can be mounted on the circuit board described. The circuit board can be designed to provide power to various transceivers as needed. The power can be provided from a battery or external power source via the terminal block.
Another approach is illustrated by FIG. 7 . The adapter assembly 82 of FIG. 7 is sized and shaped to cover substantially the entire back panel of the camera. Instead of providing an aperture for a power connection to the native power connector ( 30 in FIG. 4 ) as described earlier, this adapter includes a “pig tail” assembly 83 for connecting the adapter to the camera's native power connector before attaching the adapter 82 to the camera. Here, power is supplied for both the camera and the video signal transmission electronics from a terminal block 88 . This embodiment can include a fiber optic output 74 or any of the wired or wireless transmission media described earlier. This design avoids multiple power connections.
Referring now to FIGS. 11A and 11B , another example of an embodiment of the present invention is illustrated. Here, an alternative interface adapter 90 is shown attached to the video camera 10 . Various input and output connections can be provided in the adapter as discussed above. For example, the drawing shows an RJ-45 receptacle 92 for IP connection and a terminal block 94 (which could serve as a UTP output or a power input). A conventional camera power input connector 26 is shown.
The interface adapter assembly 90 illustrates the concept of an adapter design that generally conforms to more than one face of the camera 10 . Here, the adapter includes a rear section 96 , similar to embodiments described above, and a top section 98 extending at least partially along the top side of the camera and having a width substantially equal to the width of the camera. Sections 96 and 98 are substantially contiguous, forming a smooth exterior surface, and are substantially contiguous or at least communicating with one another in the interior (the space generally between the camera and the adapter housing).
This type of configuration provides considerable additional space inside the adapter to house power supply and various interface circuitry as may be required. In general, the adapter can extend over any side or sides of the camera, part way or the full length of the camera. Preferably, it will cover at least a part of the back panel for engaging at least one native connector. Again, the adapter should generally comply with the camera shape and size, at least in part, for a neat appearance.
It will be obvious to those having skill in the art that many changes may be made to the details of the above-described embodiments without departing from the underlying principles of the invention. The scope of the present invention should, therefore, be determined only by the following claims. | An interface adapter ( 32, 46, 48, 52, 82, 90 ) is connectable to a video camera ( 10 ) for example in security or surveillance applications. The adapter ( 32 , etc.) conveniently provides interfacing for transmission of video signals generated by the camera, employing any one or more interfaces or transmission media, such as fiber-optic, radio frequency (RF), internet protocol (IP), wireless, twisted-pair (UTP), etc. By using the adapter, a single camera model having one native output transmission connector ( 14 ) can be deployed for a variety of applications that may require various other transmission media or connections ( 34, 36, 50, 92 ). The adapter makes the camera immediately ready for installation and connection to any desired transmission media without time-consuming wiring of external or standalone transmitters or transceivers. And the adapter preferably conforms to the camera enclosure for a clean, unitary appearance of the combined apparatus (FIG. 3 , FIG. 11 ). | 7 |
CROSS-REFERENCE OF RELATED APPLICATIONS
This application is a continuation of application Ser. No. 12/280,359, filed on Oct. 31, 2008 (now abandoned), the entire contents of which are incorporated herein by reference, and which is a 371 national stage of International Application No. PCT/EP06/12342, filed Dec. 20, 2006. This application also claims foreign priority to European Patent Application 06003636.5, filed Feb. 22, 2006.
BACKGROUND OF THE INVENTION
1. Field of the Disclosure The present invention relates to a semiconductor compound having the general formula A x B 1-x C y , to a method of optimizing positions of a conduction band and a valence band of a semiconductor material using said semiconductor compound, and to a photoactive device comprising said semiconductor compound.
2. Description of the Related Art
Photoelectrochemical cells based on sensitisation of nanocrystalline TiO 2 by molecular dyes (so called dye-sensitised solar cells, DSSC) have been first reported by B. O'Regan and M. Grätzel, Nature 353 (1991) 737; WO 91/16719 [1] and have been continuously improved over the last decade. In operation, absorption of a photon leads to the excitation of an electron, which is then injected from the dye molecule into the conduction band of the TiO 2 and transported to the front electrode. The dye molecule is regenerated from a platinum counter electrode via a redox couple in electrolyte. Most crucial for a further success of dye-sensitised solar cells is to increase their power conversion efficiency. It depends on short circuit current density J SC , fill factor FF, and the open circuit voltage V OC . J SC depends among others, on the number of absorbed photons and the efficiency to convert those absorbed photons into photoelectrons. FF mainly depends on the conductivity of the materials in use. V OC is dependent on both the energy difference between the conduction band of the semiconducting material and the redox potential of the redox couple as well as the recombination rate of electrons from the semiconductor into the electrolyte ( FIG. 1 ). Most effort has been taken in the past to increase J SC by means of different dye molecules and light management. V OC was increased by means of co-adsorption of smaller molecules together with the dye molecules to suppress recombination. No improvement by changing the semiconductor material or the redox-couple has been reported. Core-shell structures with oxide materials other than TiO 2 on the surface of the TiO 2 particles partly increased the efficiency ([2] Y. Diamant, S. Chappel, S. G. Chen, O. Melamed, A. Zaban, Coordination Chemistry Reviews 248, 1271 (2004)) but must be regarded as another way of surface treatment.
SUMMARY
The main disadvantage of the state of the art DSSC is the low power conversion efficiency when compared with other, well-established solar cell technologies. As described above, the three main parameters to be improved are short circuit current density J SC , fill factor FF, and the open circuit voltage V OC . Little innovation has been reported with respect to the latter one since the advent of DSSC. This is especially true with respect to the nanoporous semiconductor material, which is in almost all cases TiO 2 . ZnO has been used as a substitute mainly due to the possibility to grow ZnO at low temperatures, but lower V OC and minor efficiencies have been obtained when compared to TiO 2 ([3] K. Keis, E. Magnusson, H. Lindström, S.-E. Lindquist, A. Hagfeldt, Sol. Energy Mat. Sol. Cells 72, 51 (2002)).
There have been reports on TiO 2 electrodes which have been coated with a thin layer of various wide band gap materials so as to form core-shell-structures. Such core-shell-structures as reported by Diamant et al. (see above) were prepared by electrochemical deposition of the shell material on the core material or by dipping the core electrode (usually the TiO 2 electrode) into a solution containing a precursor of the respective shell material. In such core-shell-structures, the shell-materials only form a thin coating on the TiO 2 core particle [2] (see above). The idea behind such a core-shell-structure is to avoid recombination processes between the photo-injected electrons in the semiconductor and the oxidized ions in the redox mediator or oxidized dye at the semiconductor's surface. In such a core-shell-structure, the recombination processes can possibly be slowed down by the formation of an energy barrier at the TiO 2 surface. However, the influence on the overall DSSC characteristics, for example J SC , FF, and V OC is limited, and furthermore, such core-shell-particles are subject to faster degradation.
Furthermore, J SC can also be improved by changing the properties of the semiconductor material. As an example, dyes with a different absorption spectrum which could otherwise not be used in the DSSC, e.g. because their LUMO (where LUMO stands for lowest unoccupied molecular orbital) is too low to inject excited electrons into the conduction band of the semiconductor material, can be used when the conduction band edge of the semiconductor material is lowered.
Accordingly, it was an object of the present invention to provide for a dye-sensitized solar cell of which the energy efficiency is at least comparable to the energy efficiency of a dye-sensitised solar cell as reported in the prior art. More specifically, it was one object of the present invention to improve the open circuit voltage V OC of a dye-sensitised solar cell.
The objects of the present invention are solved by method of optimizing positions of a conduction band and a valence band and/or the energy difference between a conduction band and a valence band of a semiconductor material in a semiconductor layer of a photoactive device, preferably a dye-sensitised solar cell having a dye in said semiconductor layer, and/or of optimizing an open circuit voltage of said device, preferably of said dye-sensitised solar cell, using a semiconductor compound having a formula A x B 1-x C y , wherein A and B are metals or metalloids, and wherein C is a non-metal or a metalloid, preferably selected from the group comprising C, N, O, P, S, Se, As, NO 2 , NO 3 , SO 3 , SO 4 , PO 4 , PO 3 , CO 3 , x is in the range of from 0.001 to 0.999 and y is in the range of from 0.1 to 10.
In one embodiment said semiconductor compound has an upper edge of a valence band and a lower edge of a conduction band, wherein said upper edge of said valence band is between an upper edge of a valence band of a first semiconductor compound AC v and an upper edge of a valence band of a second semiconductor compound BC z , and said lower edge of said conduction band of said semiconductor compound is between a lower edge of a conduction band of said first semiconductor compound AC v and a lower edge of a conduction band of said second semiconductor compound BC z , wherein A and B are metals or metalloids, and wherein v and z are in the range of from 0.1 and 10, and wherein y in said semiconductor compound having the formula A x B 1-x C y is y=(1−x)*z+x*v.
Preferably, A and B are metals or metalloids selected from the group comprising Zr, Ti, Hf, V, Ta, Cr, Mo, W, Mn, Fe, Ru, Os, Co, Rh, Ir, Ni, Sn, Nb, Zn, Ag, Pt, Ce, Ge, As, Ga, Si, Al, Cu, CuAl, CuNi, PbZr, SrTi, BaZr, SrCu 2 .
In one embodiment C is O, said semiconductor compound thus being a mixed semiconductor oxide.
In one embodiment said semiconductor compound is synthesized starting from at least two precursor compounds, preferably metal isopropoxides of the general formulae A u (iPrO) w and B s (iPrO) t , wherein A and B are metals or metalloids selected from the group comprising Zr, Ti, Hf, V, Ta, Cr, Mo, W, Mn, Fe, Ru, Os, Co, Rh, Ir, Ni, Sn, Nb, Zn, Ag, Pt, Ce, Ge, As, Ga, Si, Al, Cu, CuAl, CuNi, PbZr, SrTi, BaZr, SrCu 2 , and s, u, t and w are in the range of from 1 to 10, and (iPrO) is an isopropoxide-group.
In one embodiment, said semiconductor compound is synthesized starting from three, four or more different precursor compounds, preferably metal isopropoxides as defined above.
In one embodiment AC v and BC z are independently selected from the group comprising TiO 2 , SnO 2 , ZnO, Nb 2 O 5 , ZrO 2 , CeO 2 , WO 3 , Cr 2 O 3 , CrO 2 , CrO 3 , SiO 2 , Fe 2 O 3 , CuO, Al 2 O 3 , CuAlO 2 , SrTiO 3 , SrCu 2 O 2 , ZrTiO4.
It should be noted that other than the compounds defined by A x B 1-x C y , semiconductor compounds in accordance with the present invention may also have the formula A x1 B x2 C x3 . . . X xn , having a number n of elemental components A, B, . . . X, wherein n>3, and each of x1 to xn is in the range of from 0.001 to 0.999. Hence, in such compounds there may be more than three elemental components, such as 4, 5, 6 or 7. In compounds in accordance with this embodiment, the ratio between the respective components A, B, C, . . . , X is chosen such to adjust and/or optimise the band edge positions of the semiconductor compound in accordance with the aforementioned requirements, and is optimized as described further below. In compounds in accordance with this embodiment, A, B, C, . . . X are metals or metalloids or non-metals, wherein the metals or metalloids are selected from the group comprising Zr, Ti, Hf, V, Ta, Cr, Mo, W, Mn, Fe, Ru, Os, Co, Rh, Ir, Ni, Sn, Nb, Zn, Ag, Pt, Ce, Ge, As, Ga, Si, Al, Cu, CuAl, CuNi, PbZr, SrTi, BaZr, SrCu 2 , and wherein the non-metals are selected from the group comprising C, N, O, P, Se, As, NO 2 , NO 3 , SO 3 , SO 4 , PO 4 , PO 3 , CO 3 , with the proviso that at least one of A, B, C, . . . X is a metal or metalloid as defined above, and at least one of A, B, C, . . . X is a non-metal as defined above.
In one embodiment the components A and B are present in said semiconductor compound in a ratio of from 1:1000 to 1000:1.
In one embodiment said semiconductor compound is synthesized starting from an oxide, A m and a nitrate, B(NO 3 ) q , A and B are metals or metalloids being selected from the group comprising Zr, Ti, Hf, V, Ta, Cr, Mo, W, Mn, Fe, Ru, Os, Co, Rh, Ir, Ni, Sn, Nb, Zn, Ag, Pt, Ce, Ge, As, Ga, Si, Al, Cu, CuAl, CuNi, PbZr, SrTi, BaZr, SrCu 2 , and m and q being in the range of from 0.1 to 10, wherein said oxide and said nitrate have been reacted together, preferably by mixing them, wherein, preferably, after said oxide and said nitrate have been reacted together, the resulting product is sintered, preferably at T>300° C.
In one embodiment said semiconductor compound is synthesized by a process comprising the steps: mixing and reacting at least two precursor molecules, preferably metal isopropoxides of the general formulae A u (iPrO) w and B s (iPrO) t , wherein A and B are metals or metalloids selected from the group comprising Zr, Ti, Hf, V, Ta, Cr, Mo, W, Mn, Fe, Ru, Os, Co, Rh, Ir, Ni, Sn, Nb, Zn, Ag, Pt, Ce, Ge, As, Ga, Si, Al, Cu, CuAl, CuNi, PbZr, SrTi, BaZr, SrCu 2 , s, u, t and w are in the range of from 0.1 to 10, and (iPrO) is an isopropoxide-group, preferably in a ratio in which said metals are desired to be present in the resulting compound, heating the resulting mixture, optionally in the presence of an acid, to a temperature between 50° C. and 300° C. for a period of time between 1 h and 20 h, filtering the product to obtain said semiconductor compound as a residue, or, alternatively, reacting an oxide, AO m , and a nitrate, B(NO 3 ) q , A and B being as defined before, and m and q being in the range of from 0.1 to 10, sintering the resulting product at a temperature >300° C., for a period of 10 minutes to 60 minutes, preferably at a temperature >400° C. for approximately 30 minutes.
In one embodiment said semiconductor compound is incorporated in said semiconductor layer of said device as semiconductor particles having an average diameter ≦1 μm, preferably ≦500 nm, more preferably ≦100 nm, wherein, preferably, said semiconductor particles have an outer shell made of the same and/or a further semiconductor compound, preferably a semiconductor oxide.
In one embodiment said semiconductor particles have a shape selected from the group comprising rods, tubes, cylinders, cubes, parallelipeds, spheres, balls and ellipsoids.
Preferably, said semiconductor particles are a mixture of at least two kinds of particles differing in their average diameter or length, and/or differing in their composition.
In one embodiment said semiconductor particles are a mixture of a first kind of particles and a second kind of particles, said first kind of particles having an average diameter or length in the range of from 1 nm to 30 nm, and said second kind of particles having an average diameter in the range of from 50 nm to 500 nm and/or length in the range of from 50 nm to 5 μm.
In one embodiment said semiconductor particles are a mixture of a first kind of particles and a second kind of particles, said first kind of particles being made of a first semiconductor compound A x B 1-x C y as defined above, with C being O, and said second kind of particles being made either of a second semiconductor compound A x B 1-x C y as defined above, with C being O, or of any semiconductor oxide as defined in claim 7 with respect to AC v and/or BC z and wherein said first semiconductor compound and said semiconductor compound may be the same or different.
Preferably, said semiconductor layer has pores having a diameter in the range ≦1 μm, preferably in the range of from 1 nm to 500 nm, more preferably in the range of from 10 nm to 50 nm.
In one embodiment said semiconductor particles, during manufacturing of said device, preferably said dye-sensitised solar cell (DSSC), are applied via screen printing, doctor blading, drop casting, spin coating, inkjet printing, electrostatic layer-by-layer self-assembly, lift-off-process, mineralization process or anodic oxidation.
Preferably, said semiconductor material is chosen such that it has an upper edge of a conduction band which is below or equal to a photo-excited state of said dye to allow electron injection from said dye into said conduction band upon photo-excitation of said dye, but which upper edge is between the upper edges of conduction bands of AC v and BC z as defined in any of claims 2 - 11 .
Preferably said optimizing is a widening or narrowing of said energy difference between said conduction band and said valence band of said semiconductor material or is a shift in the position of a band gap between said conduction band and said valence band.
In one embodiment said optimizing is with respect to a photoexcited state of said dye, so as to enable electron injection from said photoexcited state into said conduction band of said semiconductor material, and is furthermore with respect to the redox potential of a redox couple present in said dye-sensitised solar cell (DSSC).
The objects of the present invention are also solved by a photoactive device, which is not an inorganic solar cell, said photoactive device comprising a semiconductor layer having as semiconductor material a semiconductor compound as defined above, preferably a mixed semiconductor oxide as defined in claim 4 , wherein, preferably, the photoactive device is optimized by the method according to the present invention.
The objects of the present invention are also solved by a photoactive device, preferably a dye-sensitised solar cell (DSSC), comprising a semiconductor layer having as semiconductor material a semiconductor compound as defined above, preferably a mixed semiconductor oxide as defined in claim 4 , wherein, preferably, the photoactive device is optimized by the method according to the present invention.
In one embodiment, said photoactive device is not an inorganic solar cell.
Preferably, the photoactive device according to the present invention further comprises a dye in said semiconductor layer and is further characterized in that the conduction band of said semiconductor material has been adjusted with respect to the excited state of said dye to ensure an efficient electron injection from the excited state of said dye to the conduction band of said semiconductor material, whilst making the upper edge of said conduction band of said semiconductor material to be as close as possible to said excited state of said dye.
In one embodiment the photoactive device according to the present invention is a device selected from the group comprising dye-sensitised solar cells, photoactive catalysts, self-cleaning windows, and water purification systems.
The present inventors have found that it is possible to optimize the open circuit voltage of a dye-sensitised solar cell by using said new semiconductor material in the active layer, i.e. the new semiconductor layer participating in the electron transport within the solar cell. The new semiconductor material A x B 1-x C y has different physical and chemical characteristics, such as band gap, band edge positions, composition etc, in comparison to the at least two different semiconductor compounds AC v and BC z on their own.
In many instances, in the present application, reference is made to an “energy difference between a conduction band and a valence band of a semiconductor material”. This term as used herein, is to be equated with the term “band gap”.
Sometimes, in this application, reference is also made to a “conduction band edge” which is meant to signify the lowest energy level of the conduction band of a given semiconductor material. Analogous, the “valence band edge” is meant to signify the highest energy level of the valence band of the respective semiconductor material.
Sometimes, in this application, reference is made to “positions of a conduction band and a valence band” which is meant to signify the positions of the respective edges of the respective bands. The term “semiconductor material” is meant to signify any material having one or several semiconductor compounds in it. The term “semiconductor compound”, as used herein, is meant to signify a chemical compound having semiconducting qualities. The term “mixed semiconductor oxide”, as used herein, is meant to signify a semiconductor oxide in accordance with the present invention, of the formula A x B 1-x C y , wherein C is O (oxygen). The symbols A, B and C are variables for which a number of chemical elements can be substituted, as further specified and defined above. The symbols O, S, As, Cr, Ti, Sn, Nb, Cn, Ce, W, Si, Al, Cu, Sr, etc. are the chemical elemental symbols as used in the periodic table and refer to the respective chemical element.
It should be noted that other than the compounds defined by A x B 1-x C y , semiconductor compounds in accordance with the present invention may also have the formula A x1 B x2 C 13 . . . X xn , having a number n of elemental components A, B, . . . X, wherein n≧3, and each of x1 to xn is in the range of from 0.001 to 0.999. In this case, the symbols A, B, C, . . . X are variables for which a number of chemical elements can be substituted, as further specified and defined in the respective paragraph on A x1 , B x2 , C x3 above.
As used herein, the term “metalloid” refers to an element the properties of which are intermediate between metals and non-metals. More specifically, a “metalloid” which is sometimes also called “semi-metal”, has the physical appearance and properties of a metal but behaves chemically like a non-metal. The known metalloids include B, Se, Ge, Si, As, Sb, Te and Po.
The term “dye-sensitised solar cell” (DSSC), as used herein, refers to a solar cell, wherein the light absorption capabilities have been improved by the presence of a dye in the photoactive layer. The “dye-sensitised solar cells” in accordance with the present invention are so-called “hybrid devices” in that their photoactive layer contains both inorganic and organic materials which take part in the charge generation and transporting processes. A solar cell in accordance with the present invention is not an inorganic solar cell. This term “inorganic solar cell” is used herein in reference to a solar cell which has a photoactive layer consisting exclusively of inorganic material. Hence, a “dye-sensitised solar cell” according to the present invention always is a “hybrid solar cell” and is not an inorganic solar cell as defined above.
It should be noted that the term “optimization” as used in the present application may imply a widening or a narrowing and/or shifting of the absolute position of a band gap. If a dye is present, “optimization” may imply adjusting of the respective properties of the semiconductor material for the actual dye used. Taking a dye-sensitised solar cell as an example, the reference point of such optimization is a comparable dye-sensitised solar cell, wherein, in the active semiconductor layer, there is not a semiconductor material according to the present invention present, but only a semiconductor compound made of less constituents than said new semiconductor material present. It is with respect to this one compound that the band gap is optimised, i.e. narrowed or widened or the absolute position shifted, as the case may be. The inventors have found that, in particular semiconductor oxides are particularly useful for creating such a new semiconductor, i.e. an entirely different compound, in accordance with the present invention. In this respect, it should be noted that, more specifically, the term “mixed oxide” as used herein refers to the result of fabricating a new semiconductor compound A x B 1-x C y according to the present invention, with C being oxygen. Such mixed oxide has different physical characteristics, such as band gap and/or band edge positions, in comparison to the semiconductor oxides AC v and BC z on their own.
In many instances, in the present application, reference is made to particles having an average diameter or length <1 μm, preferably ≦500 nm, more preferably ≦100 nm. These particles are also herein sometimes being referred to as “nanoparticles”. In a preferred embodiment, such “nanoparticles” have an average diameter or length ≦300 nm. In a particularly preferred embodiment, they have an average diameter or length in the range of from 10 nm to 50 nm.
In the present application, sometimes also reference is made to pores having an average diameter in the range <1 μm, preferably in the range of from 1 nm to 500 nm, more preferably in the range of from 10 nm to 50 nm. Such pores <1 μm are herein also sometimes referred to as “nanopores”.
In a preferred embodiment, the new semiconductor compound is the result of combining the precursors for TiO 2 and ZrO 2 and the dye used is red-dye-bis-TBA (cis-bis (isothiocyanato) bis (2,2′-bipyridyl-4,4′-dicarboxylato)-ruthenium(II) bis-tetrabutylammonium). The mixture ratio of Ti:Zr in the semiconductor compound according to the present invention is 1000:1-1:1000, preferably approximately 200:1-10:1, more preferably approximately 99:1. Exemplary compounds in accordance with the present invention are Ti 0.8 Zr 0.2 O 2 , Ti 0.9 Zr 0.1 O 2 and Ti 0.99 Zr 0.01 O 2 .
The various application techniques by which the semiconductor particles are applied, as e.g. referred to in claim 19 , are known to someone skilled in the art. The lift-off process is e.g. described in EP 04009742.0 and EP 04009743.8, both filed on Apr. 23,2004, the contents of which is incorporated in its entirety by reference thereto.
To increase the efficiency of DSSC towards a value compatible with conventional solar cell techniques, not only J SC and FF, but also V OC has to be increased substantially. To increase open circuit voltage by changing the semiconductor material, the present inventors have found the following: Since V OC is dependent on the difference between conduction band edge of the semiconductor material and the redox potential of the charge mediator (compare FIG. 1 ), it is possible to increase V OC by raising the conduction band edge of the semiconductor material. However, the energetic level of the conduction band edge also determines the efficiency of electron injection from the dye molecule into the conduction band. It therefore must not lie too high when compared to the excited state of the dye molecule. As a consequence, one cannot expect to find the perfect fit of the conduction band edge position in nature. To adjust and optimise the position of the conduction band edge, the present inventors therefore made use of band-gap engineered semiconductor materials. In one embodiment they used band-gap engineered, synthesised mixed oxides. They allow for the careful adjustment of the band edge energies within some given limits. E.g., when one component A of a binary compound AC v is in part exchanged by another component B and the two binary components AC v and BC z have a different band gap, then the band gap of the ternary component A x B 1-x C y will change with the amount of A and B in the compound between the values of AC v and BC z . This is illustrated in FIG. 2 . Additionally, for more specific applications, the use of dyes with different absorption spectrum, e.g. longer wavelength region and therefore energetically lower LUMO (where LUMO stands for lowest unoccupied molecular orbital) might be of advantage. To optimise the efficiency of these cells, a mixed oxide with reduced conduction band edge is preferred.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following reference is made to the figures, wherein
FIG. 1 shows the schematics of the energy levels in a DSSC under illumination. V OC is determined by the band edge of the conduction band (CB) and the redox potential of a redox-couple as charge mediator, e.g. I − I − 3 . VB denotes the valence band of the semiconductor.
FIG. 2 shows a schematic description of the dependence of the energetic positions of valence band edge and conduction band edge on atomic composition of the semiconductor material.
FIG. 3 shows results of absorption measurements with porous layers using an integrating sphere to collect directly transmitted and scattered light. The layers consist either of TiO 2 alone (smaller band gap) or of a mixed semiconductor oxide made of Ti 0.8 Zr 0.2 O 2 .
FIG. 4 shows the current density as a function of voltage for cells measured under illumination with white light (100 nmW/cm 2 ). The mixed oxide layer (x=0.99, Ti 0.99 Zr 0.01 O 2 ) shows higher open circuit voltage and higher short current density. As a result, the power conversion efficiency is higher than for a “pure” oxide (TiO 2 ).
FIG. 5 shows the lattice spacing of a mixed oxide as a function of Zr content.
FIG. 6 shows the current open circuit voltage of DSSCs as a function of Zr content.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Furthermore, reference is made to the following example which is given to illustrate, not to limit the present invention.
EXAMPLE
By means of UV-vis spectroscopy it could be shown that using Ti and Zr in a mixed oxide leads to an increased band gap when compared to the pure TiO 2 since ZrO 2 has a larger band gap. The absorption of a porous film of mixed oxide with an atomic ratio of Zr:Ti=1:4 is depicted in FIG. 3 together with the absorption of a pure TiO 2 material. To correctly account for direct transmitted and scattered light, the measurement has been done with the help of an integrating sphere. Comparison between the mixed oxide and the pure TiO 2 clearly shows the onset of the absorption of the mixed oxide to be at shorter wavelengths indicating a larger band gap of the mixed oxide. In FIG. 5 , the lattice spacing as obtained by X-ray diffraction is shown as a function of Zr content. The continuous increase proved that a new material/compound rather than a mixture of two materials has been produced. When measuring I-V-characteristics of cells with this mixed oxide, they show indeed an increased V OC as illustrated in FIG. 6 . It can be seen that V OC increases as the Zr content increases in comparison to pure TiO 2 . However, the conduction band edge can be too high for an effective injection of electrons into the conduction band, depending on the dye molecule and band edge shift. This is indeed the case for the dye molecules used in the present case of the 1:4 ratio of Zr and Ti. Reduced Zr content however leads to an increase of both V OC and I SC as shown in FIG. 4 . As a consequence, the overall power conversion efficiency was improved from η=7.1% for the reference cell to η=8.0% for the cell based on the mixed oxide with a content of 1% Zr (measured at 100 mW/cm 2 , irradiated area was 0.25 cm 2 ).
Scheme for Preparing Mixed Oxides and Solar Cells:
Mixed oxides were prepared either by means of a post treatment of the pre-sintered porous TiO 2 layers or by the synthesis of mixed oxides by means of thermal hydrolysis using at least two different precursor molecules.
A general synthetic route for the synthesis of mixed oxides can be described as follows: x mole of zirconium isopropoxide, Zr( i PrO) 4 were mixed with (1−x) mole of titanium isopropoxide, Ti( i PrO) 4 . The mixture was poured under continuous stirring into a beaker containing distilled water. The resulting milky mixed oxide suspension was heated up at 80° C. in the presence of HNO 3 0.1 M. Finally the mixture was poured into a teflon inlet inside a reactor and heated up at 240° C. for 12 hours. The reaction conditions were adjusted to give the required average particle size and a homogeneous distribution of the compounds in the particles.
The DSSC are assembled as follows: A 30-nm-thick bulk TiO 2 blocking layer is formed on FTO (approx. 100 nm on glass). A 10-μm-thick porous layer of semiconductor particles is screen printed on the blocking layer and sintered at 450° C. for half an hour. If the mixed oxide is formed by means of a post treatment of the first material, the porous layer, which might be, e.g., TiO 2 , is immersed in, e.g., ZrO(NO 3 ) 2 for 1 h. The layer is then again sintered at 450° C. for 30 min. As a result, the Zr ions are penetrated into the TiO 2 material and have replaced some of the Ti ions and a mixed oxide is formed which is not just a core-shell-structure as described in Diamant et al, but wherein Zr has replaced Ti throughout the semiconductor layer. As a second possibility, the mixed oxide from the synthesis described above can be used directly for preparation of the porous layers.
Red-dye-bis-TBA molecules were adsorbed to the particles via self-assembling out of a solution in ethanol (0.3 mM) and the porous layer was filled with electrolyte containing I − /I 3 − as redox couple (15 mM). A reflective platinum back electrode was attached with a distance of 6 μm from the porous layer.
The improvement in efficiency of a mixed oxide DSSC in comparison to a DSSC based on TiO 2 only is 12.7% (8.0% vs. 7.1%).
The features of the present invention disclosed in the specification, the claims and/or in the accompanying drawings, may, both separately, and in any combination thereof, be material for realizing the invention in various forms thereof. | The present invention relates to a semiconductor compound having the general formula A x B 1-x C y , to a method of optimizing positions of a conduction band and a valence band of a semiconductor material using said semiconductor compound, and to a photoactive device comprising said semiconductor compound. | 8 |
This is a Request for filing a continuation or continuation-in-part application, entitled CONTROLLING AN UNDERGROUND OBJECT, under 35 U.S.C. 111(a) of pending prior application Ser. No. 09/504,833, filed on Feb. 16, 2000, now U.S. Pat. No. 6,606,032 entitled CONTROLLING AN UNDERGROUND OBJECT,
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to the control of an underground object. It is particularly, but not exclusively, concerned with the control of a sonde forming part of an underground boring tool.
Summary of the Prior Art
It is well known that if an underground boring tool generates a magnetic field, that magnetic field can be detected above ground by a suitable locator. An example of this is described in e.g WO96/29615 in which a solenoid on or in the underground tool generates a magnetic field which is detected to measuring locations. It is also possible, by modulating the magnetic field, to transmit information from the underground boring tool to the locator. Therefore, it is possible to have a sonde in which such field generation, modulation, etc is controlled. The sonde then makes it possible to transmit information from the underground boring tool to the locator.
In particular, it is possible for the sonde to transmit data representing the orientation of the underground boring tool. In. WO96/29615, the boring tool incorporated a tilt sensor, and the sonde could then transmit the data from that sensor to the locator. Other sensors, such as roll sensors, may also be provided.
In such arrangements, the sonde generated a low frequency electromagnetic field (typically 8 to 30 kHz), which carrier is modulated to transmit sensor data. Such communication is thus from the sonde to the locator, and there-is no direct communication from the locator to the sonde.
Normally, the carrier signal generated by the sonde is at a predetermined frequency. The locator is then controlled to detect that carrier frequency, and the modulations thereon. However, signalling between the sonde and the locator may be affected by interference from underground sources of electromagnetic radiation such as electrical cables, or the magnetic field distortion effects of buried metallic structures. Such interference effects are frequency dependent, and therefore it is possible that transmission between the sonde and the locator at a particular frequency may be greatly affected by such interference, whereas transmission at another frequency may not be affected, or affected much less. Of course, changing the carrier frequency may also affect the range of transmission between the sonde and the locator, battery life, etc, and therefore there is potentially a balance between these factors. If the operator of the locator finds that interference is a problem, the operator may decide that operating at another carrier frequency would be beneficial. However, in the existing systems, it is not possible for the operator to signal to the sonde to change frequency.
It would, of course, be possible to provide a suitable signalling path from the locator to the sonde by increasing the complexity of both the locator and the sonde. This would increase the size and cost of the sonde, which may not be desirable or practical for an underground boring tool.
However, existing underground boring tools are normally connected to their drive in a way which permits the drive to rotate the boring tool. Many underground boring tools have an axially offset slanted face which enables the boring tool to be steered so that it moves in the desired direction at any time. In order to detect this rotation, sondes associated with such tools include a roll sensor, information from which can be transmitted to the locator. In normal circumstances, the information from the roll sensor is used by the operator to control the direction of movement of the boring tool.
SUMMARY OF THE INVENTION
However, it has been realised in accordance with the present invention that if a predetermined rotation or rotation sequence is applied to the underground boring tool, a roll sensor can detect such rotation and the rotation may be treated as a command for the sonde. Thus, if the operator wants to signal to the sonde to change carrier frequency, a predetermined rotation or sequence of rotations is applied to the underground or inaccessible boring tool, detected by the roll sensor of the sonde, which sonde then determines the frequency change needed.
Although the present invention has been formulated with particular application to an underground boring tool, it is applicable to an control of an underground or inaccessible object in which a predetermined rotation or sequence of rotations is applied to that object, which rotations are treated as commands to signalling operations from the underground object.
Where there is a single rotation, the present invention may provide that a change in carrier frequency of a sonde in the underground boring tool may be triggered by a rotation which is different from that needed to trigger a change of the sonde to a state in which it does not generate electromagnetic radiation (a “park” state). Alternatively, if the sonde does not have such a park state, the change in frequency may be triggered by a single rotation.
It should be noted that the present invention is not limited to the case where the command triggers a change in carrier frequency but includes arrangements in which the command triggers other changes in functions of the sonde.
Preferably, a sequence of rotations is used to transmit a command, each rotation of which must be completed within pre-set time limits. The sequence is then chosen so that it will not occur during the normal operation of the boring tool. The use of a time limit for each rotation in the sequence of rotations significantly reduce the probability of the detection of a command during normal activities of the underground boring tool.
The present invention thus permits signalling to the sonde in an underground boring tool without modification to the boring tool or significant alteration of the features or the physical size of the sonde. In addition to altering the carrier frequency of the sonde, other features of operation, such as data output sequence, data transfer rate, or carrier output power may be controlled by signalling using the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the present invention will now be described in detail, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a schematic block diagram of an embodiment of the present invention;
FIG. 2 shows the underground boring tool of FIG. 1 in more detail;
FIG. 3 is a block circuit diagram of the sonde of the boring tool of FIG. 2 ; and
FIG. 4 is a block circuit diagram of the locator of the embodiment of FIG. 1 .
DETAILED DESCRIPTION
Referring first to FIG. 1 , an underground boring tool 10 is driven from a drive means 11 via a drive shaft 12 . The drive means is arranged to move the boring tool 10 forward, but also to impart rotations to the boring tool 10 . The boring tool 10 has a slanted leading face 13 , and thus the orientation of the boring tool 10 affects the direction in which it will move.
The boring tool 10 contains a sonde 20 , which incorporates a roll sensor which can detect the axial orientation of the boring tool 10 . The sonde also includes means for generating a magnetic field, which generating means is controllable so that the magnetic field has a carrier frequency and a modulation means, thus the frequency may be modulated to transmit data from the sonde 20 . That magnetic field is detected by a suitable locator 30 . That locator 30 has means for signalling to a remote station 40 , which remote station is connected to the drive means 11 . It is thus possible for the operator of the locator 30 to control the movement of the underground boring tool 10 from the location of the locator, by signalling to the remote station 40 , which then controls the drive means to drive the underground boring tool 10 in a suitable direction.
The sonde 20 is normally battery-driven and therefore to extend the total number of hours the sonde 20 underground, it may have a power saving mode for times in which the sonde 20 is not required to transmit data. This is known as the “park” mode. In that park mode, the sonde turns off the electromagnetic transmission, and also any other circuits of the sonde 20 which are not used. In order to initiate the park mode, the boring tool 10 is rotated through a predetermined roll angle, which can be detected by the tilt sensor of the sonde 20 . When the roll sensor detects that such a rotation has occurred, and there has been no subsequent rotation for a suitable period such as 2 or 3 minutes, the sonde enters the park mode. When the sonde detects that predetermined rotation, it may trigger a display on the remote station 40 to indicate to the operator that it has received the command to change to the park mode after the predetermined delay, so that the operator can initiate another rotation if the park mode is not needed. The park mode is cancelled immediately a further rotation of the underground boring tool is detected by the sonde 20 .
FIG. 2 shows the underground boring tool 10 in more detail. The slanted leading face 13 is more clearly shown, and FIG. 2 also shows that the boring tool 10 has a slot 21 therein to aid the radiation of electromagnetic signals from the sonde 20 . The sonde 20 is rotationally keyed to the rest of the boring tool 10 by a key 22 .
In accordance with the present invention, the underground boring tool is rotated through a predetermined angle a plurality of times. That predetermined angle may be the same as that needed to initiate the park mode, but this is not a problem provided the time interval between successive rotations is less than that needed-to trigger the park mode itself.
If there are n steps in the sequence, the number of possible commands to the sonde 20 , in addition to the park command, is n−1. If the angle of successive rotations in the sequence is different from that needed to trigger the park mode, there would then be n possible commands, but it is convenient for the angles to be the same.
In such an arrangement, each rotation in the sequence must be completed within a suitable time, such as 60s otherwise the command will not be recognised. This use of a time limit for each step to be completed significantly reduces the probability of a command being identified during normal activities of the underground boring tool 10 .
The ability to send commands to the sonde 20 by rotating the boring tool 10 in a suitable sequence of rotations permits an operator to change the operation of the sonde. For example, signalling between the sonde 20 and the locator 30 may be affected by conductors such as utility lines and pipes 50 , 51 underground adjacent the boring tool 10 . The interference generated is often frequency dependent, and therefore a change in carrier frequency may reduce the interference of the signalling. Therefore, if the operator using the locator 30 finds that there is interference, e.g because particular signals from the sonde 20 are not detected, a signal may be generated via the remote station 40 to the drive means 11 to generate a command by rotation of the underground boring tool which causes the sonde 20 to change its carrier frequency. The operator may then determine if the interference is reduced, and then the sonde 20 continues to operate at that new frequency. If there is still interference, the operator may again trigger the sonde 20 to change frequency by causing another command to be transmitted to the sonde 20 by rotation of the boring tool 10 . Other commands may change data output sequence, data transfer rate, or the output power of the carrier signal.
FIG. 3 shows the electrical structure of the sonde 20 in more detail. The sonde 20 is powered by a battery pack 60 , which provides the input to a power supply module 61 which outputs regulated supplies for the circuits of the sonde 20 . The control of the sonde 20 is by a microprocessor 62 which receives inputs from a battery sensor 63 , a pitch sensor 64 , a roll sensor 65 and a temperature sensor 66 . The processor receives data representing the outputs of the sensor 63 to 66 and generates two outputs. One output controls a modulation unit 67 which encodes the data which the sonde 20 is to transmit, and the second output from the microprocessor 62 controls an output signal clock 68 which generates a carrier signal which is modulated by the output from the modulation unit 67 in an amplifier 69 . The signal from the microprocessor 62 to the output signal clock 68 determines the frequency or frequencies which that clock outputs to the amplifier 69 . The amplifier 69 then controls a solenoid 70 to generate electromagnetic signals in which the carrier signal from the output clock 68 is modulated by the output from the modulation unit 67 .
In this embodiment, it is preferable for the sensors to operate step wise and thus, as shown in FIG. 3 , the battery sensor has four output levels, the pitch sensor determines the pitch plus or minus 45° in steps of 0.1°, and the roll sensor determines rotations in 12 or 16 equal sectors. Thus, the roll sensor permits a sequence of rotations to be detected, in order to send commands to the sonde 20 by rotating the boring tool 10 in a suitable sequence of rotations. If such a sequence of rotations generates a command which is identified by the microprocessor 62 as one involving change of the output frequency, a suitable change is applied to the output clock 68 .
FIG. 4 then shows in more detail a possible structure for the locator 30 . The locator has a detection coil 80 , the output of which is passed via a pre-amplifier 81 , a band pass filter 82 , and an adjustable gain amplifier 83 to a mixer 84 . The mixer 84 also receives an input from a frequency synthesiser 85 , the frequency of which is selected by a suitable input from the remote station 40 in a way which corresponds to the frequency of the carrier signal from the sonde 20 . Additionally, when the sonde frequency is changed, the locator frequency synthesiser 85 is also changed under control of the operator/computer so that the data can be received at the new frequency. The output of the mixer 84 is then passed via a band pass filter 86 and an automatic gain control amplifier 87 to a demodulator 88 . The demodulator 88 receives the signal from the automatic gain control amplifier 87 and passes it directly, and via a band pass filter 89 , to a mixer 90 , the output of which passes via a low pass filter 91 and a comparator 92 , to output data representing the data applied as a modulation to the carrier signal from the sonde 20 . That data output may then be passed back to the remote station 40 . | In order to control the sonde of an underground object, such as an underground boring tool, a predetermined sequence of rotation steps is applied to the object and that sequence is detected. The detection of the appropriate sequence causes the sonde to change its function, for example by changing the carrier frequency of the signal transmitted by the sonde on to change the data output sequence or transfer rate, or to change output power. While it is possible to use a single rotation step, the use of more than one step, with each step to be carried out within a predetermined time, reduces the risk of error. | 4 |
BACKGROUND
[0001] 1. Technical Field
[0002] The present invention relates to workload balancing and, more particularly, to meeting scheduling.
[0003] 2. Description of the Related Art
[0004] In many large companies, a significant amount of employee time is spent in meetings, leaving little time for actual work during the day. As a result, many workers end up working after hours or over the weekends to complete their tasks. The requester of the meeting may not be aware of already-committed workloads for people being invited to attend the meetings, which may be especially problematic for workers who are expected to bill a certain number of billable hours per week.
[0005] This reflects a modern-day tragedy of the commons, referring to an economic theory in which individuals, acting independently and rationally according to each one's self-interest, behaves contrary to the whole group's long-term best interests by depleting some common resource. In this case, the common resource is time, and an overabundance of meetings cuts sharply into the amount of man-hours available to the company for productive work.
[0006] Existing solutions to this problem include individuals blocking out a set number of hours on their calendar for meetings. However, this may decrease the overall productivity of teams for the benefit of individual productivity if it makes the person inaccessible. This can be a particularly difficult problem in globally distributed teams. Another option is for an individual to decline the meeting invitation, which may make the individual appear rude to co-workers and management.
SUMMARY
[0007] A method for scheduling includes comparing a time commitment for a scheduling request, belonging to a scheduling category, to a difference between an invitee's existing time commitments for the scheduling category and a maximum time limit for the scheduling category. The scheduling request is allowed if a sum of the time commitment for the scheduling request and the invitee's existing time commitments for the scheduling category falls below the maximum time limit. The scheduling request is allowed if the scheduling request matches one or more override rules.
[0008] A method for scheduling includes comparing a time commitment for a scheduling request to a difference between an invitee's existing time commitments for a scheduling category that includes the scheduling request and a maximum time limit for the scheduling category. The scheduling request is allowed if a sum of the time commitment for the scheduling request and the invitee's existing time commitments for the scheduling category falls below the maximum time limit. The scheduling request is allowed if the scheduling request matches one or more override rules. The override rules include a rule that allows scheduling requests that come from external users that are external to the invitee's organization, a rule that allows scheduling requests that come from a member of a group shared by the invitee, a rule that allows scheduling requests that come from an executive or other person of authority in the invitee's organization, and a rule that allows scheduling requests that are marked as being urgent.
[0009] A scheduling system includes a scheduling module. The scheduling monitor includes a processor configured to compare a time commitment for a scheduling request to a difference between an invitee's existing time commitments for a scheduling category that includes the scheduling request and a maximum time limit for the scheduling category, to allow the scheduling request if a sum of the time commitment for the scheduling request and the invitee's existing time commitments for the scheduling category falls below the maximum time limit, and to allow the scheduling request if the scheduling request matches one or more override rules.
[0010] These and other features and advantages will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] The disclosure will provide details in the following description of preferred embodiments with reference to the following figures wherein:
[0012] FIG. 1 is a block/flow diagram of a scheduling method in accordance with the present principles;
[0013] FIG. 2 is a block diagram of a scheduling system in accordance with the present principles; and
[0014] FIG. 3 is a block/flow diagram of a scheduling method in accordance with the present principles.
DETAILED DESCRIPTION
[0015] Embodiments of the present invention allow invitees (alternatively called “users” herein) to set a limit for the number of hours per week to be allocated to meetings. The user can further configure the settings to override the limit when the meeting request is from important stakeholders, such as clients, or when meeting requests are related to billable work. In this manner, the user can increase the number of hours available for productive work, while still being responsive to meeting requests that have a high importance.
[0016] The present embodiments may be integrated with existing scheduling software, for example through the use of a plugin. It is particularly contemplated that the present embodiments may be implemented as a software module using a portable programming language. The present embodiments allow a user to improve their productivity and work-life balance by setting a limit on meetings that are not directly related to currently committed deliverables. This process is performed automatically, according to pre-set priorities, allowing a user to filter meeting requests automatically. When a meeting request passes through the filter, either because there are sufficient unallocated hours for it, or because it matches one or more override criteria, the user is given the option of accepting or declining the request manually.
[0017] Referring now to FIG. 1 , a method for scheduling a meeting is shown. Block 102 receives a meeting request for the user. The request may come from a co-worker, a boss, any other third party, or even from the user themselves. Block 104 determines whether the request would put the user over their limit for meetings. The limit in this case may represent a set number of hours allocated for meetings in a week, a percentage of the week to be so allocated, a set number of meetings, or some other threshold meant to place a limit on how much time the user spends in meetings relative to more directly productive types of work. It should be noted that the meeting request may also be categorized according to a meeting type, and so there may be multiple limits pertaining to different meeting types. For example, meetings with clients may have more time allotted to them in a week than meetings with co-workers. If the request does not put the user over their limit, block 106 allows the meeting request and presents the request to the user for a decision as to whether to accept or decline the request.
[0018] Otherwise, block 108 determines whether the request triggers an override. The overrides are a set of user-configurable rules that determine whether a request will be allowed despite running over a user's limit. The overrides thereby provide a way to prioritize important meeting requests, so that they do not get ignored accidentally. The overrides may include one or more of the following rules:
[0019] 1. Internal vs. external rule. This rule determines whether the meeting requester is internal or external to the company. One way of accomplishing this would be to compare a domain name of the requester to a list of approved internal addresses. External requests are more likely to be from clients, for example, and therefore more likely to be high-priority requests. Implementing this rule would therefore override the limit to allow the user to accept or reject the request.
[0020] 2. Group rule. The user can create specific groups of users that will have override capability. In one example, these groups might represent teams or committees that the user belongs to, where meeting requests from such people are more likely to be particularly relevant to the user or to be directly related to the user's productivity. In this case, members of the same team would then be able to issue meeting requests that exceed the user's limits.
[0021] 3. Executive rule. If the meeting request is from an executive of the user's company, the invitee's supervisor, or other person of authority, then an override may be triggered so that the user may personally review requests they will be held accountable for.
[0022] 4. Urgency rule. If the meeting request is marked urgent, then an override may be triggered. An urgency rule may furthermore be configured with exceptions for particular parties in the event that the user receives many invitations from some party that are needlessly marked as being urgent.
[0023] 5. Customizable rules. Users may have the ability to develop override rules of their own based on a wide variety of conditions or combinations of conditions. For example, the user might select one or more customizable conditions (e.g., a source country for a request) and set parameters that determine when the condition is triggered (e.g., allow overrides for meeting requests from China). These conditions may also include temporal conditions, relating to a time of day, week, or month that the request is for, geographic conditions (e.g., where the meeting is to be located), conditions relating to the type of meeting (e.g., in-person versus teleconference), and so on. Through a combination of such conditions, the user has substantial flexibility in controlling the portion of their time spent in meetings.
[0024] If the request triggers an override, block 106 allows the meeting request to go to the user for personal review. If not, block 110 declines the meeting request using, for example, a standard template or form message. The user may have the option of personalizing the automated message for block 110 and may use more than one template in accordance with one or more criteria.
[0025] The present invention may be a system, a method, and/or a computer program product. The computer program product may include a computer readable storage medium (or media) having computer readable program instructions thereon for causing a processor to carry out aspects of the present invention.
[0026] The computer readable storage medium can be a tangible device that can retain and store instructions for use by an instruction execution device. The computer readable storage medium may be, for example, but is not limited to, an electronic storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, a semiconductor storage device, or any suitable combination of the foregoing. A non-exhaustive list of more specific examples of the computer readable storage medium includes the following: a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a static random access memory (SRAM), a portable compact disc read-only memory (CD-ROM), a digital versatile disk (DVD), a memory stick, a floppy disk, a mechanically encoded device such as punch-cards or raised structures in a groove having instructions recorded thereon, and any suitable combination of the foregoing. A computer readable storage medium, as used herein, is not to be construed as being transitory signals per se, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through a waveguide or other transmission media (e.g., light pulses passing through a fiber-optic cable), or electrical signals transmitted through a wire.
[0027] Computer readable program instructions described herein can be downloaded to respective computing/processing devices from a computer readable storage medium or to an external computer or external storage device via a network, for example, the Internet, a local area network, a wide area network and/or a wireless network. The network may comprise copper transmission cables, optical transmission fibers, wireless transmission, routers, firewalls, switches, gateway computers and/or edge servers. A network adapter card or network interface in each computing/processing device receives computer readable program instructions from the network and forwards the computer readable program instructions for storage in a computer readable storage medium within the respective computing/processing device.
[0028] Computer readable program instructions for carrying out operations of the present invention may be assembler instructions, instruction-set-architecture (ISA) instructions, machine instructions, machine dependent instructions, microcode, firmware instructions, state-setting data, or either source code or object code written in any combination of one or more programming languages, including an object oriented programming language such as Smalltalk, C++ or the like, and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The computer readable program instructions may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider). In some embodiments, electronic circuitry including, for example, programmable logic circuitry, field-programmable gate arrays (FPGA), or programmable logic arrays (PLA) may execute the computer readable program instructions by utilizing state information of the computer readable program instructions to personalize the electronic circuitry, in order to perform aspects of the present invention.
[0029] Aspects of the present invention are described herein with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer readable program instructions.
[0030] These computer readable program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks. These computer readable program instructions may also be stored in a computer readable storage medium that can direct a computer, a programmable data processing apparatus, and/or other devices to function in a particular manner, such that the computer readable storage medium having instructions stored therein comprises an article of manufacture including instructions which implement aspects of the function/act specified in the flowchart and/or block diagram block or blocks.
[0031] The computer readable program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus or other device to produce a computer implemented process, such that the instructions which execute on the computer, other programmable apparatus, or other device implement the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0032] The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions.
[0033] Reference in the specification to “one embodiment” or “an embodiment” of the present principles, as well as other variations thereof, means that a particular feature, structure, characteristic, and so forth described in connection with the embodiment is included in at least one embodiment of the present principles. Thus, the appearances of the phrase “in one embodiment” or “in an embodiment”, as well any other variations, appearing in various places throughout the specification are not necessarily all referring to the same embodiment.
[0034] It is to be appreciated that the use of any of the following “/”, “and/or”, and “at least one of”, for example, in the cases of “A/B”, “A and/or B” and “at least one of A and B”, is intended to encompass the selection of the first listed option (A) only, or the selection of the second listed option (B) only, or the selection of both options (A and B). As a further example, in the cases of “A, B, and/or C” and “at least one of A, B, and C”, such phrasing is intended to encompass the selection of the first listed option (A) only, or the selection of the second listed option (B) only, or the selection of the third listed option (C) only, or the selection of the first and the second listed options (A and B) only, or the selection of the first and third listed options (A and C) only, or the selection of the second and third listed options (B and C) only, or the selection of all three options (A and B and C). This may be extended, as readily apparent by one of ordinary skill in this and related arts, for as many items listed.
[0035] Referring now to FIG. 2 , a scheduling system 200 is shown. The system 200 includes a processor 202 and memory 204 . The processor 202 is a hardware processor, and it is contemplated that one or more software modules may be stored in memory 204 and may be executed using the processor 202 . Alternatively, the modules may be implemented as hardware in the form of, e.g., an application-specific integrated chip or a field-programmable gate array. The memory 204 stores a user profile 206 which includes the user's scheduling information. The scheduling information may include, for example, a calendar that represents existing commitments as well as a user-settable time limit for meetings in one or more categories. The memory 204 also includes one or more override rules 208 that provide conditions under which a scheduling request may override a user's time limit for meetings.
[0036] A scheduling module 210 then accepts new scheduling requests and determines whether to allow them to pass to the user for review or to deny them based on the user's time limit, the user's existing commitments, and the override rules 208 . The scheduling module 210 may be, for example, a plugin to an existing mail client or groupware application that provides the above functionality on an existing calendar system, or alternatively the scheduling module 210 can be a standalone application configured to manage users' calendars. The scheduling module 210 determines whether or not to present a given request to the user. If the scheduling module 210 determines that the request should be declined, it automatically declines the request in accordance with settings stored in the user profile 206 . A user interface 212 allows the user to make changes to the user profile 206 and override rules 208 and furthermore allows the user to make direct decisions as to whether to accept or decline a scheduling request that has made it through the scheduling module 210 . The user interface 212 may be local to the scheduling system 200 or may be on a separate device that accesses the scheduling system through a network.
[0037] Referring now to FIG. 3 , a block/flow diagram of an overview of the present principles is provided. Block 302 blocks an incoming meeting request if it exceeds a number of hours that a user has allotted for meetings (or a number of such hours remaining). Block 304 then overrides the block if the request meets one or more rules as described above.
[0038] Having described preferred embodiments of improving productivity through automated work balancing (which are intended to be illustrative and not limiting), it is noted that modifications and variations can be made by persons skilled in the art in light of the above teachings. It is therefore to be understood that changes may be made in the particular embodiments disclosed which are within the scope of the invention as outlined by the appended claims. Having thus described aspects of the invention, with the details and particularity required by the patent laws, what is claimed and desired protected by Letters Patent is set forth in the appended claims. | Methods and systems for scheduling include comparing a time commitment for a scheduling request, belonging to a scheduling category, to a difference between an invitee's existing time commitments for the scheduling category and a maximum time limit for the scheduling category. The scheduling request is allowed if a sum of the time commitment for the scheduling request and the invitee's existing time commitments for the scheduling category falls below the maximum time limit. The scheduling request is allowed if the scheduling request matches one or more override rules. | 6 |
This application is a continuation of U.S. Non-Provisional application Ser. No. 09/634,038, filed Aug. 8, 2000, and now U.S. Pat. No. 7,412,978,which is a divisional of U.S. Non-Provisional application Ser. No. 09/003,378, filed Jan. 6, 1998, now abandoned which claimed the benefit of U.S. Provisional Application Ser. No. 60/037,961, filed Feb. 20, 1997. The disclosures of U.S. Non-Provisional application Ser. Nos. 09/634,038 and 09/003,378 and U.S. Provisional Application Ser. No. 60/037,961 are incorporated herein by reference in their entirety.
FIELD OF INVENTION
The field of the present invention is the long-term augmentation and/or repair of dermal, subcutaneous, or vocal cord tissue.
BACKGROUND OF INVENTION
I. In Vitro Cell Culture
The majority of in vitro vertebrate cell cultures are grown as monolayers on an artificial substrate which is continuously bathed in a nutrient medium. The nature of the substrate on which the monolayers may be grown may be either a solid (e.g., plastic) or a semi-solid (e.g., collagen or agar). Currently, disposable plastics have become a preferred substrate for cell culture.
While the growth of cells in two-dimensions is frequently used for the preparation and examination of cultured cells in vitro, it lacks the characteristics of intact, in vivo tissue which, for example, includes cell-cell and cell-matrix interactions. Therefore, in order to characterize these functional and morphological interactions, various investigators have examined the use of three-dimensional substrates in such forms as a collagen gel (Yang et al., Cancer Res. 41:1027 (1981); Douglas et al., In Vitro 16:306 (1980); Yang et al., Proc. Nat'l Acad. Sci. 2088 (1980)), cellulose sponge (Leighton et al., J. Nat'l Cancer Inst. 12:545 (1951)), collagen-coated cellulose sponge (Leighton et al., Cancer Res. 28:286 (1968)), and GELFOAM® (Sorour et al., J. Neurosurg. 43:742 (1975)). Typically, these aforementioned three-dimensional substrates are inoculated with the cells to be cultured, which subsequently penetrate the substrate and establish a “tissue-like” histology similar to that found in vivo. Several attempts to regenerate “tissue-like” histology from dispersed monolayers of cells utilizing three-dimensional substrates have been reported. For example, three-dimensional collagen substrates have been utilized to culture a variety of cells including breast epithelium (Yang, Cancer Res. 41:1021 (1981)), vascular epithelium (Folkman et al., Nature 288:551 (1980)), and hepatocytes (Sirica et al., Cancer Res. 76:3259 (1980)), however long-term culture and proliferation of cells in such systems has not yet been achieved. Prior to the present invention, a three-dimensional substrate had not been utilized in the autologous in vitro culture of cells or tissues derived from the dermis, fascia, or lamina propria.
II. Augmentation and/or Repair of Dermal and Subcutaneous Tissues
In the practice of cosmetic and reconstructive plastic surgery it is frequently necessary to employ the use of various injectable materials to augment and/or repair defects of the subcutaneous or dermal tissue, thus effecting an aesthetic result. Non-biological injectable materials (e.g., paraffin) were first utilized to correct facial contour defects as early as the late nineteenth century. However, numerous complications and the generally unsatisfactory nature of long-term aesthetic results caused the procedure to be rapidly abandoned. More recently, the use of injectable silicone became prevalent in the 1960's for the correction of minor defects, although various inherent complications also limited the use of this substance. Complications associated with the utilization of injectable liquid silicone include local and systemic inflammatory reactions, formation of scar tissue around the silicone droplets, rampant and frequently-distant unpredictable migration throughout the body, and localized tissue breakdown. Due to these potential complications, silicone is not currently approved for general clinical use. Although the original proponents of silicone injection have continued experimental programs utilizing specially manufactured “Medical Grade” silicone (e.g., Dow Corning MDX 4.40110) with a limited number of subjects, it appears highly unlikely that its use will be generally adopted by the surgical community. See e.g., Spira and Rosen, Clin. Plastic Surgery 20:181 (1993); Matton et al., Aesthetic Plastic Surgery 9:133 (1985).
It has also been suggested to compound extremely small particulate species in a lubricious material and inject such combination micro-particulate media subcutaneously for both soft and hard tissue augmentation and repair, however success has been heretofore limited. For example, bioreactive materials such as hydroxyapatite or cordal granules (osteo conductive) have been utilized for the repair of hard tissue defects. Subsequent undesirable micro-particulate media migration and serious granulomatous reactions frequently occur with the injection of this material. These undesirable effects are well-documented with the use of such materials as polytetrafluoroethylene (TEFLON®) spheres of small diameter (˜90% of particles having a diameter of 30 μm) in glycerin. See e.g., Malizia et al., JAMA 251:3277 (1984). Additionally, the use of very small diameter particulate spheres (˜1-20 μm) or small elongated fibrils (˜1-30 μm in diameter) of various materials in a biocompatible fluid lubricant as injectable implant composition are disclosed in U.S. Pat. No. 4,803,075. However. while these aforementioned materials create immediate augmentation and/or repair of defects, they also have a tendency to migrate and be reabsorbed from the original injection site.
The poor results initially obtained with the use of non-biological injectable materials prompted the use of various non-immunogenic, proteinaceous materials (e.g., bovine collagen and fibrin matrices). Prior to human injection, however, the carboxyl- and amino-terminal peptides of bovine collagen must first be enzymatically-degraded, due to its highly immunogenic nature. Enzymatic degradation of bovine collagen yields a material (atelocollagen) which can be used in limited quantities in patients pre-screened to exclude those who are immunoreactive to this substance. The methodologies involved in the preparation and clinical utilization of atelocollagen are disclosed in U.S. Pat. Nos. 3,949,073; 4,424,208; and 4,488,911. Atelocollagen has been marketed as ZYDERM® brand atelocollagen solution in concentrations of 35 mg/ml and 65 mg/ml. Although atelocollagen has been widely employed, the use of ZYDERM® has been associated with the development of anti-bovine antibodies in approximately 90% of patients and with overt immunologic complications in 1-3% of patients. See DeLustro et al., Plastic and Reconstructive Surgery 79:581 (1987).
Injectable atelocollagen solution also was shown to be absorbed from the injection site, without replacement by host material, within a period of weeks to months. Clinical protocols calling for repeated injections of atelocollagen are, in practice, primarily limited by the development of immunogenic reactions to the bovine collagen. In order to mitigate these limitations, bovine atelocollagen was further processed by cross-linking with 0.25% glutaraldehyde, followed by filtration and mechanical shearing through fine mesh. The methodologies involved in the preparation and clinical utilization of this material are disclosed in U.S. Pat. Nos. 4,582,640 and 4,642,117. The modified atelocollagen was marketed as ZYPLAST® brand cross-linked bovine atelocollagen. The propertied advantages of cross-linking was to provide increased resistance to host degradation, however this was off-set by an increase in solution viscosity. In addition, cross-linking of the bovine atelocollagen was found to decrease the number of host cells which infiltrated the injected collagen site. The increased viscosity, and in particular irregular increased viscosity resulting in “lumpiness,” not only rendered the material more difficult to utilize, but also made it unsuitable for use in certain circumstances. See e.g., U.S. Pat. No. 5,366,498. In addition, several investigators have reported that there is no or marginally-increased resistance to host degradation of ZYPLAST® cross-linked bovine atelocollagen in comparison to that of the non-cross-linked ZYDERM® atelocollagen and that the overall longevity of the injected material is, at best, only 4-6 months. See e.g., Ozgentas et al., Ann. Plastic Surgery 33:171 (1994); and Matti and Nicolle, Aesthetic Plastic Surgery 14:227 (1990). Moreover, bovine atelocollagen cross-linked with glutaraldehyde may retain this agent as a high molecular weight polymer which is continuously hydrolyzed, thus facilitating the release of monomeric glutaraldehyde. The monomeric form of glutaraldehyde is detectable in body tissues for up to 6 weeks after the initial injection of the cross-linked atelocollagen. The cytotoxic effect of glutaraldehyde on in vitro fibroblast cultures is indicative of this substance not being an ideal cross-linking agent for a dermal equivalent which is eventually infiltrated by host cells and in which the bovine atelocollagen matrix is rapidly degraded, thus resulting in the release of monomeric glutaraldehyde 5 into the bodily tissues and fluids.
Similarly, chondroitin-6-sulfate (GAG), which weakly binds to collagen at neutral pH, has also been utilized to chemically modify bovine protein for tissue graft implantation. See Hansborough and Boyce, JAMA 136:2125 (1989). However, like glutaraldehyde, GAG may be released into the tissue causing unforeseen long-term effects on human subjects. GAG has been reported to increase scar tissue formation in wounds, which is to be avoided in grafts. Additionally, a reduction of collagen blood clotting capacity may also be deleterious in the application in bleeding wounds, as fibrin clot contributes to an adhesion of the graft to the surrounding tissue.
The limitations which are imposed by the immunogenicity of both modified and non-modified bovine atelocollagen have resulted in the isolation of human collagen from placenta (see e.g., U.S. Pat. No. 5,002,071); from surgical specimens (see e.g., U.S. Pat. Nos. 4,969,912 and 5,332,802); and cadaver (see e.g., U.S. Pat. No. 4,882,166). Moreover, processing of human-derived collagen by cross-linking and similar chemical modifications is also required, as human collagen is subject to analogous degradative processes as is bovine collagen. Human collagen for injection, derived from a sample of the patient's own tissue, is currently available and is marketed as AUTOLOGEN®. It should be noted, however, that there is no quantitative evidence which demonstrates that human collagen injection results in lower levels of implant degradation than that which is found with bovine collagen preparations. Furthermore, the utilization of autologous collagen preparation and injection is limited to those individuals who have previously undergone surgery, due to the fact that the initial culture from which the collagen is produced is derived is from the tissue removed during the surgical procedure. Therefore, it is evident that, although human collagen circumvents the potential for immunogenicity exhibited by bovine collagen, it fails to provide long-term therapeutic benefits and is limited to those patient who have undergone prior surgical procedures.
An additional injectable material currently in use as an alternative to atelocollagen augmentation of the subjacent dermis consists of a mixture of gelatin powder, -aminocapronic acid, and the patient's plasma marketed as FIBREL®. See Multicenter Clinical Trial, J. Am. Acad. Dermatbloqy 16:1155 (1987). The action of FIBREL® appears to be dependent upon the initial induction of a sclerogenic inflammatory response to the augmentation of the soft tissue via the subcutaneous injection of the material. See e.g., Gold, J. Dermatologic Surg. Oncology, 20:586 (1994). Clinical utilization of FIBREL® has been reported to often result in an overall lack of implant uniformity (i.e., “lumpiness”) and longevity, as well as complaints of patient discomfort associated with its injection. See e.g., Millikan et al., J. Dermatologic. Surg. Oncoloqy, 17:223 (1991). Therefore, in conclusion, none of the currently utilized protein-based injectable materials appears to be totally satisfactory for the augmentation and/or repair of the subjacent dermis and soft tissue.
The various complications associated with the utilization of the aforementioned materials have prompted experimentation with the implantation (grafting) of viable, living tissue to facilitate augmentation and/or repair of the subjacent dermis and soft tissue. For example, surgical correction of various defects has been accomplished by initial removal and subsequent re-implantation of the excised adipose tissue either by injection (see e.g., Davies et al., Arch. of Otolaryngology - Head and Neck Surgery 121:95 (1995); McKinney & Pandya, Aesthetic Plastic Surgery 18:383 (1994); and Lewis, Aesthetic Plastic Surgery 17:109 (1993)) or by the larger scale surgical-implantation (see e.g., Ersck, Plastic & Reconstructive Surgery 87:219 (1991)). To perform both of the aforementioned techniques a volume of adipose tissue equal or greater than is required for the subsequent augmentation or repair procedure must be removed from the patient. Thus, for large scale repair procedures (e.g., breast reconstruction) the amount of adipose tissue which can be surgically-excised from the patient may be limiting. In addition, other frequently encountered difficulties with the aforementioned methodologies include non-uniformity of the injectate, unpredictable longevity of the aesthetic effects, and a 4-6 week period of post-injection inflammation and swelling. In contrast, in a preferred embodiment, the present invention utilizes the surgical engraftment of autologous adipocytes which have been cultured on a solid support typically derived from, but not limited to, collagen or isolated extracellular matrix. The culture may be established from a simple skin biopsy specimen and the amount of adipose tissue which can be subsequently cultured in vitro is not limited by the amount of adipose tissue initially excised from the patient.
Living skin equivalents have been examined as a methodology for the repair and/or replacement of human skin. Split thickness autographs, epidermal autographs (cultured autogenic keratinocytes), and epidermal allographs (cultured allogenic keratinocytes) have been used with a varying degree of success. However, unfortunately, these forms of treatment have all exhibited numerous disadvantages. For example, split thickness autographs generally show limited tissue expansion, require repeated surgical operations, and give rise to unfavorable aesthetic results. Epidermal autographs require long periods of time to be cultured, have a low success (“take”) rate of approximately 30-48%, frequently form spontaneous blisters, exhibit contraction to 60-70% of their original size, are vulnerable during the first 15 days of engraftment, and are of no use in situations where there is both epidermal and dermal tissue involvement. Similarly, epidermal allografts (cultured allogenic keratinocytes) exhibit many of the limitations which are inherent in the use of epidermal autographs. Additional methodologies have been examined which involve the utilization of irradiated cadaver dermis. However, this too has met with limited success due to, for example, graft rejection and unfavorable aesthetic results.
Living skin equivalents comprising a dermal layer of rodent fibroblast cells cast in soluble collagen and an epidermal layer of cultured rodent keratinocytes have been successfully grafted as allografts onto Sprague Dawley rats by Bell et al., J. Investigative Dermatology 81:2 (1983). Histological examination of the engrafted tissue revealed that the epidermal layer had fully differentiated to form desmonosomes, tonofilaments, keratohyalin, and a basement lamella. However, subsequent attempts to reproduce the living skin equivalent using human fibroblasts and keratinocytes has met with only limited success. In general, the keratinocytes failed to fully differentiate to form a basement lamella and the dermo-epidermal junction was a straight line.
The present invention includes the following methodologies for the repair and/or augmentation of various skin defects: (1) the injection of autologously cultured dermal or fascial fibroblasts into various layers of the skin or injection directly into a “pocket” created in the region to be repaired or augmented, or (2) the surgical engraftment of “strands” derived from autologous dermal and fascial fibroblasts which are cultured in such a manner as to form a three-dimensional “tissue-like” structure similar to that which is found in viva. Moreover, the present invention also differs on a two-dimensional level in that “true” autologous culture and preparation of the cells is performed by utilization of the patient's own cells and serum for in vitro culture.
III. Vocal Cord Tissue Augmentation and/or Repair
Phonation is accomplished in humans by the passage of air past a pair of vocal cords located within the larynx. Striated muscle fibers within the larynx, comprising the constrictor muscles, function so as to vary the degree of tension in the vocal cords, thus regulating both their overall rigidity and proximity to one another to produce speech. However, when one (or both) of the vocal cords becomes totally or partially immobile, there is a diminution in the voice quality due to an inability to regulate and maintain the requisite tension and proximity of the damaged cord in relation to that of the operable cord. Vocal cord paralysis may be caused by cancer, surgical or mechanical trauma, or similar afflictions which render the vocal cord incapable of being properly tensioned by the constrictor muscles.
One therapeutic approach which has been examined to allow phonation involves the implantation or injection of biocompatible materials. It has long been recognized that a paralyzed or damaged vocal cord may be repositioned or supported so as to remain in a fixed location relative to the operable cord such that the unilateral vibration of the operable cord produces an acceptable voice pattern. Hence, various surgical methodologies have been developed which involve the formation of an opening in the thyroid cartilage and subsequently providing a means for the support and/or repositioning of the paralyzed vocal cord.
For example, injection of TEFLON® into the paralyzed vocal cord to increase its inherent “bulk” has been described. See e.g., von Leden et al., Phonosurgery 3:175 (1989). However, this procedure is now considered unacceptable due to the inability of the injected TEFLON® to close large glottic gaps, as well as its tendency to induce inflammatory reactions resulting in the formation of fibrous infiltration into the injected cord. See e.g., Maves et al., Phonosurgery: Indications and Pitfalls 98:577 (1989). Moreover, removal of the injected TEFLON® may be quite difficult should it subsequently be desired or become necessary.
Another methodology for supporting the paralyzed vocal cord which has been employed involves the utilization of a custom-fitted block of siliconized rubber (SILASTIC®). In order to ensure the proper fit of the implant, the surgeon hand carves the SILASTIC® block during the procedure in order to maximize the ability of the patient to phonate The patient is kept under local anesthesia so that he or she can produce sounds to test the positioning of the implant. Generally, the implanted blocks are formed into the shape of a wedge which is totally implanted within the thyroid cartilage or a flanged plug which can be moved back-and-forth within the opening in the thyroid cartilage to fine-tune the voice of the patient.
Although SILASTIC® implants have proved to be superior over TEFLON® injections, there are several areas of dissatisfaction with the procedure including difficulty in the carving and insertion of the block, the large amount of time required for the procedure, and a lack of an efficient methodology for locking the block in place within the thyroid cartilage. In addition, vocal cord edema, due to the prolonged nature of the procedure and repeated voice testing during the operation, may also prove problematic in obtaining optimal voice quality.
Other methodologies which have been utilized in the treatment of vocal cord paralysis and damage include GELFOAM® hydroxyapatite, and porous ceramic implants, as well as injections of silicone and collagen. See e.g., Koufman, Laryngoplastic Phonosurgery (1988). However, these materials have also proved to be less than ideal due to difficulties in the sizing and shaping of the solid implants as well as the potential for subsequent immunogenic reactions. Therefore, there still remains a need for the development of a methodology which allows the efficacious treatment of vocal cord paralysis and/or damage.
SUMMARY OF THE INVENTION
The present invention discloses a methodology for the long-term augmentation and/or repair of dermal, subcutaneous, or vocal cord tissue by the injection or direct surgical placement/implantation of: (1) autologous cultured fibroblasts derived from connective tissue, dermis, or fascia; (2) lamina propria tissue; (3) fibroblasts derived from the lamina propria; or (4) adipocytes. The fibroblast cultures utilized for the augmentation and/or repair of skin defects are derived from either connective tissue, dermal, and/or fascial fibroblasts. Typical defects of the skin which can be corrected with the injection or direct surgical placement of autologous fibroblasts or adipocytes include rhytids, stretch marks, depressed scars, cutaneous depressions of traumatic or non-traumatic origin, hypoplasia of the lip, and/or scarring from acne vulgaris. Typical defects of the vocal cord which can be corrected by the injection or direct surgical placement of lamina propria or autologous cultured fibroblasts from lamina propria include scarred, paralyzed, surgically or traumatically injured, or congenitally underdeveloped vocal cord(s).
The use of autologous cultured fibroblasts derived from the dermis, fascia, connective tissue, or lamina propria mitigates the possibility of an immunogenic reaction due to a lack of tissue histocompatibility. This provides vastly superior post-surgical results. In a preferred embodiment of the present invention, fibroblasts of connective tissue, dermal, or facial origin as well as adipocytes are derived from full-thickness biopsies of the skin. Similarly, lamina propria tissue or fibroblasts derived from the lamina propria are obtained from vocal cord biopsies. It should be noted that the aforementioned tissues are derived from the individual who will subsequently undergo the surgical procedure, thus mitigating the potential for an immunogenic reaction. These tissues are then expanded in vitro utilizing standard tissue culture methodologies.
Additionally, the present invention further provides a methodology of rendering the cultured cells substantially free of potentially immunogenic serum-derived proteins by late-stage passage of the cultured fibroblasts; lamina propria tissue, or adipocytes in serum-free medium or in the patient's own serum. In addition, immunogenic proteins may be markedly reduced or eliminated by repeated washing in phosphate-buffered saline (PBS) or similar physiologically-compatible buffers.
DESCRIPTION OF THE INVENTION
I. Histology of the Skin
The skin is composed of two distinct layers: the epidermis, a specialized epithelium derived from the ectoderm, and beneath this, the dermis, of vascular dense connective tissue, a derivative of mesoderm. These two layers are firmly adherent to one another and form a region which varies in overall thickness from approximately 0.5 to 4 mm in different areas of the body. Beneath the dermis is a layer of loose connective tissue which varies from areolar to adipose in character. This is the superficial fascia of gross anatomy, and is sometimes referred to as the hypodermis, but is not considered to be part of the skin. The dermis is connected to the hypodermis by connective tissue fibers which pass from one layer to the other.
A. Epidermis
The epidermis, a stratified squamous epithelium, is composed of cells of two separate and distinct origins. The majority of the epithelium, of ectodermal origin, undergoes a process of keratinization resulting in the formation of the dead superficial layers of skin. The second component comprises the melanocytes which are involved in the synthesis of pigmentation via melanin. The latter cells do not undergo the process of keratinization. The superficial keratanized cells are continuously lost from the surface and must be replaced by cells that arise from the mitotic activity of cells of the basal layers of the epidermis. Cells which result from this proliferation are displaced to higher levels, and as they move upward they elaborate keratin, which eventually replaces the majority of the cytoplasm. As the process of keratinization continues the cell dies and is finally shed. Therefore, it should be appreciated that the structural organization of the epidermis into layers reflects various stages in the dynamic process of cellular proliferation and differentiation.
B. Dermis
It is frequently difficult to quantitatively differentiate the limits of the dermis as it merges into the underlying subcutaneous layer (hypodermis). The average thickness of the dermis varies from 0.5 to 3 mm and is further subdivided into two strata—the papillary layer superficially and the reticular layer beneath. The papillary layer is composed of thin collagenous, reticular, and elastic fibers arranged in an extensive network. Just beneath the epidermis, reticular fibers of the dermis form a close network into which the basal processes of the cells of the stratum germinativum are anchored. This region is referred to as the basal lamina.
The reticular layer is the main fibrous bed of the dermis. Generally, the papillary layer contains more cells and smaller and finer connective tissue fibers than the reticular layer. It consists of coarse, dense, and interlacing collagenous fibers, in which are intermingled a small number of reticular fibers and a large number of elastic fibers. The predominant arrangement of these fibers is parallel to the surface of the skin. The predominant cellular constituent of the dermis are fibroblasts and macrophages. In addition, adipose cells may be present either singly or, more frequently, in clusters. Owing to the direction of the fibers, lines of skin tension, Langer's lines, are formed. The overall direction of these lines is of surgical importance since incisions made parallel with the lines tend to gape less and heal with less scar tissue formation than incisions made at right-angles or obliquely across the lines. Pigmented, branched connective tissue cells, chromatophores, may also be present. These cells do not elaborate pigment but, instead, apparently obtain it from melanocytes.
Smooth muscle fibers may also be found in the dermis. These fibers are arranged in small bundles in connection with hair follicles (arrectores pilorum muscles) and are scattered throughout the dermis in considerable numbers in the skin of the nipple, penis, scrotum, and parts of the perineum. Contraction of the muscle fibers gives the skin of these regions a wrinkled appearance. In the face and neck, fibers of some skeletal muscles terminate in delicate elastic fiber networks of the dermis.
C. Adipose Tissue/Adipocytes
Fat cells, or adipocytes, are scattered in areolar connective tissue. When adipocytes form large aggregates, and are the principle cell type, the tissue is designated adipose tissue. Adipocytes are fully differentiated cells and are thus incapable of undergoing mitotic division. New adipocytes therefore, which may develop at any time within the connective tissue, arise as a result of differentiation of more primitive cells. Although adipocytes, prior to the storage of lipid, resemble fibroblasts, it is likely that they arise directly from undifferentiated mesenchymal tissue.
Each adipocyte is surrounded by a web of fine reticular fibers; in the spaces between are found fibroblasts, lymphoid cells, eosinophils, and some mast cells. The closely spaced adipocytes form lobules, separated by fibrous septa. In addition, there is a rich network of capillaries in and between the lobules. The richness of the blood supply is indicative of the high rate of metabolic activity of adipose tissue.
It should be appreciated that adipose tissue is not static. There is a dynamic balance between lipid deposit and withdrawal. The lipid contained within adipocytes may be derived from three sources. Adipocytes, under the influence of the hormone insulin, can synthesize fat from carbohydrate. They can also produce fat from various fatty acids which are derived from the initial breakdown of dietary fat. Fatty acids may also be synthesized from glucose in the liver and transported to adipocytes as serum lipoproteins. Fats derived from different sources also differ chemically. Dietary fats may be saturated or unsaturated, depending upon the individual diet. Fat which is synthesized from carbohydrate is generally saturated. Withdrawals of fat result from enzymatic hydrolysis of stored fat to release fatty acids into the blood stream. However, if there is a continuous supply of exogenous glucose, then fat hydrolysis is negligible. The normal homeostatic balance is affected by hormones, principally insulin, and by the autonomic nervous system, which is responsible for the mobilization of fat from adipose tissue.
Adipose tissue may develop almost anywhere areolar tissue is prevalent, but in humans the most common sites of adipose tissue accumulation are the subcutaneous tissues (where it is referred to as the panniculus adiposus), in the mesenteries and omenta, in the bone marrow, and surrounding the kidneys. In addition to its primary function of storage and metabolism of neutral fat, in the subcutaneous tissue, adipose tissue also acts as a shock absorber and insulator to prevent excessive heat loss or gain through the skin.
II. Histology of the Larynx and Vocal Cords
The larynx is that part of the respiratory system which connects the pharynx and trachea. In addition to its function as part of the respiratory system, it plays an important role in phonation (speech). The wall of the larynx is composed of a “skeleton” of hyaline and elastic cartilages, collagenous connective tissue, striated muscle, and mucous glands. The major cartilages of the larynx (the thyroid, cricoid, and arytenoids) are hyaline, whereas the smaller cartilages (the corniculates, cuneiforms, and the tips of the arytenoids) are elastic, as is the cartilage of the epiglottis. The aforementioned cartilages, together with the hyoid bone, are connected by three large, flat membranes: the thyrohyoid, the quadrates, and the cricovocal. These are composed of dense fibroconnective tissue in which many elastic fibers are present, particularly in the cricovocal membrane. The true and false vocal cords (vocal and vestibular ligaments) are, respectively, the free upper boarders of the cricovocal (cricothyroid) and the free lower boarders of the quadrate (aryepiglottic) membranes. Extending laterally on each side between the true and false cords are the sinus and saccule of the larynx, a small slit-like diverticulum. Behind the cricoid and arytenoid cartilages, the posterior wall of the pharynx is formed by the striated muscle of the pharyngeal constrictor muscles.
The epithelium of the mucous membrane of the larynx varies with location. For example, over the vocal folds, the lamina propria of the stratified squamous epithelium is extremely dense and firmly bound to the underlying connective tissue of the vocal ligament. While there is no true submucosa in the larynx, the lamina propria of the mucous membrane is thick and contains large numbers of elastic fibers.
III. Methodologies
A. In Vitro Cell Culture of Fibroblasts or Lamina Propria
While the present invention may be practiced by utilizing any type of non-differentiated mesenchymal cell found in the skin which can be expanded in in vitro culture, fibroblasts derived from dermal, connective tissue, fascial, lamina proprial tissues, adipocytes, and/or extracellular tissues derived from the cells are utilized in a preferred embodiment due to their relative ease of isolation and in vitro expansion in tissue culture. In general, tissue culture techniques which are suitable for the propagation of non-differentiated mesenchymal cells may be used to expand the aforementioned cells/tissue and practice the present invention as further discussed below. See e.g., Culture of Animal Cells: A Manual of Basic Techniques , Freshney, R. I. ed., (Alan R. Liss & Co., New York 1987); Animal Cell Culture: A Practical Approach , Freshney, R. I. ed., (IRL Press, Oxford, England 1986), whose references are incorporated herein by reference.
The utilization of autologous engraftment is a preferred therapeutic methodology due to the potential for graft rejection associated with the use of allograft-based engraftment. Autologous grafts (i.e., those derived directly from the patient) ensure histocompatibility by initially obtaining a tissue sample via biopsy directly from the patient who will be undergoing the corrective surgical procedure and then subsequently culturing fibroblasts derived from the dermal, connective tissue, fascial, or lamina proprial regions contained therein.
While the following sections will primarily discuss the autologous culture of fibroblasts of connective tissue, dermal, or fascial origins, in vitro culture of lamina propria tissue may also be established utilizing analogous methodologies. An autologous fibroblast culture is preferably initiated by the following methodology. A full-thickness biopsy of the skin (˜3×6 mm) is initially obtained through, for example, a punch biopsy procedure. The specimen is repeatedly washed with antibiotic and anti-fungal agents prior to culture. Through a process of sterile microscopic dissection, the keratinized tissue-containing epidermis and subcutaneous adipocyte-containing tissue is removed, thus ensuring that the resultant culture is substantially free of non-fibroblast cells (e.g., adipocytes and keratinocytes). The isolated adipocytes-containing tissue may then be utilized to establish adipocyte cultures. Alternately, whole tissue may be cultured and fibroblast-specific growth medium may be utilized to “select” for these cells.
Two methodologies are generally utilized for the autologous culture of fibroblasts in the practice of the present invention—mechanical and enzymatic. In the mechanical methodology, the fascia, dermis, or connective tissue is initially dissected out and finely divided with scalpel or scissors. The finely minced pieces of the tissue are initially placed in 1-2 ml of medium in either a 5 mm petri dish (Costar), a 24 multi-well culture plate (Corning), or other appropriate tissue culture vessel. Incubation is preferably performed at 37° C. in a 5% CO 2 atmosphere and the cells are incubated until a confluent monolayer of fibroblasts has been obtained. This may require up to 3 weeks of incubation. Following the establishment of confluence, the monolayer is trypsinized to release the adherent fibroblasts from the walls of the culture vessel. The suspended cells are collected by centrifugation, washed in phosphate-buffered saline, and resuspended in culture medium and placed into larger culture vessels containing the appropriate complete growth medium.
In a preferred embodiment of the enzymatic culture methodology, pieces of the finely minced tissue are digested with a protease for varying periods of time. The enzymatic concentration and incubation time are variable depending upon the individual tissue source, and the initial isolation of the fibroblasts from the tissue as well as the degree of subsequent outgrowth of the cultured cells are highly dependent upon these two factors. Effective proteases include, but are not limited to, trypsin, chymotrypsin, papain, chymopapain, and similar proteolytic enzymes. Preferably, the tissue is incubated with 200-1000 U/ml of collagenase type II for a time period ranging from 30 minutes to 24 hours, as collagenase type II was found to be highly efficacious in providing a high yield of viable fibroblasts. Following enzymatic digestion, the cells are collected by centrifugation and resuspended into fresh medium in culture flasks.
Various media may be used for the initial establishment of an in vitro culture of human fibroblasts. Dulbecco's Modified Eagle Medium (DMEM, Gibco/BRL Laboratories) with concentrations of fetal bovine serum (FBS), cosmic calf serum (CCS), or the patient's own serum varying from 5-20% (v/v)—with higher concentrations resulting in faster culture growth—are readily utilized for fibroblast culture. It should be noted that substantial reductions in the concentration of serum (i.e., 0.5% v/v) results in a loss of cell viability in culture. In addition, the complete culture medium typically contains L-glutamine, sodium bicarbonate, pyridoxine hydrochloride, 1 g/liter glucose, and gentamycin sulfate. The use of the patient's own serum mitigates the possibility of subsequent immunogenic reaction due to the presence of constituent antigenic proteins in the other serums.
Establishment of a fibroblast cell line from an initial human biopsy specimen generally requires 2 to 3.5 weeks in total. Once the initial culture has reached confluence, the cells may be passaged into new culture flasks following trypsinization by standard methodologies known within the relevant field. Preferably, for expansion, cultures are “split” 1:3 or 1:4 into T-150 culture flasks (Corning) yielding ˜5×10 7 cells/culture vessel. The capacity of the T-150 culture flask is typically reached following 5-8 days of culture at which time the cultured cells are found to be confluent.
Cells are preferably removed for freezing and long-term storage during the early passage stages of culture, rather than the later stages due to the fact that human fibroblasts are capable of undergoing a finite numbers of passages. Culture medium containing 70% DMEM growth medium, 10% (v/v) serum, and 20% (v/v) tissue culture grade dimethylsulfoxide (DMSO, Gibco/BRL) may be effectively utilized for freezing of fibroblast cultures. Frozen cells can subsequently be used to inoculate secondary cultures to obtain additional fibroblasts for use in the original patient, thus doing away with the requirement to obtain a second biopsy specimen.
To minimize the possibility of subsequent immunogenic reactions in the engraftment patient, the removal of the various antigenic constituent proteins contained within the serum may be facilitated by collection of the fibroblasts by centrifugation, washing the cells repeatedly in phosphate-buffered saline (PBS), and then either re-suspending or culturing the washed fibroblasts for a period of 2-24 hours in serum-free medium containing requisite growth factors which are well known in the field. Culture media include, but are not limited to, Fibroblast Basal Medium (FBM). Alternately, the fibroblasts may be cultured utilizing the patient's own serum in the appropriate growth medium.
After the culture has reached a state of confluence, the fibroblasts may either be processed for injection or further cultured to facilitate the formation of a three-dimensional “tissue” for subsequent surgical engraftment. Fibroblasts utilized for injection consist of cells suspended in a collagen gel matrix. The collagen gel matrix is preferably comprised of a mixture of 2 ml of a collagen solution containing 0.5 to 1.5 mg/ml collagen in 0.05% acetic acid, 1 ml of DMEM medium, 270 μl of 7.5% sodium bicarbonate, 48 μl of 100 μg/ml solution of gentamycin sulfate, and up to 5×10 6 fibroblast cells/ml of collagen gel. Following the suspension of the fibroblasts in the collagen gel matrix, the suspension is allowed to solidify for approximately 15 minutes at room temperature or 37° C. in a 5% CO 2 atmosphere. The collagen may be derived from human or bovine sources, or from the patient and may be enzymatically- or chemically-modified (e.g., atelocollagen).
Three-dimensional “tissue” is formed by initially suspending the fibroblasts in the collagen gel matrix as described above. Preferably, in the culture of three-dimensional tissue, full-length collagen is utilized, rather than truncated or modified collagen derivatives. The resulting suspension is then placed into a proprietary “transwell” culture system which is typically comprised of culture well in which the lower growth medium is separated from the upper region of the culture well by a microporous membrane. The microporous membrane typically possesses a pore size ranging from 0.4 to 8 μm in diameter and is constructed from materials including, but not limited to, polyester, nylon, nitrocellulose, cellulose acetate, polyacrylamide, cross-linked dextrose, agarose, or other similar materials. The culture well component of the transwell culture system may be fabricated in any desired shape or size (e.g., square, round, ellipsoidal, etc.) to facilitate subsequent surgical tissue engraftment and typically holds a volume of culture medium ranging from 200 μl to 5 ml. In general, a concentration ranging from 0.5×10 6 to 10×10 6 cells/ml, and preferably 5×10 6 cells/ml, are inoculated into the collagen/fibroblast-containing suspension as described above. Utilizing a preferred concentration of cells (i.e., 5×10 6 cells/ml), a total of approximately 4-5 weeks is required for the formation of a three-dimensional tissue matrix. However, this time may vary with increasing or decreasing concentrations of inoculated cells. Accordingly, the higher the concentration of cells utilized the less time due to a higher overall rate of cell proliferation and replacement of the exogenous collagen with endogenous collagen and other constituent materials which form the extracellular matrix synthesized by the cultured fibroblasts. Constituent materials which form the extracellular matrix include, but are not limited to, collagen, elastin, fibrin, fibrinogen, proteases, fibronectin, laminin, fibrellins, and other similar proteins. It should be noted that the potential for immunogenic reaction in the engrafted patient is markedly reduced due to the fact that the exogenous collagen used in establishing the initial collagen/fibroblast-containing suspension is gradually replaced during subsequent culture by endogenous collagen and extracellular matrix materials synthesized by the fibroblasts.
B. In Vitro Culture of Adipocytes
Adipocytes require a “feeder-layer” or other type of solid support on which to grow. One potential solid support may be provided by utilization of the previously discussed collagen gel matrix. Alternately, the solid support may be provided by cultured extracellular matrix. In general, the in vitro culture of adipocytes is performed by the mechanical or enzymatic disaggregation of the adipocytes from adipose tissue derived from a biopsy specimen. The adipocytes are “seeded” onto the surface of the aforementioned solid support and allowed to grow until near-confluence is reached. The adipocytes are removed by gentle scraping of the solid surface. The isolated adipocytes are then cultured in the same manner as utilized for fibroblasts as previously discussed in Section III A.
C. Isolation of the Extracellular Matrix
The extracellular matrix (ECM) may be isolated in either a cellular or acellular form. Constituent materials which form the ECM include, but are not limited to, collagen, elastin, fibrin, fibrinogen, proteases, fibronectin, laminin, fibrellins, and other similar proteins. ECM is typically isolated by the initial culture of cells derived from skin or vocal cord biopsy specimens as previously described. After the cultured cells have reached a minimum of 25-50% sub-confluence, the ECM may be obtained by mechanical, enzymatic, chemical, or denaturant treatment. Mechanical collection is performed by scraping the ECM off of the plastic culture vessel and re-suspending in phosphate-buffered saline (PBS). If desired, the constituent cells are lysed or ruptured by incubation in hypotonic saline containing 5 mM EDTA. Preferably, however, scraping followed by PBS re-suspension is generally utilized. Enzymatic treatment involves brief incubation with a proteolytic enzyme such as trypsin. Additionally, the use of detergents such as sodium dodesyl sulfate (SDS) or treatment with denaturants such as urea or dithiotheritol (DTT) followed by dialysis against PBS, will also facilitate the release of the ECM from surrounding associated tissue.
The isolated ECM may then be utilized as a “filler” material in the various augmentation or repair procedures disclosed in the present application. In addition, the ECM may possess certain cell growth- or metabolism-promoting characteristics.
D. In Vitro Culture of Fetal or Juvenile Cells or Tissues
In another preferred embodiment, rather than utilizing the patient's own tissue, all of the aforementioned cells, cell suspensions, or tissues may be derived from fetal or juvenile sources. Fetal cells lack the immunogenic determinants responsible for eliciting the host graft-rejection reaction and thus may be utilized for engraftment procedures with little or no probability of a subsequent immunogenic reaction. An acellular ECM may also be obtained from fetal ECM by hypotonic lysing of the constituent cells. The acellular ECM derived from fetal or juvenile sources or from in vitro culture of early passage cells typically possesses differs in both quantity and characteristics from that of the ECM derived from senescent or late-passage cells. The cellular or acellular ECM derived from fetal or juvenile sources may be used as a “filler” material in the various augmentation or repair procedures disclosed in the present application. In addition, the fetal or juvenile ECM may possess certain cell growth- or metabolism-promoting characteristics.
E. Injection of Autologous Cultured Dermal/Fascial Fibroblasts
To augment or repair dermal detects, autologously cultured fibroblasts are injected initially into the lower dermis, next in the upper and middle dermis, and finally in the subcutaneous regions of the skin as to form raised areas or “wheals.” The fibroblast suspension is injected via a syringe with a needle ranging frog 30 to 18 gauge, with the gauge of the needle being dependent upon such factors as the overall viscosity of the fibroblast suspension and the type of anesthetic utilized. Preferably, needles ranging from 22 to 18 gauge and 30 to 27 gauge are used with general and local anesthesia, respectively.
To inject the fibroblast suspension into the lower dermis, the needle is placed at approximately a 45° angle to the skin with the bevel of the needle directed downward. To place the fibroblast suspension into the middle dermis the needle is placed at approximately a 20-30° angle. To place the suspension into the upper dermis, the needle is placed almost horizontally (i.e., ˜10-15° angle). Subcutaneous injection is accomplished by initial placement of the needle into the subcutaneous tissue and injection of the fibroblast suspension during subsequent needle withdrawal. In addition, it should be noted that the needle is preferably inserted into the skin from various directions such that the needle tract will be somewhat different with each subsequent injection. This technique facilitates a greater amount of total skin area receiving the injected fibroblast suspension.
Following the aforementioned injections, the skin should be expanded and possess a relatively taut feel. Care should be taken so as not to produce an overly hard feel to the injected region. Preferably, depressions or rhytids appear elevated following injection and should be “overcorrected” by a slight degree of over-injection of the fibroblast suspension, as typically some degree of settling or shrinkage will occur post-operatively.
In some scenarios, the injections may pass into deeper tissue layers. For example, in the case of lip augmentation or repair, a preferred manner of injection is accomplished by initially injecting the fibroblast suspension into the dermal and subcutaneous layers as previously described, into the skin above the lips at the vermillion border. In addition, the vertical philtrum may also be injected. The suspension is subsequently injected into the deeper tissues of the lip, including the muscle, in the manner described for subcutaneous injection.
F. Surgical Placement of Autologously Cultured Dermal/Fascial Fibroblast Strands
In a preferred methodology utilized to augment or repair the skin and/or lips by the surgical placement of autologously cultured dermal and/or fascial fibroblast strands, a needle (the “passer needle”) is selected which is larger in diameter and greater in length than the area to be repaired or augmented. The passer needle is then placed into the skin and threaded down the length of the area. Guide sutures are placed at both ends through the dermal or fascial fibroblast strand. One end of the guide suture is fixed to a Keith needle which is subsequently placed through the passer needle. The guide suture is brought out through the skin on the side furthest (distal point) from the initial entry point of the passer needle. The dermal or fascial fibroblast graft is then pulled into the passer needle and its position may be adjusted by pulling on the distal point guide suture or, alternately, the guide suture closest to the passer needle entry point. While the dermal or fascial strand is held in place by the distal point suture, the passer needle is pulled backward and removed, thus resulting in the final placement of the graft following the final cutting of the remaining suture.
Generally, the fascial or dermal graft is placed into the subcutaneous layer of the skin. However, in some situations, it may be placed either more deeply or superficially.
If the area to be repaired or augmented is either smaller or larger than would be practical to fill with the aforementioned needle method, a subcutaneous “pocket” may be created with a myringotomy knife, scissors, or other similar instrument. A piece of dermis or fascia is then threaded into this area by use of guide sutures and passer needle, as described above.
G. Injection of Cells or Other Substances into the Vocal Cords or Larynx
Generally, it is not possible to inject cellular matter or other substances directly into the vocal cord epithelium due to its extreme thinness. Accordingly, injections are usually made into the lamina propria layer or the muscle itself.
Generally, lamina propria tissue (finely minced if required for injection), fibroblasts derived from lamina propria tissue, or gelatinous substances are utilized for injection. The preferable methodology consists of injection directly into the space containing the lamina propria, specifically into Reinke's space. Injection is accomplished by use of laryngeal injection needles of the smallest possible gauge which will accommodate the injectate without the use of extraneous pressure during the actual injection process. This is a subjective process as to the overall “feel” and the use of too much pressure may irreparably damage the injected cells. The material is injected via a syringe with a needle ranging from 30 to 18 gauge, with the gauge of the needle being dependent upon such factors as the overall viscosity of the injectate and the type of anesthetic utilized. Preferably, needles ranging from 22 to 18 gauge and 30 to 27 gauge are used with general and local anesthesia, respectively. If required, several injections may be performed along the length of the vocal cord.
To medialize a vocal cord with autologously cultured fascial or dermal fibroblasts, the materials are preferably injected directly into the tissue lateral or at the lateral edge of the vocal cord. The fibroblasts may be injected into scar, Reinke's space, or muscle, depending upon the specific vocal cord pathology. Preferably, it would be injected into the muscle.
The procedure may be performed under general, local, topical, monitored, or with no anesthesia, depending upon patient compliance and tolerance, the amount of injected material, and the type of injection performed.
If a greater degree of augmentation is required, a “pocket” may be created by needle dissection. Alternately, laryngeal microdisection, using knives and dissectors, may be performed. The desired material is then placed into the pocket with laryngeal forceps, or directly injected, depending upon the size of the pocket, the size of the graft material, the anesthesia, and the open access. If the pocket is left open after the procedure, it is preferably closed with sutures, adhesive, or a laser, depending upon the size and availability of these materials and the individual preferences of the surgeon.
While embodiments and applications of the present invention have been described in some detail by way of illustration and example for purposes of clarity and understanding, it would be apparent to those individuals whom are skilled within the relevant art that many additional modifications would be possible without departing from the inventive concepts contained herein. | A method for corrective surgery in a human subject of a vocal cord defect amenable to rectification by the augmentation of tissue subadjacent to the vocal cord defect, the method comprising: injecting an effective amount of autologous in vitro cultured fibroblast cells into the lamina propia, Reinke's space, the lateral tissue or the lateral edge of the vocal cord tissue of the subject in a position subadjacent to the vocal cord defect, wherein the in vitro fibroblast cultured cells are retrieved from the subject. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to alignment of liquid crystals in liquid crystal devices.
BACKGROUND OF THE INVENTION
[0002] Liquid crystal (LC) materials are rod-like or lath-like molecules which have different optical properties along their long and short axes. The molecules exhibit some long range order so that locally they tend to adopt similar orientations to their neighbours. The local orientation of the long axes of the molecules is referred to as the “director”. There are three types of LC materials: nematic, cholesteric (chiral nematic), and smectic. For a liquid crystal to be used in a display device, it must typically be made to align in a defined manner in the “off” state and in a different defined manner in the “on” state, so that the display has different optical properties in each state. Two principal alignments are homeotropic (where the director is substantially perpendicular to the plane of the cell walls) and planar (where the director is inclined substantially parallel to the plane of the cell walls). In practice, planar alignments may be tilted with respect to the plane of a cell wall, and this tilt can be useful in aiding switching. The present invention is concerned with alignment in liquid crystal displays.
[0003] Hybrid Aligned Nematic (HAN), Vertical Aligned Nematic (VAN), Twisted nematic (TN) and super-twisted nematic (STN) cells are widely used as display devices in consumer and other products. The cells comprise a pair of opposed, spaced-apart cell walls with nematic liquid crystal material between them. The walls have transparent electrode patterns that define pixels between them.
[0004] In TN and STN displays, the inner surface of each wall is treated to produce a planar unidirectional alignment of the nematic director, with the alignment directions being at 90° to each other. This arrangement causes the nematic director to describe a quarter helix within the TN cell, so that polarised light is guided through 90° when a pixel is in the “field off” state. In an STN cell, the nematic liquid crystal is doped with a chiral additive to produce a helix of shorter pitch which rotates the plane of polarisation in the “field off” state. The “field off” state may be either white or black, depending on whether the cell is viewed through crossed or parallel polarisers. Applying a voltage across a pixel causes the nematic director to align normal to the walls in a homeotropic orientation, so that the plane of polarised light is not rotated in the “field on” state.
[0005] In a HAN cell, one wall is treated to align a nematic LC in a homeotropic alignment and the other wall is treated to induce a planar alignment, typically with some tilt to facilitate switching. The LC has positive dielectric anisotropy, and application of an electric field causes the LC directors to align normal to the walls so that the cell switches from a birefringent “field off” state to a non-birefringent “field on” state.
[0006] In the VAN mode, a nematic LC of negative dielectric anisotropy is homeotropically aligned in the “field off” state, and becomes birefringent in the “field on” state. A dichroic dye may be used to enhance contrast.
[0007] Liquid crystal (LC) planar alignment is typically effected by the unidirectional rubbing of a thin polyimide alignment layer on the interior of the LC cell, which gives rise to a unidirectional alignment with a small pretilt angle. It has been proposed to increase the pretilt angle for a rubbed surface by incorporating small projections in the rubbed alignment layer, in “Pretilt angle control of liquid-crystal alignment by using projections on substrate surfaces for dual-domain TN-LCD” T. Yamamoto et al, J. SID, 4/2, 1996.
[0008] Whilst having a desirable effect on the optical characteristics of the device, the rubbing process is not ideal as this requires many process steps, and high tolerance control of the rubbing parameters is needed to give uniform display substrates. Moreover, rubbing may cause static and mechanical damage of active matrix elements which sit under the alignment layer. Rubbing also produces dust, which is detrimental to display manufacture.
[0009] Photoalignment techniques have recently been introduced whereby exposure of certain polymer coating to polarised UV light can induce planar alignment. This avoids some of the problems with rubbing, but the coatings are sensitive to LC materials, and typically produce only low pre-tilt angles.
[0010] An alternative is to use patterned oblique evaporation of silicon oxide (SiO) to form the alignment layer.
[0011] This also effects a desired optical response; however the process is complicated by the addition of vacuum deposition and a lithography process. Moreover, control of process parameters for SiO evaporation is critical to give uniformity, which is typically difficult to achieve over large areas.
[0012] A useful summary of methods of aligning liquid crystals is given in “Alignment of Nematic Liquid Crystals and Their Mixtures”, J. Cognard, Mol. Cryst. Liq. Cryst. 1-78 (1982) Supplement 1.
[0013] The use of surface microstructures to align LCs has been known for many years, for example as described in “The Alignment of Liquid Crystals by Grooved Surfaces” D. W. Berriman, Mol. Cryst. Liq. Cryst. 23 215-231 1973.
[0014] It is believed that the mechanism of planar alignment involves the LC molecules aligning along the grooves to minimise distortion energy derived from deforming the LC material. Such grooves may be provided by a monograting formed in a photoresist or other suitable material.
[0015] It has been proposed in GB 2 286 467 to provide a sinusoidal bigrating on at least one cell wall, by exposing a photopolymer to an interference pattern of light generated by a laser. The bigrating permits the LC molecules to lie in two different planar angular directions, for example 45° or 90° apart. An asymmetric bigrating structure can cause tilt in one or both angular directions. Other examples of alignment by gratings are described in WO 96/24880, WO 97/14990 WO 99/34251, and “The liquid crystal alignment properties of photolithographic gratings”, J. Cheng and G. D. Boyd, Appl. Phys. Lett. 35(6) 15 Sep. 1979. In “Mechanically Bistable Liquid-Crystal Display Structures”, R. N. Thurston et al, IEEE trans. on Electron Devices, Vol. ED-27 No 11, November 1980, LC planar alignment by a periodic array of square structures is theorised.
[0016] LC homeotropic alignment is also a difficult process to control, typically using a chemical treatment of the surface, such as lecithin or a chrome complex. These chemical treatments may not be stable over time, and may not adhere very uniformly to the surface to be treated. Homeotropic alignment has been achieved by the use of special polyimide resins (Japan Synthetic Rubber Co). These polyimides need high temperature curing which may not be desirable for low glass transition plastic substrates. Inorganic oxide layers may induce homeotropic alignment if deposited at suitable angles. This requires vacuum processes which are subject to the problems discussed above in relation to planar alignment. Another possibility for producing homeotropic alignment is to use a low surface energy material such as PTFE. However, PTFE gives only weak control of alignment angle and may be difficult to process.
[0017] It is desirable to have a more controllable and manufacturable alignment for LC devices.
SUMMARY OF THE INVENTION
[0018] According to an aspect of the present invention there is provided a liquid crystal device comprising a first cell wall and a second cell wall enclosing a layer of liquid crystal material;
[0019] electrodes for applying an electric field across at least some of the liquid crystal material;
[0020] a surface alignment structure on the inner surface of at least the first cell wall providing alignment to the liquid crystal molecules, wherein the said surface alignment structure comprises a random or pseudorandom two dimensional array of features which are shaped and/or orientated to produce the desired alignment.
[0021] We have surprisingly found that the orientation of the director is induced by the geometry of the features, rather than by the array or lattice on which they are arranged.
[0022] Because the features are arranged in a random or pseudorandom array instead of a regular lattice, diffraction colours which result from the use of regular grating structures are reduced and may be substantially eliminated. Such an array can act as a diffuser, which may remove the need for an external diffuser in some displays. Of course, if a diffraction colour is desired in the display, the array may be made less random, and the posts may be spaced at intervals which produce the desired interference effect. Thus, the structure may be separately optimised to give the required alignment and also to mitigate or enhance the optical effect that results from a textured surface.
[0023] Using a random or pseudorandom array also mitigates optical and LC alignment effects that arise as a result of variations of phasing between regular arrays on two surfaces, for example Moire effects.
[0024] The desired alignment features are produced without rubbing or evaporation of inorganic oxides, and hence without the problems associated with such production methods.
[0025] In a preferred embodiment, the features comprise a plurality of upstanding posts. The features could also comprise mounds, pyramids, domes, walls and other promontories which are shaped and/or orientated to permit the LC director to adopt a desired alignment for a particular display mode. Where the features are walls, they may be straight (eg, a monograting), bent (eg, L-shaped or chevron-shaped) or curved (eg, circular walls). The invention will be described for convenience hereinafter with respect to posts; however it is to be understood that the invention is not limited to this embodiment. The posts may have substantially straight sides, either normal or tilted with respect to the major planes of the device, or the posts may have curved or irregular surface shape or configuration. For example, the cross section of the posts may be triangular, square, circular, elliptical or polygonal.
[0026] The term “azimuthal direction” is used herein as follows. Let the walls of a cell lie in the x,y plane, so that the normal to the cell walls is the z axis. Two tilt angles in the same azimuthal direction means two different director orientations in the same x,z plane, where x is taken as the projection of the director onto the x,y plane.
[0027] The director tends to align locally in an orientation which depends on the specific shape of the post. For an array of square posts, the director may align along either of the two diagonals of the posts. If another shape is chosen, then there may be more than two azimuthal directions, or just one. For example an equilateral triangular post can induce three directions substantially along the angle bisectors. An oval or diamond shape, with one axis longer than the others, may induce a single local director orientation which defines the azimuthal direction. It will be appreciated that such an orientation can be induced by a very wide range of post shapes. Moreover, by tilting a square post along one of its diagonals it is possible to favour one direction over another. Similarly, tilting of a cylindrical post can induce an alignment in the tilt direction.
[0028] Shorter and wider posts tend to induce a planar alignment, whilst taller and thinner posts tend to induce a homeotropic alignment. Posts of intermediate height and width can induce tilted alignments and may give rise to bistable alignments in which the director may adopt either of two tilt angles in substantially the same azimuthal direction. By providing posts of suitable dimensions and spacing, a wide range of alignment directions, planar, tilted and homeotropic, can easily be achieved, and the invention may therefore be used in any desired LC display mode.
[0029] The posts may be formed by any suitable means; for example by photolithography, embossing, casting, injection moulding, or transfer from a carrier layer. Embossing into a plastics material is particularly preferred because this permits the posts to be formed simply and at low cost. Suitable plastics materials will be well known to those skilled the art, for example poly(methyl methacrylate).
[0030] By providing a plurality of upstanding tall or thin posts on at least the first cell wall, the liquid crystal molecules can be induced to adopt a state in which the director is substantially parallel to the plane of the local surface of the posts, and normal to the plane of the cell walls.
[0031] If the posts are perpendicular to the cell walls, the LC may be homeotropically aligned at substantially 90° to the plane of the cell walls. However, for some applications it is desirable to achieve a homeotropic alignment which is tilted by a few degrees. This may readily be achieved by using posts which are inclined from the perpendicular. As the posts are inclined more, the average LC tilt angle away from the normal will increase. The invention therefore provides a simple way of inducing LC homeotropic alignment with any preferred tilt angle.
[0032] When exposing a photoresist, a desired post tilt angle can readily be achieved by exposing the photoresist through a suitable mask with a light source at an angle related to the desired angle by Snell's law as is known to allow for the refractive index of the photoresist material.
[0033] The preferred height for the posts will depend on factors such as the cell thickness, the thickness and number of the posts, and the LC material. For homeotropic alignment, the posts preferably have a vertical height which is at least equal to the average post spacing. Some or all of the posts may span the entire cell, so that they also function as spacers.
[0034] It is preferred that one electrode structure (typically a transparent conductor such as indium tin oxide) is provided on the inner surface of each cell wall in known manner. For example, the first cell wall may be provided with a plurality of “row” electrodes and the second cell wall may be provided with a plurality of “column” electrodes. However, it would also be possible to provided planar (interdigitated) electrode structures on one wall only, preferably the first cell wall.
[0035] The inner surface of the second cell wall could have low surface energy so that it exhibits little or no tendency to cause any particular type of alignment, so that the alignment of the director is determined essentially by the features on the first cell wall. However, it is preferred that the inner surface of the second cell wall is provided with a surface alignment to induce a desired alignment of the local director. This alignment may be homeotropic, planar or tilted. The alignment may be provided by an array of features of suitable shape and/or orientation, or by conventional means, for example rubbing, photoalignment, a monograting, or by treating the surface of the wall with an agent to induce homeotropic alignment.
[0036] For planar and tilted alignments, the shape of the features is preferably such as to favour only one azimuthal director orientation adjacent the features. The orientation may be the same for each feature, or the orientation may vary from feature to feature so as to give a scattering effect in one of the two states.
[0037] Alternatively, the shape of the features may be such as to give rise to a plurality of stable azimuthal director orientations. Such alignments may be useful in display modes such as bistable twisted nematic (BTN) modes. These aziumthal director orientations may be of substantially equal energy (for example vertical equilateral triangular posts will give three azimuthal alignment directions of equal energy) or one or more alignment directions may be of different energy so that although one or more lower energy alignments are favoured, at least one other stable azimuthal alignment is possible.
[0038] The liquid crystal device will typically be used as a display device, and will be provided with means for distinguishing between switched and unswitched states, for example polarisers or a dichroic dye.
[0039] The cell walls may be formed from a non-flexible material such as glass, or from rigid or flexible plastics materials which will be well known to those skilled in the art of LC display manufacture, for example poly ether sulphone (PES), poly ether ether ketone (PEEK), or poly(ethylene terephthalate) (PET).
[0040] For many displays, it is desirable to have a uniform alignment throughout the field of view. For such displays, the posts may all be of substantially the same shape, size, orientation and tilt angle. However, where variation in alignment is desired these factors, or any of them, may be varied to produced desired effects. For example, the posts may have different orientations in different regions where different alignment directions are desired. A TN cell with quartered sub-pixels is an example of a display mode which uses such different orientations, in that case to improve the viewing angle. Alternatively, if the heights of the posts are varied, the strengths of interactions with the LC will vary, and may provide a greyscale. Similarly, variation of the shape of the posts will vary the strength of interaction with the LC.
[0041] The features may optionally be provided on both walls to provide a desired local director alignment in the region of both walls. Different features may be provided on each wall, and the features may be independently varied in different regions of each wall depending on the desired alignment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] The invention will now be further described by way of example, with reference to the following drawings in which:
[0043] [0043]FIG. 1 is a schematic cross section, parallel to the cell walls, through a region around a post in a liquid crystal device in accordance with one aspect of the present invention. The long axes of the ellipses represent typical orientations of the LC director;
[0044] [0044]FIG. 2 is a schematic cross section, perpendicular to the cell walls, through a part of a device in accordance with another aspect of the present invention along a diagonal of a post;
[0045] [0045]FIG. 3 is a cross section, perpendicular to the cell walls, parallel and near to a side of a post of a bistable nematic device in accordance with a further aspect of the invention;
[0046] [0046]FIG. 4 is a plan view of a unit cell of a device in accordance with the present invention, having posts in a pseudorandom array; and
[0047] [0047]FIG. 5 is a cross section, perpendicular to the cell walls, parallel and near to a side of a post of a device in accordance with a further aspect of the invention;
[0048] [0048]FIGS. 6 and 7 are schematic cross sectional views similar to FIG. 1 for, respectively, a post of elliptical cross section and a post of triangular cross section; and
[0049] FIGS. 8 to 12 are views of different arrays of features of devices in accordance with further embodiments of the invention.
DETAILED DESCRIPTION
[0050] The liquid crystal cell shown schematically in FIG. 2 comprises a first cell wall 2 and a second cell wall 4 which enclose a layer of nematic LC material of negative dielectric anisotropy. The molecules of the LC are represented as ellipses, with the long axis indicating the local director. The inner surface of each cell wall is provided with a transparent electrode pattern, for example row electrodes 12 on the first cell wall 2 and column electrodes 14 on the second cell wall 4 , in a known manner. The LC alignment is bistable.
[0051] The inner surface of the first cell wall 2 is textured with an array of square posts 10 , and the inner surface of the second cell wall 4 is flat. The posts are in a pseudorandom array, as will be described below with reference to FIG. 4. The posts 10 are approximately 1 μm high and the cell gap is typically 3 μm. The flat surface is treated to give homeotropic alignment. The posts are not homeotropically treated.
[0052] Such an array of square posts has two preferred orientations of the LC director in the azimuthal direction. These are along the two diagonals of the post. FIG. 1 shows a cross-section through a post with the LC distorted around it, from one corner to the diagonally opposite one. This alignment around the post then tends to seed the alignment of the LC above the post such that the average orientation is also along that diagonal.
[0053] By tilting the posts along one of the diagonals (FIG. 2) it is possible to favour that alignment direction. Through computer simulation of this geometry we found that although there is only one azimuthal alignment direction there are in fact two states with similar energies but which differ in how much the LC tilts. FIG. 2 is a schematic of the two states. In one state (shown on the left of FIG. 2) the LC is highly tilted, and in the other it is planar around the posts. The exact nature of the LC orientation depends on the details of the structure, but for a range of parameters there are two distinct states with different tilts. The two states may be distinguished by viewing through a polariser 8 and an analyser 6 . The low tilt state has high birefringence and the high tilt state has low birefringence.
[0054] Without limiting the scope of the invention in any way, we think that the two states may arise because of the way in which the LC is deformed by the post. Flowing around a post causes regions of high energy density at the leading and trailing edges of the post where there is a sharp change in direction. This can be seen in FIG. 1 at the bottom left and top right corners of the post. This energy density is reduced if the LC molecules are tilted because there is a less severe direction change. This is clear in the limit of the molecules being homeotropic throughout the cell. In that case there is no region of high distortion at the post edges. In the higher tilt state this deformation energy is therefore reduced, but at the expense of a higher bend/splay deformation energy at the base of the posts. The LC in contact with the flat surface between posts is untilted but undergoes a sharp change of direction as it adopts the tilt around the post.
[0055] In the low tilt state the energy is balanced in the opposite sense, with the high deformation around the leading and trailing edges of the post being partially balanced by the lack of the bend/splay deformation at the base of the post because the tilt is uniform around the post. Our computer simulations suggest that, for the current configuration, the higher tilt state is the lower energy state.
[0056] This is supported by the results of computer simulation and in actual cells. When viewed at an appropriate angle between crossed polarisers the cells always cool into the darker of the two states. From FIG. 2 it would appear that the high tilt state will have lower birefringence and therefore appear darker than the low tilt state. The exact amount of tilt in the high tilt state will be a function of the elastic constants of the LC material and the planar anchoring energy of the post material.
[0057] The posts may be formed using hard contact mask exposure of a photoresist layer on a glass substrate as will described below. By way of example, the posts may be 0.7×0.7 μm across and typically up to 1.5 μm high.
[0058] [0058]FIG. 4 shows a unit cell of a pseudorandom array of posts. Each square post is about 0.8×0.8 μm, and the pseudorandom array has a repeat distance of 56 μm. The positions of the posts are effectively randomised, but the orientation of the posts is kept fixed. In this case, there is no regular lattice to align the LC so that any alignment must be due to the posts. We find experimentally for a HAN cell with LC material of positive dielectric anisotropy that the LC aligns along the post diagonal, just as for a regular array.
[0059] Referring now to FIG. 3, there is shown a computer-generated model of LC alignment around a square post similar to that shown in FIG. 2, but with the inner surface of the second cell wall treated to give planar alignment. In the state shown in the left in FIG. 3, the local director is highly tilted, and in the other it is planar around the posts. As with the cell of FIG. 2, switching between the two states is achieved by the application of suitable electrical signals.
[0060] We have done some computer simulation of the homeotropic alignment by posts. We have modelled 3 μm thick cells with an array of square posts which are 300 nm across on one substrate, with the other substrate flat, but modelled as a material that will give strong planar alignment. We have modelled a variety of post heights and spacings to see when the LC adopts a homeotropic alignment around the posts. FIG. 5 shows a computer simulation side view of a region containing a single post about 1.8 μm tall on the bottom substrate. Around the post the LC is strongly tilted, whilst above the post the alignment is more planar, due to the interaction with the upper substrate.
[0061] In the computer simulations we have modelled the effect of varying the post height from 0.2 to 2.6 μm, with the gap between posts varying from 0.6 to 1.2 μm. As post height is increased, the alignment goes from being just planar to being bistable or multistable between the planar state and a more tilted state. As post height is increased further, then the planar state becomes too high in energy and there is just the highly tilted homeotropic state. Present studies indicate that homeotropic alignment begins when the post height is approximately equal to the average post spacing. The effect is expected to persist down to very small cross-section posts. An expected upper limit of the post cross-section for homeotropic alignment is when the post width is of the order of the cell gap.
[0062] Referring now to FIGS. 6 and 7, there are shown examples of different post shapes which produce LC alignment when in a random or pseudorandom array. The post shown in FIG. 6 has an elliptical cross section, and the LC director aligns locally along the long axis of the ellipse. For the equilateral triangular post of FIG. 7 there are three director alignments possible which are equal energy, each of which is parallel to a line which bisects the triangle into equal halves. One such alignment is illustrated. By tilting the posts in the direction of one of the apices, that alignment direction can be favoured. Alternatively, elongating the triangle will cause one director orientation to be favoured. For example, an isosceles triangle will favour a director alignment along the major axis of the triangle. In each case, depending on the height of the posts, the LC adopts a locally planar or tilted planar alignment. If the inner surface of the second cell wall is treated to give local homeotropic alignment, application of an electric field will cause LC molecules of positive dielectric anisotropy to line up with the field in a homeotropic orientation. The cell therefore functions in a HAN mode. By providing a different planar alignment on the second cell wall, which could also be posts, other display modes could also be used, for example TN or (with a chirally doped LC material) STN mode.
[0063] FIGS. 8 to 11 show perspective views of posts of devices in accordance with alternative embodiments of the invention. The posts are arranged in pseudorandom arrays. In FIG. 8, elliptical posts are shown, with the long axes of the ellipses parallel. Depending on their height, the posts produce either a uniform planar alignment, a bistable or multistable alignment (planar or tilted), or a homeotropic alignment (which may be tilted). In FIG. 9, elliptical posts are randomly orientated, providing an alignment structure in which there is no strongly preferred long range orientation of the nematic director. It is envisaged that this structure and others like it may be used with an LC material of positive dielectric anisotropy in a display with a scattering mode. FIG. 10 illustrates an arrangement of posts of a plurality of shapes and sizes which may be used to give controlled alignment in different areas, and different effects such as greyscale. Other arrangements and effects are of course possible. For example, the posts may be different heights in different regions, as illustrated in FIG. 12, which also shows different post sizes and orientations in a pseudorandom arrangement. The posts in FIG. 11 are tilted at different angles in different regions of the display, thereby producing different tilt angles in the LC alignment and the possibility of producing a greyscale, for example in a HAN mode. In a HAN display mode, varying the post height will give a variation in the switching performance.
[0064] Cell Manufacture
[0065] A typical process is described below, by way of non-limiting example. A clean glass substrate 2 coated with Indium Tin Oxide (ITO) is taken and electrode patterns 12 are formed using conventional lithographic and wet etch procedures. The substrate is spin-coated with a suitable photoresist (Shipley S1813) to a final thickness of 1.3 μm. A photomask (Compugraphics International PLC) with an array of suitably-dimensioned opaque regions, for example in unit cells corresponding to FIG. 4, is brought into hard contact with the substrate and a suitable UV source is used to expose the photoresist for 10 s at −100 mW/cm 2 . The substrate is developed using Microposit Developer diluted 1:1 with deionised water for 20 s and rinsed dry. The substrate is flood exposed using a 365 nm UV source for 3 minutes at 30 mW/cm 2 , and hardbaked at 85° C. for 12 hours. The substrate is then deep UV cured using a 254 nm UV source at −50 mW/cm 2 for 1 hour. By exposing through the mask using a UV source at an offset angle to the normal to the plane of the cell wall, tilted posts may be produced. The tilt angle (or blaze angle) is related to the offset angle by Snell's law. The posts may have somewhat rounded edges and are not necessarily overhung. The precise shape is dependent on processing parameters as is well known and understood in the art of photolithography of fine features.
[0066] A second clean ITO substrate 4 with electrode patterns 14 is taken and treated to give a homeotropic alignment of the liquid crystal using a stearyl-carboxy-chromium complex, in a known manner.
[0067] An LC test cell is formed by bringing the substrates together using suitable spacer beads (Micropearl) contained in UV curing glue (Norland Optical Adhesives N73) around the periphery of the substrates 2 , 4 , and cured using 365 nm UV source. The cell is capillary filled with a nematic liquid crystal mixture of positive dielectric anisotropy, for example ZLI 2293 (Merck). It is known that switching in conventional LC devices can be improved by addition of surfactant oligomers to the LC. See, for example, G P Bryan-Brown, E L Wood and I C Sage, Nature Vol. 399 p338 1999. A surfactant may optionally dissolved in the LC material. Methods of spacing, assembling and filling LC cells are well known to those skilled in the art of LCD manufacture, and such conventional methods may also be used in the spacing, assembling and filling of devices in accordance with the present invention. | A liquid crystal device has a surface alignment structure comprising a random or pseudorandom two dimensional array of alignment features ( 10 ) which are shaped and/or orientated to produce a desired alignment. Depending on the geometry and spacing of the features ( 10 ), the liquid crystal may be induced to adopt a planar, tilted, or homeotropic alignment. | 6 |
[0001] This application claims the benefit of U.S. Provisional Application No. 60/497,913, filed Aug. 27, 2003, the disclosure of which is herein incorporated by reference in its entirety.
FIELD OF INVENTION
[0002] The present invention relates to storage systems. More particularly, the present invention relates to allocation and reallocation of clusters to volumes for greater efficiency and performance in a storage system.
BACKGROUND OF THE INVENTION
[0003] With the accelerating growth of Internet and intranet communication, high-bandwidth applications (such as streaming video), and large information databases, the need for networked storage systems has increased dramatically. The key apparatus in such a networked storage system is the storage controller. One primary function of storage controllers in a networked storage system is to assume the responsibility of processing storage requests so that the host processors are free to perform other processing tasks. Storage controllers manage all of the incoming, outgoing, and resident data in the system through specialized architectures, algorithms, and hardware. However, it should also be recognized that there is also a need for high performance non-networked storage systems. Thus, while this application consistently discusses network storage systems, it should be recognized that the invention may also be practiced by non-networked storage systems. More particularly, the storage controller of the present invention also may be adapted for non-networked storage systems.
[0004] Typical storage controller systems use cluster allocation and volume mapping of those clusters to manage data, I/O, and other administrative tasks within the networked storage system. Clusters reside on volumes formed of a portion of a disk drive or many disk drives in a redundant array of independent disks (RAID) storage architecture. Clusters are typically identical in size; however, each may be assigned to a different RAID architecture. Their physical locations are stored in volume maps, which are updated as new clusters are allocated or deleted. Clusters provide system granularity and aid in the transfer and management of large quantities of data by breaking them down into smaller quantities of data.
[0005] The storage system is monitored by one or more data collection mechanisms to evaluate system performance and compare the current performance output to the required output, which is usually outlined in a Quality of Service (QoS) contract. The statistical data gathered by the statistics collection system facilitates achievement of a desired QoS.
[0006] In a networked storage system, it is critical that the system perform to a given QoS. In general, each host that accesses the networked storage system establishes a service level agreement (SLA) that defines the minimum guaranteed bandwidth and latency that the host can expect from the networked storage system. The SLA is established to ensure that the system performs at the level specified in the QoS contract.
[0007] QoS, redundancy, and performance requirements may not be met after the system has been running for a certain period because the volume profiles that define the system configuration are static and were created prior to system launch. Therefore, any deviation in the types and amounts of data to be processed may affect system performance. In other words, system needs may change over time and, as a result, performance may drop. Many RAID storage architectures account for this decrease in productivity by over-provisioning the system. Over-provisioning is accomplished by increasing the number of drives in the system. More drive availability in the system means more storage space to handle inefficient use of the existing system resources. This solution, however, is a waste of existing system resources and increases costs.
[0008] U.S. Pat. No. 6,487,562, “DYNAMICALLY MODIFYING SYSTEM PARAMETERS IN DATA STORAGE SYSTEM,” describes a system and method for dynamically modifying parameters in a data storage system such as a RAID system. Such parameters include QoS parameters, which control the speed at which system operations are performed for various parts of a data storage system. The storage devices addressable as logical volumes can be individually controlled and configured for preferred levels of performance and service. The parameters can be changed at any time while the data storage system is in use, with changes taking effect very quickly. These parameter changes are permanently stored and therefore allow system configurations to be maintained. A user interface allows a user or system administrator to easily observe and configure system parameters, preferably using a graphic user interface (GUI) that allows a user to select system changes along a scale from minimum to a maximum.
[0009] The method described in the '562 patent offers a solution to over-provisioning in a RAID architecture by introducing a GUI and using external human intervention. While this saves physical disk drive and hardware costs, the costs are now transferred to paying a person to manage and operate the system on a daily basis. Furthermore, the system is prone to human error in the statistical data analysis of the system performance and, as a result, the system may not be filly optimized.
[0010] Therefore, it is an object of the present invention to provide a method of optimizing system resources and capabilities in a networked storage system.
[0011] It is another object of the present invention to provide a method of configuring system resources that improves system performance.
[0012] It is yet another object of the present invention to provide a means to eliminate the need for over-provisioning in a networked storage system.
[0013] It is yet another object of the present invention to provide a means to decrease cost in a networked storage system by efficiently utilizing existing system resources.
SUMMARY OF THE INVENTION
[0014] The present invention incorporates QoS mechanisms, fine-grain mapping, statistical data collection systems, redundThe present invention incorporates QoS mechanisms, fine-grain mapping, statistical data collection systems, redundancy requirements, performance measurements, and statistical analysis algorithms to provide a means for predicting volume profiles and dynamically reconfiguring those profiles for optimum performance in a networked storage system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The foregoing and other advantages and features of the invention will become more apparent from the detailed description of exemplary embodiments of the invention given below with reference to the accompanying drawings, in which:
[0016] FIG. 1 is a flow diagram of a predictive and dynamically reconfigurable volume profiling method;
[0017] FIG. 2 is a flow diagram of an asynchronous cluster allocation method;
[0018] FIG. 3 is a flow diagram of a background reallocation and optimization method;
[0019] FIG. 4 shows an example I/O density histogram; and
[0020] FIG. 5 is a block diagram of a storage system interfaced to a network having two hosts.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] Now referring to the drawings, where like reference numerals designate like elements, there is shown in FIG. 5 a block diagram of a storage system 500 in accordance with the principles of the present invention. The storage system 500 includes a first interface 1010 for managing host communications and a second interface 1011 for managing communications with one or more storage devices 2000 . The storage devices 2000 may comprise a plurality of clusters (not illustrated) which are each comprised of a plurality of sectors (not illustrated). The storage controller 1000 also includes a memory 1020 . The controller 1000 may also comprise one or more functional units (not illustrated), which collectively manage the storage. At least some of the functional units may have access to the memory 1020 . As illustrated, the storage system 500 is a networked storage system since the storage system 500 communicates to hosts 4000 over a network 3000 . However, interface 1010 may also be a non-network interface, and hosts 4000 may communicate directly with the storage system via interface 1010 . Thus, the present invention is also applicable to non-networked storage systems.
[0022] FIG. 1 a flow diagram of a predictive and dynamically reconfigurable volume profiling method 100 . The method 100 is executed by the controller 1000 and operates as described below:
[0023] Step 110 : Establishing Volume Profile
[0024] In this step, a new volume profile, known as the baseline profile, is created for each new volume. Every volume in the system has a baseline profile created for it as it comes online. New volumes are created in the system when new drives are added, when old volumes are deleted and reused, or when the system is running for the first time.
[0025] The baseline volume profile includes information about the size of the volume, the number of drives in the volume, the number of clusters needed to define the volume, the RAID types of those clusters, and their preferred location in relation to the radius or diameter of the disk. Clusters located closer to the outer (i.e., larger) radius are higher-performance clusters than those located toward the inner (i.e., smaller) radius of the disk because the disk inherently spins faster at the outer radius than it does at the innermost radius. The clusters outlined in the baseline volume may or may not be allocated. Clusters that have been allocated also have their disk location stored in the baseline profile. Clusters that have not yet been allocated have only their RAID type stored in the baseline volume profile. In most cases, however, baseline volume profiles do not contain clusters allocated to physical storage space. This allocation occurs later, when the cluster is required for a write action.
[0026] The baseline profile is created using predictive algorithms based on QoS requirements, redundancy requirements, the size of the volume, the number of drives per volume, the read/write activity (I/O) that will likely address the volume, the likely amount of data to be read from or written to the volume, and the performance expectations. Method 100 proceeds to step 120 .
[0027] Step 120 : Storing Current State of Volume Profile
[0028] In this step, the most current volume profile is stored as a table in memory 1020 so that other system resources may access the information. Method 100 proceeds to step 130 .
[0029] Step 130 : Collecting Volume Statistics
[0030] In this step, a statistical data collection system begins to gather volume statistics, i.e., information related to host commands. The information may include, for example, total number of read sectors, total number of write sectors, total number of read commands, total number of write commands, and system latency time associated with each read and write command. In one exemplary embodiment, the information is recorded in an I/O density histogram. An exemplary I/O density histogram is illustrated in FIG. 4 . In one exemplary embodiment, the statistical collection system is the one which is described in a U.S. application Ser. No. 10/______ (Attorney Docket A7995.0012/P012), filed Nov. 17, 2003, entitled “METHOD OF COLLECTING AND TALLYING OPERATIONAL DATA USING AN INTEGRATED I/O CONTROLLER IN REAL TIME,” which is hereby incorporated by reference in its entirety.
[0031] The data collection system continues to record data from time zero and aggregates the data into the I/O density histogram. At any time, the system may reset the I/O density histogram and begin recording data from that point on. The I/O density histogram is available to other system resources for analyzing and making decisions based on its data. Method 100 proceeds to step 140 .
[0032] Step 140 : Does Volume Profile Need to be Updated?
[0033] In this decision step, algorithms are used to analyze the statistical data in the I/O density histogram and to compare the results to the current state of the volume profile. The matrix shown in FIG. 2 illustrates example performance-to-configuration decisions that may be made based on the statistical data analysis. For example, a particular cluster may have many more write transactions than read transactions. It should be noted that while clusters are used in the description herein, the present invention may also be practiced by applying the I/O density histogram to storage units other than clusters. In higher capacity storage systems, it may be useful to apply the I/O density histogram to larger allocation units. In general, the present invention may be practiced by applying the I/O density histogram to any type of subvolume granularity, and the size of the subvolume granularity may also be a programmable or configurable quantity. The system may decide that a RAID with redundancy through mirroring (e.g., RAID 10) cluster would be more appropriate than the currently allocated RAID with redundancy through parity (e.g., RAID 5) cluster and that the volume profile should be updated. On the other hand, for example, a RAID 5 cluster may have large numbers of sequential data burst transfers in its histogram and, therefore, the system may decide that the original RAID 5 assignment is correct for that particular cluster. If the volume profile needs to be updated, method 100 proceeds to step 150 ; if not, method 100 returns to step 130 .
[0034] Step 150 : Updating Volume Profile
[0035] In this step, method 100 updates the current volume profile with the decision made in step 140 . For example, clusters of one RAID type may be changed to a different RAID type, clusters at inner diameter disk locations may be moved to outer diameter locations. The current volume profile no longer matches the actual system configuration at this point. Other asynchronous methods described in reference to FIG. 3 and FIG. 4 perform the task of matching the system configuration to that of the current volume profile. Method 100 returns to step 130 .
[0036] FIG. 2 is an example I/O density histogram 200 . Data is collected by a system that records all transaction requests for a given volume. Histogram 200 includes data such as the total volume read commands, total volume write commands, number of read sectors for each cluster, number of write sectors for each cluster, etc. Alternately, totals collected by volume region may have courser granularity, where a region is some number of contiguous logical clusters. This may also change the bin size of histogram 200 .
[0037] The data aggregates from time zero; more data continues to be incorporated as time increases. Histogram 200 is used by method 100 to determine whether a volume profile needs to be updated based on the statistical information contained therein. Method 100 may reset histogram 200 at any time and start a new data collection for another example I/O density histogram 200 , perhaps altering histogram 200 granularity. Moreover, method 100 may utilize different types of statistical data depending on system needs. For example, statistical data may include queue depth data or command latency data for a given functional unit of the controller 1000 .
[0038] FIG. 3 is a flow diagram of a cluster allocation method 300 .
[0039] Step 310 : Evaluating Current State of Volume Profile
[0040] In this step, the controller 1000 evaluates the current state of the volume profile stored in memory. From the current state volume profile, the controller 1000 knows which clusters have been allocated and which may need to be reserved so that the cluster allocator may allocate them later. Method 300 proceeds to step 320 .
[0041] Step 320 : Is New Cluster Needed?
[0042] In this decision step, the controller 1000 evaluates the need for reserving new cluster pointers that coincide with the cluster configurations in the volume profile. Additionally, the controller 1000 may determine that a new cluster is needed due to a message from the cluster free list that it is empty or below threshold. Finally, a system request may trigger the need for a new cluster if a host requests a write to a volume with no cluster allocation. If the controller needs to create a new cluster, method 300 proceeds to step 330 ; if not, method 300 returns to step 310 .
[0043] Step 330 : Evaluating System Resources
[0044] In this step, the controller 1000 looks at system resources to determine where space is available for the new cluster. The controller 1000 scans for any new drives in the system and checks to see if any clusters that have been deleted are ready for reallocation. Method 300 proceeds to step 340 .
[0045] Step 340 : Is Adequate Apace Available?
[0046] In this decision step, the controller 1000 determines whether there is physical storage space available for the new cluster identified in step 320 . If so, method 300 proceeds to step 350 ; if not, method 300 proceeds to step 370 . In one exemplary embodiment, the controller 1000 includes a functional unit known as a cluster manager (not illustrated), and steps 310 , 320 , and 330 are executed by the cluster manager.
[0047] Step 350 : Allocating New Cluster
[0048] In this step, the controller 1000 removes a cluster pointer from the head of the appropriate cluster free list and allocates the cluster to its respective volume. Since the allocation process is asynchronous from the cluster reservation process, the cluster allocation may occur at any time after the reservation has been made and does not necessarily follow step 340 chronologically. The controller 1000 sends a message to the cluster manager that the cluster has been allocated and no longer has a status of “reserved”. Method 300 proceeds to step 360 .
[0049] Step 360 : Updating Volume Profile
[0050] In this step, the cluster controller 1000 updates the volume profile to reflect that a cluster has been allocated. Additional information regarding the position and location of the newly allocated cluster are also added to the volume profile. The new profile is stored in memory as the current volume profile. Method 300 returns to step 310 . In one exemplary embodiment, the controller 1000 includes a functional unit known as a cluster allocator (not illustrated), and steps 350 and 360 are executed by the cluster allocator.
[0051] Step 370 : Generating Error Message
[0052] In this step, the system is notified by the controller 1000 that there was an error reserving the requested cluster pointer. Reasons for the failure are recorded in the error message. Method 300 returns to step 310 .
[0053] FIG. 4 is a flow diagram of a background cluster reallocation and optimization method 400 . Method 400 is a background process that runs when there is an opportunity. Method 400 does not have priority over any other system transactions and, therefore, does not contribute to system latency.
[0054] Step 410 : Evaluating Current Volume Profile
[0055] In this step, the system reviews the current state of a volume profile stored in memory and observes the currently allocated clusters and their locations as well as the types of clusters that are in the volume profile. Method 400 proceeds to step 420 .
[0056] Step 420 : Is Existing Allocation Different from Profile?
[0057] In this decision step, the system compares the existing allocation of clusters for a particular volume to the optimized cluster allocation in the volume profile and determines whether they are the same. If yes, method 400 proceeds to step 430 , if no, method 400 returns to step 410 .
[0058] Step 430 : Is New Allocation Feasible?
[0059] In this decision step, the system evaluates its resources to determine whether the new, optimal cluster allocation is feasible given the current state of the system. If yes, method 400 proceeds to step 440 ; if no, method 400 returns to step 410 .
[0060] Step 440 : Reallocating Clusters
[0061] In this step, clusters are reallocated to the optimal type defined by the volume profile. Method 400 returns to step 410 .
[0062] While the invention has been described in detail in connection with the exemplary embodiment, it should be understood that the invention is not limited to the above disclosed embodiment. Rather, the invention can be modified to incorporate any number of variations, alternations, substitutions, or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Accordingly, the invention is not limited by the foregoing description or drawings, but is only limited by the scope of the appended claims. | A method of predictive baseline volume profile creation for new volumes in a networked storage system and a system for dynamically reevaluating system performance and needs to create an optimized and efficient use of system resources by changing volume profiles as necessary. The system gathers statistical data and analyzes the information through algorithms to arrive at an optimal configuration for volume clusters. Clusters are then reallocated and reassigned to match the ideal system configuration for that point in time. The system continually reevaluates and readjusts its performance to meet throughput requirements specified in the quality of service agreement | 6 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to a flat belt support system configured with an arrangement of a supporting roller, pulleys and a continuous flat belt such that flat belt may be driven by a driving roller and a belt path is created and controlled by articulating the support pulleys relative to the driving roller such that the flat belt will naturally tend to stay roughly centered on the pulleys while traveling about the belt path created. A variety of configurations using these components are common practice in many applications where the centerline of the belt path is essentially coplanar in a plane which is normal to the axis of the driving roller. However, this invention allows the pulleys to be articulated relative to the roller such that the centerline of the belt path is no longer coplanar. This invention allows objects conveyed by the flat belt to be selectively diverted from the plane normal to the axis of the driving roller. This invention also allows the belt path to move laterally along the axis of the driving roller.
[0002] This invention creates an advantage in applications in which it is desirable to have a single or plurality of flat belts being driven by a single driving roller while also needing to articulate each belt path independently to each other by adjusting both the relative spacing between the belts and the skew of the belts from the plane normal to the axis of the drive roller.
[0003] There are two very common industrial uses for flat belts as shown on FIG. 5 . The first is the transmission of power from one driving rotary shaft to another driven rotary shaft via the use of pulleys and one or more flat belts. The second is for the purpose of conveyance in which one or more flat belts are driven with the intention of transporting another material or objects along the conveyance surface of the flat belting.
[0004] This invention is related to a need for conveyance of objects. It can be used in any industry where there is a need to convey objects in a flow direction with the added requirement of needing to laterally shift the conveyed objects relative to a straight flow direction and/or relative to the other objects being conveyed.
[0005] While it can be used in a variety of industrial applications, one common application is in the material handling of cardboard/corrugated sheets. In particular, during the production of corrugated flat boxes by a machine known as a Rotary Die Cutter, corrugated flat boxes are produced by converting a large rectangular feed sheet into multiple smaller flat boxes using a die cutting processes. The die boards are attached to a rotating drum and the material is fed through with the die board cutting the large rectangular sheet in both the material flow direction and perpendicular to the material flow direction to produce the multiple smaller flat boxes. These flat boxes qualify as objects which may be conveyed by the conveyance surface.
[0006] The term “UPS” is used throughout this patent in reference to the number of flat boxes produced due to cutting in the perpendicular to the material flow direction where as the term “OUTS” will be used in reference to the boxes produced due to cutting in the direction parallel to the material flow direction.
[0007] For many years there has been the need to collect these multiple UPS and OUTS of smaller flat boxes as they exit the Rotary Die Cutter and place the boxes into stacks of boxes for further processing downstream. There have been a multitude of stacking machines that have been produced to service this need. One form of sheet stacker is found in U.S. Pat. No. 2,901,250 granted to Martin on Aug. 25, 1959. A second form of sheet stacker is found in U.S. Pat. No. 5,026,249 granted to TEI on Jun. 25, 1991.
[0008] One of the challenges of stacking the flat boxes is that during the process of making the stacks of boxes, it is often desired to separate the OUTS laterally as they are conveyed away from the Rotary Die Cutter. This lateral separation keeps the individual flat boxes from becoming interleaved with each other during transport and also allows for dividers to be placed between the individual stacks being produced to improve the integrity of the stacks of boxes. In FIG. 7B , a set of grooved belts referred to as Layboy Arms 53 are arranged in order to create the lateral separation. This need has also been addressed in the following patents: U.S. Pat. No. 3,860,232 granted to Martin on Jan. 14, 1975, U.S. Pat. No. 5,026,249 granted to TEI on Jun. 25, 1991, U.S. Pat. No. 6,000,531 granted to Martin on Dec. 14, 1999, and U.S. Pat. No. 6,427,097 granted to Martin on Jul. 30, 2002.
[0009] The usage of round, V-grooved and other grooved type belt conveying means affords the option of creating the laterally skewed belt path in a multiple number of ways since they each can be controlled by the position of the entrance and exit pulleys. These pulleys do not even have to stay in the same plane as the plane defined generally by the centerline of the belt path since the belts are forced to track each pulley with some method of grooving or rim on the pulleys. One form of this method in shown in U.S. Pat. No. 3,860,232 granted to Martin on Jan. 14, 1975
[0010] Because of the total width of large industrial machinery including the sheet stackers, it is desirable to be able to skew larger width flat belts which rely on the tracking of their belts back surface as opposed to providing the large number of narrow grooved belts which would be required to support both large and small boxes across the entire width of the sheet stacker.
[0011] The prior art includes systems that allow the diversion of flat belts but do so by keeping the entrance velocity plane and exit velocity plane essentially coplanar or parallel, unlike the current invention which allows the exit velocity plane to be both non-coplanar and non-parallel.
[0012] U.S. Pat. No. 2,901,250 granted to Martin on Aug. 25, 1959, U.S. Pat. No. 3,860,232 granted to Martin on Jan. 14, 1975, U.S. Pat. No. 5,026,249 granted to TEI on Jun. 25, 1991, U.S. Pat. No. 6,000,531 granted to Martin on Dec. 14, 1999, and U.S. Pat. No. 6,427,097 granted to Martin on Jul. 30, 2002 are hereby incorporated by reference.
SUMMARY OF THE INVENTION
[0013] The Diverting Flat Belt Support System of the present invention is a support system configured from rollers and pulleys that create a belt path for a continuous flat belt which can be used for the conveyance of objects. The flat belt conveyance surface has an entrance portion, entrance velocity point, entrance velocity plane, entrance velocity vector and entrance axis of rotation. The conveyance surface has an exit portion, exit velocity point, exit velocity plane, exit velocity vector and entrance axis of rotation. While not required, entrance velocity point and exit velocity point are typically the beginning and end of the entrance portion and exit portion respectively. While not a requirement of the invention, a static conveyance surface support member may be provided to increase conveying capacity. The entrance velocity plane and the exit velocity plane may selectively be changed between coplanar and variable degrees of non-coplanar and non-parallel by articulating the supporting pulleys relative to the rollers.
[0014] Another objective of this invention is to allow the flat belt to track the support system properly even when the entrance velocity plane and exit velocity plane are non-coplanar and non-parallel.
[0015] Another objective of this invention is to produce a belt path that curves along the conveyance surface such that the objects being conveyed will be gradually shifted laterally.
[0016] A further objective of this invention is to allow the entrance velocity plane to be shifted laterally along the associated axis of rotation in order to allow variable spacing when a plurality of flat belts share a common roller.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1A is a side view of a generic pulley and belt path used to define the terms related to a flat belt and grooved belts.
[0018] FIG. 1B is a cross-sectional view of a generic flat belt and pulley.
[0019] FIG. 1C is a cross-sectional view of a generic irregular flat belt and pulley.
[0020] FIG. 1D is a cross-sectional view of a generic V-grooved belt and pulley.
[0021] FIG. 1E is a cross-sectional view of a generic round belt and pulley.
[0022] FIG. 2A is a perspective view used to define the terms related to a roller.
[0023] FIG. 2B is a cross-sectional view used to define the terms related to average contact centerline belt path.
[0024] FIG. 3A is a perspective view used to define the terms related to a pulley, both crowned pulleys and flat pulleys.
[0025] FIG. 3B is a right side elevation view of FIG. 3A used to define the terms related to a pulley, both crowned pulleys and flat pulleys.
[0026] FIG. 3C is a cross-sectional view of FIG. 3B used to define the terms related to a crowned pulley.
[0027] FIG. 3 C′ is a cross-sectional detailed view of FIG. 3C used to define the terms related to a crowned pulley.
[0028] FIG. 3D is a cross-sectional view of FIG. 3B used to define the terms related to a flat pulley.
[0029] FIG. 3 D′ is a cross-sectional detailed view of FIG. 3D used to define the terms related to a flat pulley.
[0030] FIG. 4A is a perspective view used to define the terms related to a flat belt tracking.
[0031] FIG. 4B is a right side elevation view of FIG. 4A used to define the terms related to a flat belt tracking.
[0032] FIG. 4C is a cross-sectional view of FIG. 4B used to define the terms related to a flat belt tracking.
[0033] FIG. 4D is a cross-sectional view of FIG. 4B used to define the terms related to a flat belt tracking.
[0034] FIG. 5A is a perspective view used to define conveyance usage of flat belts.
[0035] FIG. 5B is a perspective view used to define power transmission usage of flat belts.
[0036] FIG. 6A is a top plan view of Rotary Die Cutter used to define the terms related to the production of flat boxes with a Rotary Die Cutter.
[0037] FIG. 6B is a perspective view of Rotary Die Cutter cylinders used to define the terms related to the production of flat boxes with a Rotary Die Cutter.
[0038] FIG. 7A is a side elevation view of a sheet stacker used to describe why the lateral shifting is required during the making of stacks of boxes.
[0039] FIG. 7B is a top plan view of a sheet stacker used to describe why the lateral shifting is required during the making of stacks of boxes.
[0040] FIG. 8A is a side elevation view which illustrates the basic elements of the flat belt and most basic support system in side view and isometric view. The articulating system constraining these elements has been removed for clarity.
[0041] FIG. 8B is a perspective view which illustrates the basic elements of the flat belt and most basic support system in side view and isometric view. The articulating system constraining these elements has been removed for clarity.
[0042] FIG. 8C is a perspective view which enlarges details of FIG. 8B and illustrates the exit elements of the flat belt and most basic support system in side view and isometric view.
[0043] FIG. 8D is a perspective view which enlarges details of FIG. 8B and illustrates the entrance elements of the flat belt and most basic support system in side view and isometric view.
[0044] FIG. 9A is a side elevation view which illustrates the basic elements of the flat belt and the preferred embodiment of the support system in side view and isometric view. The articulating system constraining these elements has been removed for clarity.
[0045] FIG. 9B is a perspective view which illustrates the basic elements of the flat belt and the preferred embodiment of the support system in side view and isometric view. The articulating system constraining these elements has been removed for clarity.
[0046] FIG. 9C is a perspective view which enlarges details of FIG. 9B and illustrates the entrance elements of the flat belt and the preferred embodiment of the support system in side view and isometric view.
[0047] FIG. 9D is a perspective view which enlarges details of FIG. 9B and illustrates the exit elements of the flat belt and the preferred embodiment of the support system in side view and isometric view.
[0048] FIG. 10A is a top plan view which illustrates the conveyance surface when the entrance velocity plane and the exit velocity plane are coplanar.
[0049] FIG. 10B is a top plan view which illustrates the conveyance surface when the entrance velocity plane and the exit velocity plane are not coplanar and not parallel
[0050] FIG. 11 is a side elevation view which illustrates the tangent surface vectors of this invention.
[0051] FIG. 12A is a perspective view which illustrates a parallel roller and terms related to the explanation of flat belt tracking tendencies.
[0052] FIG. 12B is a top Plan view of FIG. 12A which illustrates a parallel roller and terms related to the explanation of flat belt tracking tendencies.
[0053] FIG. 12C is a perspective view which illustrates a taper roller and terms related to the explanation of flat belt tracking tendencies.
[0054] FIG. 12D is a top plan view of FIG. 12C which illustrates a taper roller and terms related to the explanation of flat belt tracking tendencies.
[0055] FIG. 12E is a perspective view of crowned pulley and flat belt used to define the terms related to the explanation of flat belt tracking tendencies.
[0056] FIG. 12F is a cross section view of FIG. 12E used to define the terms related to the explanation of flat belt tracking tendencies.
[0057] FIG. 12 F′ is a cross section view detail of FIG. 12F showing belt with theoretical gap.
[0058] FIG. 12 F″ is a cross section view detail of FIG. 12F showing belt conforming to pulley.
[0059] FIG. 13A is a perspective view of torque source for rollers
[0060] FIG. 13B is a perspective view which illustrates the basics of an articulation system.
[0061] FIG. 14A is a perspective view which illustrates the basic elements of a plurality of flat belts and a plurality of the most basic support system.
[0062] FIG. 14B is a side elevation view which illustrates the basic elements of a plurality of flat belts and a plurality of the most basic support system.
[0063] FIG. 15A is a perspective view which illustrates the basic elements of a plurality of flat belts and a plurality of the preferred embodiment support system.
[0064] FIG. 15B is a top plan view which illustrates the basic elements of a plurality of flat belts and a plurality of the preferred embodiment support system
[0065] FIG. 16 is a perspective view which illustrates a complete sheet stacker machine with the integration of a plurality of flat belts and a plurality of the preferred embodiment support system.
DETAILED DESCRIPTION OF THE INVENTION
[0066] The following terms are defined to provide clarity throughout this patent.
[0067] The term flat belt 4 is used throughout this patent to refer to the type of belt that has its tracking controlled by the belt's back surface 7 and the support system 84 . This is unlike a class of belts which may be referred to as grooved belts 5 , 6 shown in FIG. 1 illustrated in a generic configuration 1 with two generic pulleys 2 , 3 . The tracking of grooved belts 5 , 6 is controlled by the belts being constrained by contact force with the sides 9 , 9 ′ of the belt. This is typically achieved with grooves in the pulleys 8 ′, 8 ″ and typical examples include V-Grooved Belting 5 and Round-Grooved Belting 6 . Thus, while the term flat belt 4 may describe a belt with a parallel cover 10 and back surface 7 , it would also include any belt 13 with a non-flat back surface 11 and/or a non-flat cover 12 as one example provided the tracking is still controlled by the belt's back surface 11 .
[0068] The term centerline belt path 83 is used throughout this patent and is defined in FIG. 1A-1E as the continuous path created by the belt's center of cross sectional area axis.
[0069] The term average contact centerline belt path 93 is used throughout this patent and is defined in FIG. 2B as the average lateral position of the centerline belt path 83 along the rotational axis 17 where the back 7 of the flat belt 4 is in contact with the surface 8 .
[0070] The term support system 84 , 84 ′ is used throughout this patent and is defined shown FIG. 8A-8D and FIG. 9A-9D as only those elements that directly affect the belt path 83 of the flat belt 4 .
[0071] The term articulation system 85 is used throughout this patent and is defined in FIG. 13 as the elements that interconnect the elements of the support system 84 , 84 ′ and allow the desired movement of the support system 84 , 84 ′.
[0072] The term roller 14 is used throughout this patent and is defined in FIG. 2A as a parallel cylindrical object with a center rotational axis 15 and is substantially wider than the flat belt 4 which may allow for a plurality of flat belts 4 ′, 4 ″, . . . to be in contact directly with the surface 16 of the roller 14 . In the preferred embodiment a roller 14 would have parallel surfaces 16 but this is not always required.
[0073] The term conveyance surface 30 is used throughout this patent and is defined in FIG. 2A as the cover 10 side of the flat belt 4 upon which objects may be conveyed by the motion flat belt 4 along the flat belt path 83 .
[0074] The term velocity point 31 is used throughout this patent and is defined in FIG. 2A as the point on the centerline belt path 83 where the conveyance surface 30 begins or ends contact with a roller or pulley.
[0075] The term velocity plane 28 is used throughout this patent and is defined in FIG. 2A-2B as a plane perpendicular to a central rotational axis 15 , 17 which intersects the average contact centerline belt path 93 .
[0076] The term velocity vector 29 is used throughout this patent and is defined in FIG. 2A as a vector beginning at the velocity point 31 . The magnitude of the velocity vector 29 is based on the angular velocity and geometry of the associated roller or pulley as well as the geometry of the flat belt 4 . The direction of the velocity vector is along the intersection of flat belt cover 10 and the velocity plane 28 .
[0077] The term pulley 8 is used throughout this patent and is defined in FIG. 3A-3D as generally cylindrical shape object with a center rotation axis 17 and is similar in width to the flat belt 4 and is in contact with a single flat belt 4 . If the outer diameter of the pulley 18 ″ is essentially the same across the length of the pulley, it will be referred to as a “flat pulley” 25 . If the outer diameter of the pulley 18 ′ is variable across the length of the cylinder such that the outside diameter in the center of the cylinder 19 is larger than the outside diameter at the ends of the cylinder 19 ′, it will be referred to as a “crowned pulley” 24 .
[0078] The term “tracking” is used throughout this patent and is defined in FIG. 4A-4D as maintaining the lateral position 20 of the center plane 22 of the flat belt 4 where it contacts a pulley 24 , 25 relative to center plane 21 of the pulley 24 , 25 such that there is little or no offset 23 . That is, a flat belt properly “tracking” a pulley 24 will stay on the pulley near the center of the pulley where as a flat belt that is not “tracking” a pulley 25 will run off center of the pulley or completely fall off the edge of the pulley. Note that while crowned pulleys 24 do tend to track better than flat pulleys 25 there are many other support variations that effect tracking and FIG. 4 is illustrated as an example of tracking only.
[0079] Flat belts 4 have been used for many years in industrial applications. This invention relates to a flat belt 4 in the application of conveyance 33 . A flat belt 4 is often connected to itself to form a continuous flat belt. Since the belting material is flexible it requires a support system 84 to constrain the flat belt 4 to follow a desired belt path 83 . The support system 84 is typically created from rollers 14 and pulleys 8 . Optionally, additional other static support structures 64 may be included upon which the back 7 and/or cover 10 of the flat belt 4 may slide for extra support to avoid sagging due to gravity and/or to support objects 38 being conveyed. Since the support system 84 is only those elements that directly affect the belt path 83 of the flat belt 4 , an additional articulation system 85 is required in order to interconnect the elements of the support system 84 and allow the desired movement of the support system 84 . The configuration of the support system 84 and defining the appropriate articulation constraints of the support system 84 is the primary focus of the invention. The articulation system 85 , while being required and described herein, can be accomplished in a multitude of similar ways by those skilled in the art.
[0080] For the purpose of this patent, a flat belt 4 is defined as the type of belt having a back 7 , an outer cover 10 and a centerline belt path 83 that has its tracking controlled by the belt's back surface 7 and the support system 84 .
[0081] Since a flat belt 4 is defined as the type of belt having a back 7 , an outer cover 10 and a centerline belt path 83 that has its tracking controlled by the belt's back surface 7 and the support system 84 , the support system 84 must maintain this proper tracking characteristic while being articulated. To understand why the solutions claimed work it is important to understand the basic physics behind flat belt tracking. As shown in FIGS. 12A and 12B , when a flat belt 4 is traveling around any generally cylindrical object with parallel surfaces such as a pulley 8 or roller 14 , the belt surface contact will naturally tend to track towards a direction 100 perpendicular to the surface of the contacting support surface and the back 7 of the flat belt 4 . In the case of the flat belt 4 on the parallel roller 14 shown in FIG. 12A , the flat belt 4 will not have a tendency to shift laterally. Where as, in the case of a tapered roller 92 shown in FIGS. 12C and 12D , the flat belt 4 will have a tendency to shift in the direction 101 perpendicular to the surface, thus in this case the centerline belt path 83 will gradually track towards the large end of the tapered roller 92 . This is the basic principle behind a crowned pulley 24 as shown in FIGS. 3C , 3 C′, 12 E, 12 F′, 12 F″ and 12 F′″. Since a crowned pulley has an outer diameter of the pulley 18 ′ which is variable across the length of the cylinder such that the outside diameter in the center of the cylinder 19 is larger than the outside diameter at the ends of the cylinder 19 ′, and typically is symmetrical. As a result, even though theoretically there is a gap as shown in FIG. 12 F′, in practice the flexible material of the flat belt 4 will conform to the crowned pulley's surface. The result is that there are opposing laterally shifting tendencies 102 , 103 . The strength of these tendencies is generally a function of how much contact surface area exists between the flat belt 4 and the crowned surfaces 104 , 105 . The more contact surface area, the larger the tendency. As a result, should the flat belt 4 laterally shift slightly such that contact surface area 104 is larger than contact surface area 105 , then the shifting tendency 102 which is associated with contact surface area 104 would grow relative to the shifting tendency 103 which is associated with contact surface area 105 . This imbalance in tendencies 102 , 103 will cause the flat belt to shift back towards the middle thus giving the crowned pulley 24 the desired characteristic of keeping a flat belt 4 properly tracking to the center of the crowned pulley. It is important to note that there are a variety of crowned surfaces, including but not limited to a taper with and without a flat area in the middle and a multitude of curved surfaces. It is also important to note that the belting material and other system parameters can also affect the way a belt path tracks.
[0082] As the purpose of this flat belt 4 is the application of conveyance 33 , the flat belt 4 may convey objects 38 from the entrance portion 86 of a conveyance surface 30 proximate a first roller 65 to the exit portion 87 of the conveyance surface 30 proximate a first pulley 67 .
[0083] In the most basic form of the invention the support system 84 has three rotational elements. They are a first roller 65 , a first pulley 67 and a second pulley 68 .
[0084] The first roller 65 has a rotational axis 59 , an outer surface 88 supporting the back 7 of the flat belt 4 and an entrance velocity plane 58 perpendicular to the rotational axis 59 which intersects the first roller average contact centerline belt path 96 which is the average lateral position of the centerline belt path 83 along the rotational axis 59 where the back 7 of the flat belt 4 is in contact with the first roller outer surface 88 .
[0085] The first pulley 67 has a rotational axis 63 and an outer surface 89 supporting the back 7 of the flat belt 4 with an exit velocity plane 62 perpendicular to the rotational axis 63 which intersects the first pulley average contact centerline belt path 97 which is the average lateral position of the centerline belt path 83 along the rotational axis 63 where the back 7 of the flat belt 4 is in contact with the first pulley outer surface 89 .
[0086] The second pulley 68 has a rotational axis 76 and an outer surface 91 supporting the back 7 of the flat belt 4 with a return velocity plane 75 perpendicular to the rotational axis 76 which intersects the second pulley average contact centerline belt path 99 which is the average lateral position of the centerline belt path 83 along the rotational axis 76 where the back 7 of the flat belt 4 is in contact with the second pulley outer surface 91 .
[0087] The flat belt 4 and the most basic form of a support system 84 includes: the flat belt 4 has an upper conveyance surface 30 where the conveyance surface 30 has an entrance portion 86 and an entrance velocity plane 58 proximate the first roller 65 , the conveyance surface 30 has an exit portion 87 with an exit velocity plane 62 proximate the first pulley 67 , the first pulley 67 deflects the flat belt 4 from the entrance velocity plane 58 to the exit velocity plane 62 , the entrance velocity plane 58 and the exit velocity plane 62 are not coplanar and not parallel and the return velocity plane 75 is substantially coplanar with the exit velocity plane 62 . With the flat belt 4 tracking the second pulley 68 , the lateral positioning 47 of the second pulley 68 controls the lateral positioning of the entrance velocity plane 58 . With the flat belt 4 tracking the first pulley 67 and thereby controlling the position of the exit velocity plane 62 , the exit velocity plane 62 is adjustable to any selected degree of not coplanar and not parallel to the entrance velocity plane 61 by adjusting the position of the first pulley 67 and simultaneously adjusting the second pulley 68 in order to keep the return velocity plane 75 substantially coplanar with the exit velocity plane 62 . The first roller 65 is substantially wider than the flat belt 4 and thus the second pulley 68 can controlled the lateral position of the entrance velocity plane 58 . However, the first roller 65 must to rotating at a minimum speed in order to allow the belt to laterally shift thus the entrance velocity plane 61 is laterally 47 movable along the rotational axis 59 of the first roller 65 while rotating the first roller 65 to permit the flat belt 4 to maintain proper tracking of the second pulley 68 . In the preferred embodiment, the first pulley 67 and second pulley 68 are crowned 24 to improve the ability of the flat belt 4 to track the first and second pulleys 67 , 68 . In the preferred embodiment the maximum degree to which the entrance velocity plane 58 and the exit velocity plane 62 can be not coplanar and not parallel can be increased while still maintaining proper tracking if the tracking tendencies of the first roller are not allowed to affect the tracking tendencies of the second pulley which can be minimized if spatial relationship exists between the first roller 65 , first pulley 67 and second pulley 68 such that the tangent surface vector 78 created by the first roller 65 and the first pulley 67 is substantially perpendicular to the tangent surface vector 79 created by the first roller 65 and the second pulley 68 . In order to convey objects 38 , in this most basic form of a support system 84 a torque source 94 is operatively connected to first roller 65 to provide driving power for the flat belt 4 through friction between the back 7 of the flat belt 4 and the outer surface 88 of the first roller 65 .
[0088] The flat belt 4 and the preferred embodiment of a support system 85 would have additional angular belt contract surface with the various pulleys and rollers and it is often desirable to drive the flat belt 4 with a torque source 94 such that the cover 10 of the flat belt 4 is being driven since the cover 10 typically is of higher friction than the belt back 4 . In order to achieve this preferred embodiment of a support system 85 a second roller 66 having a rotational axis 72 and an outer surface 90 is positioned between the second pulley 68 and the first roller 65 , with the second roller rotational axis 72 parallel to the first roller rotational axis 59 such that the cover 10 of the flat belt contacts the surface 90 of the second roller 66 which increases the amount of surface contact between the first roller surface 88 and the back 7 of the flat belt 4 and increases the amount of surface contact between the second pulley surface 91 and the back 7 of the flat belt 4 . A torque source 94 is operatively connected to the second roller 66 to provide driving power for the flat belt 4 through friction between the cover 10 of the flat belt 4 and the outer surface 90 of the second roller 66 . In both support embodiments 84 , 85 , the conveyance surface 30 conveys objects 38 from the entrance portion 86 proximate the first roller 65 to the exit portion 87 proximate the first pulley 67 . In applying this invention to the corrugated industry, in particular the production of flat boxes 41 by a die cutter 42 , the conveyed objects 38 are flat boxes 41 .
[0089] As the purpose of a plurality of flat belts 4 , 4 ′ is the application of conveyance 33 , each of the plurality of flat belts 4 , 4 ′ may convey objects 38 from the entrance portion 86 , 86 ′ of a conveyance surface 30 , 30 ′ proximate a first roller 65 to the exit portion 87 , 87 ′ of the conveyance surface 30 proximate each associated first pulley 67 .
[0090] In the most basic form of the invention with a plurality of flat belts 4 , 4 ′ for each support systems 84 , 84 ′ there is one roller common to the plurality of flat belts 4 , 4 ′ and support systems 84 , 84 ′ and a plurality of first pulleys 67 , 67 ′ and second pulleys 68 , 68 ′ as elements in each of the support systems 84 , 84 ′.
[0091] The first roller 65 common to the plurality of flat belts 4 , 4 ′ and support systems 84 , 84 ′ has a rotational axis 59 , an outer surface 88 supporting the back 7 , 7 ′ of the flat belt 4 , 4 ′ and an entrance velocity plane 58 , 58 ′ perpendicular to the rotational axis 59 which intersects the first roller average contact centerline belt path 96 , 96 ′ which is the average lateral position of the centerline belt path 83 , 83 ′ along the rotational axis 59 where the back 7 , 7 ′ of the flat belt 4 , 4 ′ is in contact with the first roller outer surface 88 .
[0092] Each first pulley 67 , 67 ′ has a rotational axis 63 , 63 ′ and an outer surface 89 , 89 ′ supporting the back 7 , 7 ′ of the flat belt 4 , 4 ′ with an exit velocity plane 62 , 62 ′ perpendicular to the rotational axis 63 , 63 ′ which intersects the first pulley average contact centerline belt path 97 , 97 ′ which is the average lateral position of the centerline belt path 83 , 83 ′ along the rotational axis 63 , 63 ′ where the back 7 , 7 ′ of the flat belt 4 , 4 ′ is in contact with the first pulley outer surface 89 , 89 ′.
[0093] Each second pulley 68 , 68 ′ has a rotational axis 76 , 76 ′ and an outer surface 91 , 91 ′ supporting the back 7 , 7 ′ of the flat belt 4 , 4 ′ with a return velocity plane 75 , 75 ′ perpendicular to the rotational axis 76 , 76 ′ which intersects the second pulley average contact centerline belt path 99 , 99 ′ which is the average lateral position of the centerline belt path 83 , 83 ′ along the rotational axis 76 , 76 ′ where the back 7 , 7 ′ of the flat belt 4 , 4 ′ is in contact with the second pulley outer surface 91 , 91 ′.
[0094] In the most basic form of the invention with a plurality of flat belts 4 , 4 ′ each flat belt 4 , 4 ′ and associated support systems 84 , 84 ′ includes: the flat belt 4 , 4 ′ having an upper conveyance surface 30 , 30 ′ where the conveyance surface 30 , 30 ′ has an entrance portion 86 , 86 ′ and an entrance velocity plane 58 , 58 ′ proximate the first roller 65 , the conveyance surface 30 , 30 ′ has an exit portion 87 , 87 ′ with an exit velocity plane 62 , 62 ′ proximate the first pulley 67 , 67 ′, the first pulley 67 , 67 ′ deflects the flat belt 4 , 4 ′ from the entrance velocity plane 58 , 58 ′ to the exit velocity plane 62 , the entrance velocity plane 58 and the exit velocity plane 62 , 62 ′ which are not coplanar and not parallel and the return velocity plane 75 , 75 ′ is substantially coplanar with the exit velocity plane 62 , 62 ′. With the flat belt 4 , 4 ′ tracking the second pulley 68 , 68 ′, the lateral positioning 47 of the second pulley 68 , 68 ′ controls the lateral positioning of the entrance velocity plane 58 , 58 ′. With the flat belt 4 , 4 ′ tracking the first pulley 67 , 67 ′ and thereby controlling the position of the exit velocity plane 62 , 62 ′, the exit velocity plane 62 , 62 ′ is adjustable to any selected degree of not coplanar and not parallel to the entrance velocity plane 61 , 61 ′ by adjusting the position of the first pulley 67 , 67 ′ and simultaneously adjusting each associated second pulley 68 in order to keep each associated return velocity plane 75 , 75 ′ substantially coplanar with each associated exit velocity plane 62 , 62 ′. The first roller 65 is substantially wider than each flat belt 4 , 4 ′ and thus the second pulley 68 , 68 ′ can controlled the lateral position of the entrance velocity plane 58 , 58 ′. However, the first roller 65 must to rotating at a minimum speed in order to allow the flat belts 4 , 4 ′ to laterally shift thus each associated entrance velocity plane 61 , 61 ′ is laterally 47 movable along the rotational axis 59 of the first roller 65 while rotating the first roller 65 to permit each associated flat belt 4 , 4 ′ to maintain proper tracking of each associated second pulley 68 , 68 ′. In the preferred embodiment, the plurality of first pulley 67 and plurality of second pulley 68 are crowned 24 to improve the ability of the plurality of flat belt 4 to track each associated first pulley 67 , 67 ′ and second pulleys 68 , 68 ′. In the preferred embodiment the maximum degree to which each entrance velocity plane 58 , 58 ′ and each associated exit velocity plane 62 , 62 ′ can be not coplanar and not parallel can be increased while still maintaining proper tracking if the tracking tendencies of the first roller 58 are not allowed to affect the tracking tendencies of the second pulley 68 , 68 ′ which can be minimized if spatial relationship exists between the first roller 65 , each first pulley 67 , 67 ′ and each second pulley 68 , 68 ′ is such that the each associated tangent surface vector 78 , 78 ′ created by the first roller 65 and each first pulley 67 , 67 ′ is substantially perpendicular to the tangent surface vector 79 , 79 ′ created by the first roller 65 and each associated second pulley 68 , 68 ′. In order to convey objects 38 , in this the most basic form of the invention with a plurality of flat belts 4 , 4 ′ each flat belt 4 , 4 ′ and associated support systems 84 , 84 ′ a torque source 94 is operatively connected to first roller 65 to provide driving power for each flat belts 4 , 4 ′ through friction between the back 7 , 7 of the flat belt 4 , 4 and the outer surface 88 of the first roller 65 .
[0095] In the preferred each flat belt 4 and support system 85 , 85 ′ has additional angular belt contact surface with the various pulleys and rollers and it is often desirable to drive the flat belt 4 , 4 ′ with a torque source 94 such that the cover 10 , 10 ′ of the flat belt 4 , 4 ′ is being driven since the cover 10 , 10 ′ typically is of higher friction than the belt back 4 , 4 ′. In order to achieve this preferred embodiment of a support system 85 , 85 ′ a second roller 66 having a rotational axis 72 and an outer surface 90 is positioned between the second pulleys 68 , 68 ′ and the first roller 65 , with the second roller rotational axis 72 parallel to the first roller rotational axis 59 such that the cover 10 of the flat belt contacts the surface 90 of the second roller 66 which increases the amount of surface contact between the first roller surface 88 and the back 7 , 7 ′ of the flat belt 4 , 4 ′ and increases the amount of surface contact between the plurality of each second pulley surface 91 , 91 ′ and the back 7 , 7 ′ of the flat belt 4 , 4 ′. A torque source 94 is operatively connected to the second roller 66 to provide driving power for each flat belt 4 , 4 ′ through friction between the cover 10 , 10 ′ of each flat belt 4 , 4 ′ and the outer surface 90 of the second roller 66 . In both support embodiments 94 , 95 , the conveyance surface 30 conveys objects 38 from the entrance portion 86 , 86 ′ proximate the first roller 65 to the exit portion 87 , 87 ′ proximate the first pulley 67 . In applying this invention to the corrugated industry, in particular the production of flat boxes 41 by a die cutter 42 , the conveyed objects 38 are flat boxes 41 .
[0096] The plurality of flat belts 4 , 4 ′ and support systems 84 , 84 ′ or the preferred embodiment plurality of flat belts 4 , 4 ′ and support systems 95 , 95 ′ have a direct application when integrated into a sheet stacking machine 54 which conveys flat boxes 41 for the purpose of producing stacks of boxes 50 .
[0097] An articulation system 85 is required to articulate the elements of the support system 84 , 84 ′, 95 , 95 ′ There are a multitude of means by which this can be easily accomplished by those skilled in the art with the following example described for completeness. In the simplest form, the rollers and pulleys would be rigidly mounted on framework with fixturing such that each item could be manually positioned relative to each other.
[0098] In an additional, for sophisticated example, is becomes clear that elements included in the basic support system 84 , 84 ′ and the preferred embodiment support system 95 , 95 ′ are only different in the added element of a second roller 66 for the preferred embodiment. Since the second roller 66 can be fixed to the frame 106 of a sheet stacker 54 as an example, the means for articulating the plurality of first pulleys 65 , 65 ′ and second pulleys 67 , 67 ′ will apply to all support systems 84 , 84 ′, 95 , 95 ′.
[0099] A simple articulation system would include the following for each flat belt 4 , 4 ′ and associated first pulley 65 , 65 ′ and second pulley 67 , 67 ′. A substantially rigid belt arm 107 would operatively connect each first pulley 65 , 65 ′ and second pulley 67 , 67 ′. These belt arms 107 , 107 ′ would be pivotably connected to an entrance slider block 108 , 108 ′ and supported by exit slider block 109 , 109 ′. This slider block 108 , 108 ′, 109 , 109 ′ would be able to move selectively along entrance linear rail 110 and exit linear rail 111 respectively. This results in the belt arm pivoting about pivot point 80 . By implementing one of a multitude of means to control and position these slider blocks 108 , 108 ′, 109 , 109 ′, the articulation of the support systems 84 , 84 ′, 95 , 95 ′ may be achieved. | A flat belt support system with a drive roller and paired pulleys, each pair carrying a continuous flat belt that can be moved laterally along the drive roller axis and angled away from the plane normal to the drive roller axis. Multiple belts, each carried by a pair of pulleys, can be driven by a single drive roller. An additional roller allows the drive roller to be positioned so that it contacts the flat belt cover, rather than the back of the flat belt, improving friction between the drive roller and the flat belt. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a Continuation Application of PCT Application No. PCT/JP03/15291, filed Nov. 28, 2003, which was published by the International Bureau on 17 Jun. 2004 (17. 06. 2004) under No. WO 2004/051658.
This application is based upon and claims the benefit of priority from prior Japanese Patent Applications No. 2002-346895, filed Nov. 29, 2002; and No. 2003-349458, filed Oct. 8, 2003, the entire contents of both of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a portable wireless communication terminal having a function for transmitting/receiving multimedia data; a picked-up image editing apparatus; and a picked-up image editing method. In particular, the present invention relates to a portable wireless communication terminal and a picked-up image editing apparatus and method having a function for combining and/or processing a downloaded image together with a picked-up image.
2. Description of the Related Art
In recent years, there has been a portable telephone (a type of portable wireless communication terminal) having a digital camera incorporated therein such that data picked-up by using this incorporated camera can be transmitted to be attached to E-mail and the data can be received and displayed.
Further, there exists a portable telephone comprising a function capable of processing picked-up data and capable of freely setting a motion picture, animation, sound (melody) or the like downloaded over a content provider as a call arrival image as is the case with a variety of multimedia data.
The thus downloaded data is often inhibited from being duplicated or processed, and information with copyright protection is added to the data in advance. However, a general user has few opportunities of recognizing them. Therefore, when an attempt is made to freely combine and/or process picked-up images, there are many cases in which such combining and/or processing are/is restricted or inhibited.
In addition, the image picked-up by the above-described portable telephone with the camera function and another image with copyright obtained by downloading it can be displayed to be combined with each other. However, the thus combined image cannot be transmitted. Therefore, after the combined image has been temporarily held in the portable telephone, when an attempt is made to transmit it via E-mail, the combined image is not displayed, and cannot be transmitted. At this time, the general user cannot understand why the combined image is not displayed and cannot be transmitted. In such a case, there has been a problem that the user has a trouble with operation, and the usability of the portable telephone is very poor.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide a portable wireless communication terminal capable of notifying the fact that multimedia data cannot be transmitted when the multimedia data targeted to be combined includes data downloaded via a network or protected by copyright information and a picked-up image editing apparatus and a picked-up image editing method incorporated in this portable wireless communication terminal.
According to an embodiment of the present invention, a portable wireless communication terminal having an acquiring device which acquires multimedia data, a wireless communication function, and a downloading function for downloading multimedia data over a network by using the wireless communication function, the portable wireless communication terminal comprises:
a memory which stores the multimedia data acquired by using the acquiring device and the multimedia data downloaded over the network;
a combining instruction issuing unit which issues a combining instruction to combine the multimedia data with each other;
a combining unit which, when the combining instruction issued by the combing instruction issuing unit is detected, reads out multimedia data to be combined from the memory, and combines the read out data;
a storage control unit which, when the multimedia data combined by the combining unit includes downloaded data, stores storage addresses of respective multimedia data stored in the memory so as to be associated with each other, and, when the multimedia data combined by the combining unit does not include downloaded data, stores the combined multimedia data in the memory;
a transmission instruction issuing unit which issues a transmission instruction to transmit the combined multimedia data to an outside of the portable communication terminal;
a determination unit which, when the multimedia data is read out by the transmission instruction issuing unit, determines whether or not the storage addresses of multimedia data are stored in the memory; and
a disabling unit which, when the determining unit determines that the storage addresses of multimedia data are stored in the memory, disables transmission of the combined multimedia data.
According to another embodiment of the present invention, a picked-up image editing apparatus comprises:
a memory which stores a mixture of multimedia data with processing disable information and multimedia data without processing disable information;
an image pick-up device which picks-up an image of an object as one of a still picture and a motion picture;
an image data producing unit which produces image data based on an image picked-up by the image pick-up device;
a combining instruction issuing unit which issues a combining instruction to combine the produced image data with the multimedia data stored in the memory; and
an output content storing unit which, when the multimedia data targeted to be combined has processing disable information, stores only output contents based on a processing result.
According to an embodiment of the present invention, a picked-up image editing method comprises:
storing into a memory a mixture of multimedia data with processing disable information and multimedia data without processing disable information;
picking-up an object;
producing image data based on the picked-up image;
issuing a combining instruction to combine the produced image data with the multimedia data stored in the memory; and
when the multimedia data targeted to be combined has processing disable information, storing only output contents based on a processing result.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the present invention and, together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the present invention in which:
FIG. 1A and FIG. 1B are external views each showing an example in which a foldable portable wireless communication terminal according to a first embodiment of the present invention is opened, wherein FIG. 1A is a plan view thereof, and FIG. 1B is a rear view thereof;
FIG. 2 is a block diagram showing an example of a circuit configuration of a portable telephone shown in FIG. 1 ;
FIG. 3 is a schematic view showing an example of a configuration of a RAM memory area shown in FIG. 1 ;
FIG. 4 is a schematic view showing an example of a configuration of a data folder management table shown in FIG. 3 ;
FIG. 5 is a schematic view showing an example of contents of a call arrival setting table shown in FIG. 3 ;
FIG. 6 is a flow chart showing general procedures for setting an image (a still picture or a motion picture) picked-up by the portable telephone shown in FIG. 1 on the call arrival setting table so as to be displayed upon call arrival;
FIG. 7 is a flow chart showing more detailed procedures for setting an image (a still picture or a motion picture) picked-up by the portable telephone shown in FIG. 1 on the call arrival setting table so as to be displayed upon call arrival;
FIG. 8 is a flow chart showing procedures for picking-up an image by actually using a camera function of the portable telephone shown in FIG. 1 , and producing the resulting image as a display image upon call arrival;
FIG. 9 is a flow chart showing procedures for picking-up an image by actually using a camera function of the portable telephone shown in FIG. 1 , and producing the resulting image as a display image upon call arrival;
FIG. 10 is a flow chart showing procedures for picking-up an image by actually using a camera function of the portable telephone shown in FIG. 1 , and producing the resulting image as a display image upon call arrival;
FIG. 11 is a flow chart showing procedures for picking-up an image by actually using a camera function of the portable telephone shown in FIG. 1 , and producing the resulting image as a display image upon call arrival;
FIG. 12 is a flow chart showing procedures for picking-up an image by actually using a camera function of the portable telephone shown in FIG. 1 , and producing the resulting image as a display image upon call arrival;
FIG. 13 is a schematic view showing an example of storage contents of the RAM data folder shown in FIG. 1 ;
FIG. 14 is a schematic view showing an example of contents of a call arrival setting table in step S 20 shown in FIG. 8 ;
FIG. 15 is a schematic view showing an example of contents when a combined image has been stored in the data folder shown in FIG. 3 ;
FIG. 16 is a schematic view showing an example of storage contents of a call arrival setting table when no copyright is attached to a combined image;
FIG. 17 is a schematic view showing an example of storage contents of a call arrival setting table when a sound is output upon call arrival when no copyright is attached to a combined image;
FIG. 18 is a schematic view showing an example of storage contents of a call arrival setting table when a sound is output upon call arrival when a copyright is attached to a combined image;
FIG. 19 is a schematic view showing an example of storage contents when a combined image produced by combining a motion picture with a still picture has been stored in the call arrival setting table shown in FIG. 3 ;
FIG. 20 is a schematic view showing an example of storage contents when a combined image produced by combining sound-attachment animation with a still picture has been stored in the data folder shown in FIG. 3 ;
FIG. 21 is a schematic view showing an example of storage contents when a motion picture file obtained by picking-up a motion picture by the portable telephone shown in FIG. 1 has been stored in the data folder shown in FIG. 3 ;
FIG. 22 is a schematic view showing an example of storage contents when a combined image produced by combining a motion picture which is not provided with a copyright with a still picture has been stored in the data folder shown in FIG. 3 ;
FIGS. 23A , 23 B, 23 C, 23 D, and 23 E are views each showing a screen example when an image is combined with a still picture displayed at a display device shown in FIG. 1 ;
FIGS. 24A and 24B are views each showing a screen example when an image is combined with a motion picture displayed at the display device shown in FIG. 1 ;
FIGS. 25A , 25 B, and 25 C are views each showing a screen example displayed at the display device shown in FIG. 1 when a motion picture has been combined with another motion picture;
FIG. 26 is a flow chart showing procedures when a combined image has been called by the portable telephone shown in FIG. 1 ;
FIG. 27 is a flow chart showing processing for producing a sound to be output together with a call arrival image when a motion picture has been changed to a call arrival image by a portable telephone according to a second embodiment of the present invention;
FIG. 28 is a schematic view showing an example of a configuration of a RAM memory area in another embodiment;
FIG. 29 is a schematic view showing an example of a configuration of a data folder management table shown in FIG. 28 ; and
FIG. 30 is a schematic view showing an example of a configuration of the data folder management table shown in FIG. 28 in another embodiment.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, a first embodiment of the present invention will be described with reference to the accompanying drawings. FIGS. 1A and 1B are external views each showing an example in which a foldable portable wireless communication terminal according to one embodiment of the present invention is opened, wherein FIG. 1A is a plan view thereof, and FIG. 1B is a rear view thereof.
A portable telephone 1 is provided with a camera. This telephone has a foldable structure capable of picking-up a still picture (“JPEG” compression) and a motion picture (“MPEG” compression), the structure including a cover and main body. In this portable telephone 1 , an expandable antenna 11 is provided at a rear face of the cover; a speaker 12 carrying out sound output is provided at the frontal side of the cover; and a main display device 13 with a color liquid crystal of 120 dots (wide)×160 dots (high), the main display device being capable of displaying an image and a text of E-mail with image attached is provided at the frontal side of the cover.
A key operating portion 14 is provided on a front face of the main body. This key operating portion includes a variety of function keys (such as an E-mail key 141 , an address key 141 , and a shutter key 143 ); ten numeric keys 144 ; and the like.
The E-mail key 141 is provided for starting up an E-mail function and displaying an E-mail menu. The address key 142 is provided for opening an address notebook used to select an E-mail address of a transmission destination.
The shutter key 143 is provided for closing a shutter which is mounted. The ten numeric keys 144 are used for telephone number or character input. A microphone 15 carrying out sound input is provided at the lower part of the main body.
A subsidiary display device 16 and a rear key 17 made of a transparent or semitransparent material are provided at the rear face of the cover, and incorporates an LED 171 emitting a light upon call arrival therein. An object lens 18 is provided at the lower part of the subsidiary display device 16 at the rear face of the cover. A loudspeaker 19 informing a call arrival or the like is provided at the rear lower part of the main body such that a buzzer is audible even in a state in which the cover is closed at the main body.
FIG. 2 is a block diagram showing an example of a circuit configuration of the portable telephone 1 shown in FIG. 1 . The portable telephone 1 comprises: a wireless transmitter/receiver 20 for transmitting/receiving and modulating/demodulating a sound or text (E-mail data) via the antenna 11 in a wireless manner; a wireless signal processor 21 for carrying out processing required for wireless communication such as demodulating the sound or text (E-mail data) received by the wireless transmitter/receiver 20 , or modulating a sound or text to be transmitted to the wireless transmitter/receiver 20 ; a controller 22 for controlling a variety of operations and a whole operation; an image compression/encoding processor 23 for compressing/encrypting an image or the like picked-up by an image pickup module 181 (including the object lens 18 and a rewritable flash ROM (not shown)) and a digital sound processor (DSP) 182 ; a flash ROM 24 for storing a variety of programs described later; a driver 25 for driving the display device 13 ; a driver 26 for driving the subsidiary display device 16 ; a subscriber information memory 27 for storing telephone numbers for calling the portable telephone 1 or profile data such as operator (subscriber) ID; a system ROM 28 for storing a variety of programs or the like for controlling the controller 22 ; a RAM 29 for storing a variety of data required for the portable wireless communication terminal, storing data required for the controller 22 to operate, and storing an image file picked-up by a picking-up portion (object lens 18 , image pickup module 181 , DSP 182 ) and compressed/encoded by a program stored in an image processing program region of the ROM 24 or an image file downloaded via WWW (World Wide Web); the image pickup module 181 including CCD or CMOS, for capturing a color image; the DSP 182 for encoding the image captured by the image pickup module 181 ; the broadcast speaker 19 ; a vibrator 191 ; a driver 192 for driving an LED 171 ; and a sound signal processor 200 for carrying out decoding a signal output from the wireless signal processor 21 and driving the speaker 12 , thereby outputting a sound.
The image compression/encoding processor 23 is a circuit portion which encodes a still picture in a JPEG scheme or a motion picture in an “amc” scheme compatible with MPEG-4 scheme after capturing the still picture or motion picture picked-up by the picking-up portion (object lens 18 , image pickup module 181 , DSP 182 ) and digitally encoded and a display image (still picture or motion picture) combined when a call arrival image is produced in a camera mode described later. In addition, this portion comprises a function for downloading image data over a network by means of a system (not shown) or decoding a still picture file attached to a received E-mail (JPEG (JPG) scheme, SMP scheme, PNG scheme, GIF scheme) or a motion picture file (MPEG (AMC) ASF) scheme, GIF animation scheme). In the still picture picked-up at the picking-up portion, when the still picture is encoded in the JPEG scheme, a thumbnail image or a control tag such as a picking-up condition is set and is produced as a file based on a DCF standard or an Exif standard.
FIG. 3 is a schematic view showing a memory area configuration of the RAM 29 . The RAM 29 is segmented into an area of a data folder management table 290 ; an area of a data folder 291 ; an area of a call arrival setting table 292 ; an area of an address notebook table 293 ; and an area of other data memory 294 .
A table configuration of the data folder management table 290 is as shown in FIG. 4 . Actual real data is stored in the data folder 291 . However, the data folder management table 290 managing them is provided so as to write a file name, a data size, a folder attribute, a folder title, a file attribute, and a copyright flag for each record number, and one record is formed of these elements.
The folder attribute is provided for sorting and managing items of data. On a display screen, data stored in a data folder is displayed for each folder. Any files are recorded miscellaneously in order of recording. The folder name indicates the name of folder displayed on the display screen.
The file attribute designates the attribute of data itself stored in the data folder. A motion picture indicates data (irrespective of the presence or absence of a sound) encoded/compressed in a file conforming to the AMC scheme compatible with the MPEG scheme and a motion picture file picked-up by the portable telephone 1 . Even when no-sound is provided or only a sound is provided, when encoding is carried out in the MPEG scheme, the encoded data is handled as a same folder “movie.” It is assumed that this attribute includes an animation file conforming to the GIF scheme (refer to record No. 15 of FIG. 4 ) or a file conforming to the PMD scheme (a sound-attachment animation file specialized for a format of the portable telephone (refer to record No. 14 of FIG. 4 )).
The still picture includes a still picture file conforming to the JPEG (JPG) scheme, the BMP scheme, the PNG scheme, or GIF scheme or a still picture file picked-up by the portable telephone 1 . The sound attribute includes an sound file recorded in the portable telephone 1 (refer to QCP format No. 003 ); a file conforming to the PMD format (a sound-attachment animation file specialized for the format of the portable telephone (when no animation is provided)) (refer to record Nos. 007 and 008 of FIG. 4 ); and a file conforming to the MMF scheme (a memory file specialized for the format of the portable telephone) (refer to record Nos. 009 to 010 of FIG. 4 ).
The call arrival setting table 292 is a table for setting what type of broadcast (screen display and sound (melody) output) is carried out when a call arrival request signal from the outside to an own telephone has been received. In detail, as shown in FIG. 5 , record No. of the above-described data folder management table 290 is stored.
When a file attribute of data corresponding to the stored record No. is a motion picture, this file is opened upon the receipt of the call arrival request signal, and the corresponding motion picture is displayed at the display device 13 . Then, when this motion picture file includes a sound, the corresponding sound is output. When no-sound is included, a defaulted broadcast buzzer is output.
When the file attribute of data corresponding to the stored record No. is a still picture, this file is opened upon the receipt of a call arrival request signal, and the corresponding still picture is displayed at the display device 13 . Then, in the call arrival setting table 292 , when record No. corresponding to this still picture file includes record No, of a file whose file attribute is “sound,” the sound corresponding to that record No. is output. Otherwise, a defaulted broadcast buzzer is output.
FIG. 5 is a view showing an example of contents of the call arrival setting table 292 . A transmitter number flag in FIG. 5 includes the transmitter's telephone number in a call arrival request signal. When this telephone number is identical to that stored in the address notebook table 293 , when the transmitter number flag is set, broadcasting is carried out based on that call arrival setting. A corresponding address denotes a storage address in the address notebook table 293 described above.
An operation according to the present embodiment will be described here. First, a general operation will be described in accordance with the flow charts of FIGS. 6 and 7 .
In FIG. 6 , the portable telephone 1 provides access to an image data download site over a communication network via the antenna 11 , the wireless transmitter/receiver 20 , and the wireless signal processor 21 , downloads image data, and stores the downloaded image data in an image memory 23 . In addition, the image file picked-up by the picking-up portion (object lens 18 , image pickup module 181 , DSP 182 ) and compressed/encoded by the image compression/encoding processor 23 is stored in the other data memory 294 (image memory) of the RAM 29 .
When the user sets the image (still picture or motion picture) picked-up by the portable telephone 1 so as to be displayed upon call arrival, the controller 22 determines whether or not the downloaded image is combined with the picked-up image displayed upon call arrival in step A 01 of FIG. 6 . When the determination result is negative, association with a sound file played back at the same time when this picked-up image is displayed upon call arrival is instructed in step A 02 , and a storage address of a still picture file and a storage address of the sound file are stored in the call arrival setting table 292 so as to be associated with each other in step S 03 .
When the downloaded image is combined with the picked-up image, processing goes to step A 04 in which it is determined whether or not a copyright is attached to the downloaded image to be combined. When the determination result is negative, processing goes to step A 07 , and when the determination result is affirmative, processing goes to step A 05 .
In step A 05 , association with the sound file played back at the same time when this picked-up image is displayed upon call arrival is instructed. In step A 06 , the storage address of the still picture file, the storage address and combining position of the image to be combined, and the storage address of the sound file are stored in the call arrival setting table 292 so as to be associated with each other.
When processing goes to step A 07 , the downloaded image is combined with the picked-up image, and the combining result is captured. Then, the captured result is stored in the new data folder 291 contained in the RAM 29 . In step A 08 , association with the sound file played back at the same time when this combined image is displayed upon call arrival is instructed. In step A 09 , the storage address of the combining result and the storage address of the sound file are stored in the call arrival setting table 292 so as to be associated with each other.
In short, when the image (still picture or motion picture) picked-up by the portable telephone 1 is set on the call arrival setting table 292 so as to be displayed upon call arrival, when a copyright protection flag (illegal copy protection) is set to the image to be combined, record No. of the picked-up image and the corresponding record No. are stored to be associated with each other. When no copyright protection flag (illegal copy protection) is set, the combining result is captured. Then, a file is newly created, and record No. of that file is set on the call arrival setting table 292 .
FIG. 7 is a flow chart showing more detailed operating procedures for setting the image (still picture or motion picture) picked-up by the portable telephone 1 so as to be displayed upon call arrival. In step B 01 , it is determined whether or not the downloaded image is combined with the picked-up image to be displayed upon call arrival. When the determination result is negative, it is determined in step B 02 whether or not a sound is attached to the picked-up image to be displayed upon call arrival, i.e., a call arrival image. When the determination result is negative, processing goes to step B 05 , and when the determination result is affirmative, processing goes to step B 03 .
In step B 03 , it is determined whether or not the sound attached to the call arrival image is output upon call arrival. When the determination result is negative, processing goes to step B 05 , and when the determination result is affirmative, processing goes to step B 04 . In step B 04 , the storage address of the motion picture file is stored in the call arrival setting table 292 so as to be associated with the storage address of the picked-up image.
When processing goes to step B 05 , association of the sound output when the call arrival image is displayed with the sound file is instructed. In step B 06 , the storage address of the motion picture file and the storage address of the sound file are stored in the call arrival setting table 292 so as to be associated with each other.
When it is determined in step B 01 that the downloaded image is combined with the picked-up image, processing goes to step B 07 in which it is determined whether or not a copyright is attached to the downloaded image to be combined. When the determination result is negative, processing goes to step B 13 , and when the determination result is affirmative, processing goes to step B 08 . In step B 08 , it is determined whether or not a sound is attached to either of the picked-up image file and the downloaded image file. When the determination result is negative, processing goes to step B 11 , and when the determination result is affirmative, processing goes to step B 09 .
In step B 09 , it is determined whether or not the sound attached to any image is output upon call arrival. When the determination result is negative, processing goes to step B 11 , and when the determination result is affirmative, processing goes to step B 10 . In step B 10 , the storage address of the motion picture file and the storage address and combining position of the image to be combined are stored in the call arrival setting table 292 so as to be associated with each other.
When processing goes to step B 11 , association of the sound file is instructed, and the storage address of the motion picture file, the storage address and combining position of the image to be combined, and the storage address of the sound file are stored in the call arrival setting table 292 so as to be associated with each other.
When processing goes to step B 13 , it is determined whether or not a sound is attached to both of the picked-up image file and the downloaded image file. When the determination result is negative, processing goes to step B 18 , and when the determination result is affirmative, processing goes to step B 14 . In step B 14 , a sound to be played back upon call arrival is instructed to be selected. In step B 15 , the combining result is played back and captured, and the captured combining result is newly stored in the data folder 291 .
In step B 16 , it is determined whether or not a sound is output upon call arrival. When the determination result is negative, processing goes to step B 19 , and when the determination result is affirmative, processing goes to step B 17 . In step B 17 , an address of the captured motion picture file (combined image) is stored in the call arrival setting table 292 .
When processing goes to step B 18 , it is determined whether or not a sound is attached to either of the picked-up image file and the downloaded image file. When the determination result is affirmative, processing goes to step B 15 , and when the determination result is negative, processing goes to step B 19 . In step B 19 , association with the sound file is instructed. In step B 20 , the address of the captured motion picture file (combined image) and the storage address of the sound file are stored in the call arrival setting table 292 so as to be associated with each other.
FIGS. 8 , 9 , 10 , 11 , and 12 are flow charts showing procedures for picking-up an image by actually using a camera function of the portable telephone 1 and producing the image as a display image upon call arrival.
When the key input device 14 of the portable telephone 1 is operated to enter the camera mode, the controller 22 causes the display device 13 to display a menu in step S 01 . The user selects whether to pick up a motion picture or to pick up a still picture by operating the input device 14 with referring to this menu display. Thus, the controller 22 determines whether a functional mode selected in step S 02 is a still picture or a motion picture. When the selected functional mode is a still picture, processing goes to step S 03 , and when the selected functional mode is a motion picture, processing goes to step S 48 of FIG. 11 .
FIG. 23A shows an example of screen displayed at the display device when the user has selected a still picture, wherein the “still picture” is underlined. FIG. 24A shows an example of screen when a motion picture has been selected, wherein the “motion picture” is underlined.
In step S 03 , an electrical signal obtained by picking-up an object by the image pickup module 181 is imaged by means of the DSP 182 , and the resulting image is through-displayed intact at the main display device 13 through the driver 25 . Then, in step S 04 , it is determined whether or not operation of the shutter key 143 is detected. When the determination result is negative, processing returns to step S 03 , and when the determination result is affirmative, processing goes to step S 05 in which the image output from the DSP 182 is stored to be temporarily captured in the other data memory 294 of the RAM 29 .
In step S 06 , after a file name input instruction has been displayed for the user at the display device 13 , it is determined whether or not a file name input determination has been detected in step S 07 . When the determination result is affirmative, processing goes to step S 09 , and when the determination result is negative, processing goes to step S 08 in which it is determined whether or not cancellation has been detected. When the determination result is negative, processing returns to step S 06 , and when the determination result is affirmative, processing returns to step S 03 .
In step S 09 , a file attribute and/or a still picture, and folder attribute 002 (my photo) are attached to the captured still picture, and stored in the data folder 291 . Then, in step S 10 , the display device 13 displays an image which causes the user to select whether or not this picked-up image is used for a call arrival image. FIG. 23B shows an example of display image when the user has selected that the image is used for the call arrival image, wherein “YES” is underlined.
Upon the receipt of the above operation, in step S 11 , it is determined whether or not the user has selected that the image is used for the call arrival image. When the determination result is negative, a file name (fuukei.jpg) is set in the picked-up still picture file. Then, the set file name is stored in the data folder 291 of the RAM 29 with record No. 20 , and processing returns to the menu display. When the determination result is affirmative, processing goes to step S 12 .
When a user has selected that a picked-up image is produced as a call arrival image, the user selects whether or not a downloaded image is combined with this call arrival image. Upon the receipt of this user selection, the controller 22 determines whether or not the downloaded image is combined with the picked-up image displayed upon call arrival in step S 12 . As a result, when the determination result is negative, processing goes to step S 24 , and when the determination result is affirmative, processing goes to step S 13 in which it is determined whether a still picture or a motion picture is to be combined. When the determination result is the still picture, processing goes to step S 14 , and when the determination result is the motion picture, processing goes to step S 31 shown in FIG. 10 .
In step S 14 , the file attribute and/or still picture files which have/has already been downloaded over a network are displayed at the display device 13 for each folder. In step S 15 , the display device displays a combined image as shown in FIG. 23C , for example, according to the subsequent user selecting and/or combining operation.
Image combining are carried out until a determination of the completion of producing a combined image has been detected. When the completion of producing the combined image is determined, it is determined in step S 17 whether or not a copyright flag is attached to the downloaded image used to be combined. When the determination result is negative, processing goes to step S 21 , and when the determination result is affirmative, processing goes to step S 18 .
In step S 18 , the display device 13 displays an indication for checking whether or not a valid copyright flag is attached to the downloaded image. In step S 19 , processing from step S 14 to step S 18 is repeated until YES has been detected for check. When YES is detected, processing goes to step S 20 in which association data is stored in the call arrival setting table 292 , and then, processing goes to step S 24 shown in FIG. 9 .
FIG. 14 shows an example of contents of the call arrival setting table 292 in step S 20 . The figure shows a case in which a still picture file of stamp02.png of record No. 17 has been combined with a still picture file of record No. 20 .
A display example of this case will be described with reference to FIG. 23C . Even with such a combined image, the still picture of stamp 02 .png (still picture indicating a human being on the top left of the display screen in FIG. 23C ) cannot be newly produced as a combined image because the copyright flag is set. Therefore, the storage contents of the call arrival setting table 292 are produced as record No. of picked-up image file+record No. of combined image file (combining position (upper left corner reference) X coordinate, combining position (upper left corner reference) y coordinate).
When processing goes to step S 21 , the combined still picture is played back once. In step S 22 , a file name of this combined image is input and determined. Then, record No. 21 is newly stored in the data folder 291 as shown in FIG. 15 . Then, in step S 23 , a storage address of this combined image is stored in the call arrival setting table 292 , as shown in FIG. 16 , and processing goes to step S 24 .
An example of contents of the data folder 291 in FIG. 15 shows a case in which a captured image (chakufuukei.jpg) of the combining result has been newly stored when a copyright protection flag (illegal copy protection) is not set in the combined image file.
FIG. 16 shows an example of storage contents of the call arrival setting table 292 when a still picture file of stamp 01 .png of record No. 16 has been combined with a still picture file of record No. 20 , for example, as the above-described combined image. An example of the display screen of the display device 13 will be described again with reference to FIG. 23C . The still picture of stamp01.png (still picture indicating a human being at the upper left of the display screen in FIG. 23C ) is newly produced as a combined image because the copyright flag is not set. Therefore, the storage contents of the call arrival setting table 292 are produced as record No. of the newly produced image file.
In step S 24 , when a sound is added to a call arrival image, the file attribute and/or sound which have/has been already downloaded over a network, or a file attribute animation (excluding no-sound) file are displayed for each folder. Then, the fact that the user has selected this file is displayed until the selection has been detected in step S 25 . Thereafter, when the user selection is detected, association data as shown in FIG. 17 is stored in the call arrival setting table 292 in step S 26 . Then, processing returns to the menu display screen.
An example of FIG. 17 , for example, shows storage contents of the call arrival setting table 292 when the still picture file of stamp02.png of record No. 17 is combined with the still picture file of record No. 20 , and record No. 08 is stored as a sound file to be output upon call arrival. The storage contents of the call arrival setting table 292 are produced as record No. of picked-up image file+record No. of combined image file (combining position (upper left corner reference) X coordinate, combining position (upper left corner reference) y coordinate)+record No. of associated sound file.
In step S 25 in which “No” is detected, an example of contents of the call arrival setting table 292 in step S 26 is as shown in FIG. 18 . In FIG. 18 , there is shown an example of storage contents of the call arrival setting table 292 when record No. 08 is stored in record No. 21 (in a newly produce combined image file) as a sound file to be output upon call arrival. The storage contents of the call arrival setting table 292 are produced as record No. of newly produced image file+record No. of associated sound file.
When processing goes to step S 31 shown in FIG. 10 , the display device 13 displays files whose downloaded file attribute is a motion picture for each folder. In step S 32 , the display device 13 displays a combined image according to the subsequent user selecting and/or combining operation.
FIG. 19 shows a storage example of a combined image when a motion picture has been produced to be combined with a still picture in step S 32 . The figure shows a state in which the image file (chakufuukei.gif) produced when the file attribute motion picture (movieframe 01 gif) shown in FIG. 13 is combined is captured, and is stored as record No. 021 in the data folder 291 of the RAM 29 .
That is, even when the picked-up image is a still picture, when a motion picture (animation) is targeted to be combined, the combining result is newly produced as a motion picture in a file. A description will be given by way of example with reference to FIGS. 23D and 23E . Data for which columns star-marked are changed alternately in FIGS. 23D and 23E is produced as a file called movieframe 01 .gif of record No. 18 in FIG. 19 .
Namely, even when the picked-up image is a still picture (an airplane icon in the figure), when the combined image includes a motion picture (columns star-marked in the figures), a motion picture file is produced in accordance with that file format. At this time, a folder attribute, a file attribute and the like are not set. In step S 46 described later, when a sound file (without a copyright) is associated, a sound-attachment animation file (chakufuukei.pmd) is processed as a file. Then, the processed file is stored in the data folder 291 , as shown in FIG. 20 .
Image combining is carried out until a determination of the completion of producing a combined image has been detected. When the completion of producing the combined image is determined, it is determined whether or not the copyright flag is attached to the downloaded image used to be combined in step S 34 . When the determination result is negative, processing goes to step S 38 , and when the determination result is affirmative, processing goes to step S 35 .
In step S 35 , the display device 13 displays an indication for checking whether or not a valid copyright flag is attached to the downloaded image. In step S 36 , processing from step S 31 to step S 35 is repeated until affirmative answer YES has been detected. When YES is detected, processing goes to step S 37 in which association data is stored in the call arrival setting table 292 , and then, processing goes to step S 41 .
When processing goes to step S 38 , the combined motion picture is played back from start to end timings and is compressed by means of the image compression/encoding processor 23 . Then, in step S 39 , a file name of this combined image is input and determined. Then, in step S 40 , the file name is newly stored in the data folder 291 , and processing goes to step S 41 .
In step S 41 , when a sound is added to a call arrival image, the display device 13 displays a file attribute and/or a sound which have/has been already downloaded over a network, or a file attribute animation (excluding no-sound) file for each folder. Then, the display is continued until it is detected in step S 42 that the user has selected the file. When the user selection is detected, it is determined in step S 43 whether or not the copyright flag is attached to the downloaded image used to be combined. When the determination result is negative, processing goes to step S 46 , and when the determination result is affirmative, processing goes to step S 44 .
In step S 44 , the display device 13 displays an indication for checking whether or not a valid copyright flag is attached to the downloaded image. In step S 45 , processing from step S 41 to step S 44 is repeated until affirmative answer YES has been detected. When YES is selected, processing goes to step S 47 in which association data is stored in the call arrival setting table 292 , and then, processing returns to the menu display screen.
When no copyright flag is attached to the downloaded image, processing goes to step S 46 in which a motion picture is set as a file attribute, and 001 or 004 is set in a folder attribute. Thereafter, processing goes to step S 47 in which association data is stored in the call arrival setting table 292 , and then, processing returns to the menu display screen.
When the image pick-up mode selected in step S 02 of FIG. 8 is a motion picture, processing goes to step S 48 of FIG. 11 in which an electrical signal obtained by picking-up an object by the image pickup module 181 is imaged by means of the DSP 182 , and the resulting image is through-displayed intact at the display device 13 through the driver 25 . Then, in step S 49 , it is determined whether or not operation of the shutter key 143 is detected. When the determination result is negative, processing returns to step S 48 , and when the determination result is affirmative, processing goes to step S 50 in which the motion picture output from the DSP 182 is stored to be temporarily captured in the other data memory 294 of the RAM 29 .
In step S 51 , it is determined whether or not operation of the shutter key 143 is detected. When the determination result is negative, it is determined whether or not a predetermined time interval has elapsed in step S 52 . When the determination result is negative, processing returns to step S 50 , and when the determination result is affirmative, processing goes to step S 53 . When operation of the shutter key 143 is detected, processing goes to step S 53 immediately.
When operation of the shutter key 143 is detected in step S 51 , processing goes to step S 53 in which the temporarily captured image is compressed/encoded by means of the image compression/encoding processor 23 . Then, in step S 54 , the display device 13 displays a file name input instruction for the user.
In step S 55 , it is determined whether or not a determination of file name input has been detected. When the determination result is negative, processing goes to step S 56 in which it is determined whether or not cancellation has been detected. When no cancellation has been detected, processing returns to step S 54 , and when cancellation has been detected, processing returns to step S 48 .
When a determination of file name input has been detected in step S 55 , processing goes to step S 57 in which the compressed/encoded motion picture is stored as shown in FIG. 21 in the data folder 291 of the RAM 29 by attaching the file attribute and/or motion picture or folder attribute 003 (movie) to the motion picture.
FIG. 21 shows an example in which, after a motion picture has been picked-up in the camera mode, when a motion picture file is produced, a file name (car.amc) is set for that motion picture file, and the set file name is stored as record No. 20 in the data folder 291 .
In step S 58 , the display device 13 displays an image which causes the user to select whether this picked-up image is used for a call arrival image. In response to this, in step S 59 , it is determined whether or not the user has selected that the picked-up image is used for the call arrival image. When the determination result is negative, processing returns to the display menu, and when the determination result is affirmative, processing goes to step S 60 .
FIG. 24B shows an example of screen of the display device 13 when the user has selected that the picked-up image is used for the call arrival image, wherein “YES” is underlined. In addition, at this time, when the user has selected that the picked-up image is produced as the call arrival image, the user selects whether or not the selected image is combined with a downloaded image.
The controller 22 determines whether or not the downloaded image is combined with a picked-up image to be displayed upon call arrival. When the determination result is negative, processing goes to step S 71 shown in FIG. 12 . When the determination result is affirmative, processing goes to step S 61 in which the display device 13 displays the file attribute, still picture, motion picture, or animation file which has already been downloaded over a network for each folder. In step S 62 , the display device 13 displays a combined image according to the subsequent user selecting and/or combining operation.
In step S 63 , processing of step S 62 is repeated until a determination of a combined image has been selected. When the combined image is determined, it is determined in step S 64 whether or not a copyright flag is attached to the downloaded image used to be combined. When the determination result is negative, processing goes to step S 68 , and when the determination result is affirmative, processing goes to step S 65 .
In step S 65 , the display device 13 displays an indication for checking whether a valid copyright flag is attached to the downloaded image. In step S 66 , processing from step S 61 to step S 66 is repeated until affirmative answer YES has been detected. When YES is detected, processing goes to step S 67 in which association data is stored in the call arrival setting table 292 , and then, processing goes to step S 71 of FIG. 12 .
When processing goes to step S 68 , the combined still picture is played back from start to end timings and is compressed by means of the image compression/encoding processor 23 . In step S 69 , a file name of this combined image is input and determined, and then, the determined image is newly stored as shown in FIG. 22 in the data folder 291 of the RAM 29 . Further, in step S 70 , this storage address is stored in the call arrival setting table 292 , and then, processing goes to step S 71 of FIG. 12
FIG. 22 is a view showing an example in which, when a copyright protection flag (illegal copy protection) is not set for an image file having a motion picture combined with a still picture therein, a captured image (chakucar.amc) of the combining result is newly stored in the data folder 291 .
FIGS. 25A , 25 B, and 25 C each show an example of screen on which a motion picture is combined with a still picture. In FIGS. 25A , 25 B, and 25 C, data for which star-marked columns are changed alternately is produced as a file called movieframe 01 .gif of record No. 18 in FIG. 22 . In this case, a motion picture file is produced in accordance with the file format of a picked-up image.
In step S 71 of FIG. 12 , when a sound is added to a call arrival image, the file attribute and/or sound which have/has downloaded over a network, or a file attribute animation (excluding no-sound) file is displayed for each folder. Then, the display continues until the user selection has been detected in step S 72 .
When the user selection is detected, it is determined whether or not the copyright flag is attached to the downloaded image used to be combined in step S 73 . When the determination result is negative, processing goes to step S 77 , and when the determination result is affirmative, processing goes to step S 74 .
In step S 74 , the display device 13 displays an indication for checking whether or not a valid copyright flag is attached to the downloaded image. In step S 75 , processing from step S 71 to step S 74 is repeated until affirmative answer YES has been detected. When YES is detected, processing goes to step S 76 in which association data is stored in the call arrival setting table 292 , and then, processing goes to the menu display screen.
When no copyright flag is attached to the downloaded image at step S 73 , processing goes to step S 77 in which a motion picture is set as a file attribute; 001 or 004 is set as a folder attribute; association data is stored in the call arrival setting table 292 ; and then, processing returns to the menu display screen.
When the user uses an image which has been combined and stored once (for example, when the user transmits the image via E-mail), the controller 22 makes a search for the RAM 29 . When the image to be used is stored as association data in the call arrival setting table 292 , it is determined that a copyright is attached to a portion of the combined image. Then, the display device 13 displays an indication that “the image to be used cannot be displayed because a portion of the combined image has a copyright.” In addition, when the combined image is used for transmission via E-mail, the display device displays an indication that “the image cannot be displayed and transmitted because a portion of the combined image has a copyright.”
FIG. 26 is a flow chart showing procedures of the controller 22 when the above described combined image is used.
In step D 01 , when a combined image is called, processing goes to step D 02 in which a search is made for the call arrival setting table 292 of the RAM 29 . Then, it is determined whether or not the storage addresses of picked-up image and downloaded image configuring a combined image targeted for the call request are stored differently to be associated with each other.
In step D 03 , based on the above described search, it is determined whether or not the storage addresses of the picked-up image and downloaded image are different from each other. When the determination result is negative, processing goes to step DOS in which the combined image data is read out from the data folder 291 of the RAM 29 which is a storage destination, and the readout data is displayed.
When the storage addresses of the picked-up image and downloaded image are different from each other, processing goes to step D 04 in which the display device 13 displays a message that “the image cannot be displayed because a portion of the combined image has a copyright,” and terminates processing.
According to the present embodiment, when the user uses a combined image which has been combined and stored once, when a portion of the combined image has a copyright, the display device displays an indication that “the image cannot be displayed because a portion of the combined image has a copyright.” In addition, when the combined image is used for transmission via E-mail, the display device further displays an additional indication that “transmission is impossible.” Thus, the user can know immediately why the image is not displayed and why transmission via E-mail is impossible. Therefore, operability of the portable telephone 1 can be improved.
Now, other embodiments of the present invention will be described here. In the following embodiments, like constituent elements corresponding to the first embodiment are designated by the same reference numerals. A detailed description is omitted here.
FIG. 27 is a flow chart showing processing for generating a sound to be output together with a call arrival image when a motion picture according to a second embodiment of the present invention is produced as a call arrival image. Hereinafter, with respect to each element having an identical configuration, a description of the configuration and operation thereof is omitted. A main portion of that operation will be described here.
In step C 01 , it is determined whether or not a sound is attached to a motion picture to be combined. When the determination result is affirmative, processing goes to step C 02 , and when the determination result is negative, processing goes to step C 04 . In the former case, in step C 02 , it is determined whether or nor a sound is output upon call arrival. When no-sound is output upon call arrival, processing goes to step C 04 . When a sound is output upon call arrival, processing goes to step S 03 in which a storage address of a motion picture file is stored in the call arrival setting table 292 of the RAM 29 .
When processing goes to step C 04 , association with a sound file is instructed here. In step C 05 , it is determined whether or not a copyright flag is attached to this sound file. When the determination result is affirmative, the storage address of the motion picture file and the storage address of the sound file are stored in the call arrival setting table 292 so as to be associated with each other.
When no copyright flag is attached to the sound file, processing goes to step C 07 in which a motion picture file is played back and captured while the associated sound file is output. In step C 08 , a motion picture file is newly stored in the data folder 292 . In step C 09 , the storage address of the newly produced motion picture file is stored in the call arrival setting table 292 .
When the user outputs a sound when a call arrival motion picture is displayed, i.e., when a sound is output when a combined image is displayed, and a copyright flag is attached to that image, the motion picture file and sound file are stored respectively. The respective storage addresses are stored as association data in the call arrival setting table 292 . Thus, when these addresses are detected, it is determined that a sound output together with the combined image has a copyright.
According to the present embodiment, when a combined image with a sound output is transmitted via E-mail and the sound has a copyright, the display device displays an indication that “no transmission is possible because a sound has a copyright.” In this manner, the user can know immediately why transmission is impossible, and operation of the portable telephone 1 can be improved.
In the above-described first embodiment and second embodiment, it is determined whether capturing and storage of the combined image enabled or disabled according to whether or not a file (multimedia data) which is a combining source has a copyright. The determination as to whether combining is enabled or disabled may be made on the presumption that “copyright protection is applied to file data downloaded over the Internet in principle.”
FIG. 28 is a schematic view showing a memory area configuration of the RAM 29 in the portable telephone 1 which is made compatible with the above-described case. A difference from the above first embodiment and second embodiment is that a data folder management table 295 is provided instead of the data folder management table 290 . The other circuit configuration and memory configuration are identical to those in the above described first and second embodiments.
A table configuration of the data folder management table 295 is as shown in FIG. 29 . Actual real data is stored in the data folder 291 . The data folder management table 290 managing them is provided to write a file name, a data size, a folder attribute, a folder title, and a file attribute on a record No. by record No. basis, and one record is formed of these elements.
A region of the folder title is set so as to sort a downloaded item and a produced one in the portable telephone 1 when multimedia files are stored to be mixed. That is, in the folder title, a folder called “my . . . ” stores a variety of data obtained by operating the portable telephone 1 such as startup of a camera function. On the other hand, a folder which is not called “my . . . ” is stored in a folder for storing downloaded data.
In the course of combining processing, when data (file) being a combining source is read out from a folder in which “my . . . ” is not set, the corresponding storage addresses are stored respectively without capturing a forcibly composed image.
By doing this, the determination as to whether combining is enabled or disabled can be made irrespective of the presence or absence of copyright information.
Apart from determination as to whether combining is enabled or disabled on the presumption that “copyright protection is applied, in principle, to file data downloaded over the Internet, for example,” even in a still picture file conforming to the JPEG scheme, the still picture file being picked-up by the portable telephone 1 , the determination as to whether combining is enabled or disabled may be made on the presumption that “all files may be processed as long as they are in a file format conforming to the DFC standard or Exif standard.”
FIG. 30 shows a table configuration of the data folder management table 295 of the RAM 29 in the portable telephone 1 which is made compatible with the above described case. Actual real data is stored in the data folder 291 . The data folder management table 290 managing them is provided so as to write a file name, a data size, a folder attribute, a folder title, and, a file attribute in a DCF/Exif flag area on a record No. by record No. basis. One record is formed of these elements.
The DCF/Exif flag area is provided as a flag set for sorting the downloaded item and the item produced in the portable telephone 1 according to whether they are produced in accordance with the DCF standard or Exif standard in storing a still picture file conforming to the JPEG scheme. That is, in FIG. 30 , a file name “taro.jpg” managed in record No. 002 is picked-up by the portable telephone 1 , and is stored in a folder whose folder title is “my photo.” Therefore, this file is found to be a still picture file stored after picked-up, and thus, “1” is set in the DCF/Exif flag area. On the other hand, a file name idol01.jpg managed in record No. 012 is stored in a folder whose folder title is “graphic.” Therefore, this file is found to have been downloaded, and thus, “0” is set in the DCF/Exif flag area.
By doing this, the determination as to whether combining is enabled or disabled can be made irrespective of the presence or absence of copyright information.
The above-described operations according to the embodiments can be carried out by programming them and causing a computer to execute them. At this time, a computer program can be supplied to a computer through a disk type recording medium such as a floppy disk or a hard disk; a variety of memories such as a semiconductor memory or a card type memory; or a variety of program recording mediums such as a communication network.
According to the above mentioned embodiments, when combining of multimedia data is instructed, it is determined whether or not the multimedia data targeted to be combined includes data downloaded via the network by the wireless communication function. When the determination result is affirmative, a corresponding storage address is stored, and transmission of the combined multimedia data is inhibited. Hence, when the multimedia data targeted to be combined includes data downloaded via the network or protected by copyright information, it is possible to notify to the user that transmission cannot be carried out, so that the user's usability can be improved.
It is possible to determine whether combining is enabled or disabled according to the presence or absence of copyright information.
The multimedia data combined as the content of call arrival notification can be used, and thus, the multimedia data according to the user's preference can be freely used without worrying about acquisition by use of a device incorporated in advance or acquisition by downloading.
Since the still picture data or the motion picture data is handled as one item of the multimedia data, the user can use the still picture data or the motion picture data without worrying about acquisition by picking-up or downloading.
It is possible to determine whether combining is enabled or disabled according to the presence or absence of the still picture data picked-up by the user.
When the motion picture data picked-up by the user is targeted to be combined, the multimedia data after combined is uniquely handled as motion picture data, so that the user can use motion picture data freely.
Since the sound data recorded by the user is handled as one item of the multimedia data, the multimedia data according to the user's preference can be freely used.
When the multimedia data targeted to be combined includes data downloaded via a network or protected by copyright information, it is possible to check only the combining result without combining and/or storing these items of the data, so that the user's usability can be improved.
In the case of the multimedia data which is not inhibited from being processed, the combining result is stored as new multimedia data, and thus, the user's usability can be improved.
Since the presence or absence of the flag information is used as a criterion as to whether combining of the multimedia data is enabled or disabled, the determination as to whether the combining is enabled or disabled can be easily made without making a determination based on redundant data.
Since the presence or absence of the copyright information is used as a criterion as to whether combining of the multimedia data is enabled or disabled, the determination as to whether the combining is enabled or disabled can be easily made.
When the multimedia data targeted to be combined includes data downloaded via the network or protected by copyright information, it is possible to check only the combining result without combining and/or storing items of the data, and thus, the user's usability can be improved.
In the case of the multimedia data which is not inhibited from being processed, the combining result is stored as new multimedia data, so that the user's usability can be improved.
Since the presence or absence of the flag information is used as a criterion as to whether combining of the multimedia data is enabled or disabled, the determination as to whether the combining is enabled or disabled can be made without making a determination based on redundant data.
Since the presence or absence of the copyright information is used as a criterion as to whether combing of the multimedia data is enabled or disabled, the determination as to whether the combing is enabled or disabled can be easily made.
The present invention is not limited to the above described embodiments. The present invention can be carried out according to other various modes in specific configuration, function, operation, and advantageous effect without deviating from the spirit of the invention. A similar advantageous effect can be achieved by applying the present invention to a portable wireless communication terminal PDA, a portable personal computer and the like. | A picked-up image editing apparatus comprises a memory which stores a mixture of multimedia data with processing disable information and multimedia data without processing disable information, an image pick-up device which picks-up an image of an object as one of a still picture and a motion picture, an image data producing unit which produces image data based on an image picked-up by the image pick-up device, a combining instruction issuing unit which issues a combining instruction to combine the produced image data with the multimedia data stored in the memory, and an output content storing unit which, when the multimedia data targeted to be combined has processing disable information, stores only output contents based on a processing result. | 8 |
CROSS REFERENCES TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 10/249,190, filed on Mar. 20, 2003, now U.S. Pat. No. 6,652,341, which is a continuation of U.S. patent application Ser. No. 09/843,338 filed on Apr. 25, 2001, now U.S. Pat. No. 6,537,159, which is a continuation-in-part application of U.S. Patent application Ser. No. 09/398,919 filed on Sep. 16, 1999, now U.S. Pat. No. 6,224,499.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a golf ball. More specifically, the present invention relates to a dimple pattern for a golf ball in which the dimple pattern has different sizes of dimples.
2. Description of the Related Art
Golfers realized perhaps as early as the 1800's that golf balls with indented surfaces flew better than those with smooth surfaces. Hand-hammered gutta-percha golf balls could be purchased at least by the 1860's, and golf balls with brambles (bumps rather than dents) were in style from the late 1800's to 1908. In 1908, an Englishman, William Taylor, received a patent for a golf ball with indentations (dimples) that flew better and more accurately than golf balls with brambles. A. G. Spalding & Bros., purchased the U.S. rights to the patent and introduced the GLORY ball featuring the TAYLOR dimples. Until the 1970s, the GLORY ball, and most other golf balls with dimples had 336 dimples of the same size using the same pattern, the ATTI pattern. The ATTI pattern was an octahedron pattern, split into eight concentric straight line rows, which was named after the main producer of molds for golf balls.
The only innovation related to the surface of a golf ball during this sixty year period came from Albert Penfold who invented a mesh-pattern golf ball for Dunlop. This pattern was invented in 1912 and was accepted until the 1930's.
In the 1970's, dimple pattern innovations appeared from the major golf ball manufacturers. In 1973, Titleist introduced an icosahedron pattern which divides the golf ball into twenty triangular regions. An icosahedron pattern was disclosed in British Patent Number 377,354 to John Vernon Pugh, however, this pattern had dimples lying on the equator of the golf ball which is typically the parting line of the mold for the golf ball. Nevertheless, the icosahedron pattern has become the dominant pattern on golf balls today.
In the late 1970s and the 1980's the mathematicians of the major golf ball manufacturers focused their intention on increasing the dimpled surface area (the area covered by dimples) of a golf ball. The dimpled surface for the ATTI pattern golf balls was approximately 50%. In the 1970's, the dimpled surface area increased to greater than 60% of the surface of a golf ball. Further breakthroughs increased the dimpled surface area to over 70%. U.S. Pat. No. 4,949,976 to William Gobush discloses a golf ball with 78% dimple coverage with up to 422 dimples. The 1990's have seen the dimple surface area break into the 80% coverage.
The number of different dimples on a golf ball surface has also increased with the surface area coverage. The ATTI pattern disclosed a dimple pattern with only one size of dimple. The number of different types of dimples increased, with three different types of dimples becoming the preferred number of different types of dimples. U.S. Pat. No. 4,813,677 to Oka et al., discloses a dimple pattern with four different types of dimples on the surface where the non-dimpled surface cannot contain an additional dimple. United Kingdom patent application number 2157959, to Steven Aoyama, discloses dimples with five different diameters. Further, William Gobush invented a cuboctahedron pattern that has dimples with eleven different diameters. See 500 Year of Golf Balls, Antique Trade Books, page 189. However, inventing dimple patterns with multiple dimples for a golf ball only has value if such a golf ball is commercialized and available for the typical golfer to play.
Additionally, dimple patterns have been based on the sectional shapes, such as octahedron, dodecahedron and icosahedron patterns. U.S. Pat. No. 5,201,522 discloses a golf ball dimple pattern having pentagonal formations with an equal number of dimples thereon. U.S. Pat. No. 4,880,241 discloses a golf ball dimple pattern having a modified icosahedron pattern wherein small triangular sections lie along the equator to provide a dimple-free equator.
Although there are hundreds of published patents related to golf ball dimple patterns, there still remains a need to improve upon current dimple patterns. This need is driven by new materials used to manufacture golf balls, and the ever increasing innovations in golf clubs.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a novel dimple pattern that reduces high speed drag on a golf ball while increasing its low speed lift thereby providing a golf ball that travels greater distances. The present invention is able to accomplish this by providing multiples sets of dimples arranged in a pattern that covers as much as eighty-seven percent of the surface of the golf ball.
One aspect of the present invention is a dimple pattern on a golf ball in which the dimple pattern has at least eleven different sets of dimples. Each of the sets of dimples differs from the other sets of dimples in at least one of a dimple diameter, an entry radius and an entry angle. The dimples cover at least 87% of the surface of the golf ball.
Another aspect of the present invention is a golf ball having a core and cover. The core has a diameter of 1.50 inches to 1.56 inches. The cover encompasses the core and has a surface covered with dimples. At least eleven different sets of dimples cover at least eighty-seven percent of the surface. Each set of dimples has a different diameter than the other sets of dimples. The dimple diameters range between 0.100 inch and 0.184 inch.
Having briefly described the present invention, the above and further objects, features and advantages thereof will be recognized by those skilled in the pertinent art from the following detailed description of the invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a two-piece golf ball of the present invention.
FIG. 1A is a cross-sectional view of a three-piece golf ball of the present invention.
FIG. 2 is an equatorial view of a preferred embodiment of a golf ball of the present invention.
FIG. 3 is an equatorial view of a preferred embodiment of a golf ball of the present invention.
FIG. 4 is a polar view of the golf ball of FIG. 1 .
FIG. 5 is an isolated partial cross-sectional view of a dimple to illustrate the definition of the entry radius.
FIG. 6 is an enlarged half cross-sectional view of a typical dimple of a fourth set of dimples of the golf ball of the present invention.
FIG. 7 is an enlarged half cross-sectional view of a dimple of a eleventh set of dimples of the golf ball of the present invention.
FIG. 8 is an enlarged half cross-sectional view of a dimple of a second set of dimples of the golf ball of the present invention.
FIG. 9 is an enlarged half cross-sectional view of a dimple of a first set of dimples of the golf ball of the present invention.
FIG. 10 is an enlarged half cross-sectional view of a typical dimple of a sixth set of dimples of the golf ball of the present invention.
FIG. 11 is a graph of the lift coefficient for a Reynolds number of 70,000 at 2000 rotations per minute (x-axis) versus the drag coefficient for a Reynolds number of 180,000 at 3000 rotations per minute (y-axis).
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1 , a golf ball is generally designated 20 . The golf ball 20 is preferably a two-piece with a solid core and a cover such as disclosed in co-pending U.S. patent application Ser. No. 09/768,846, for a Golf Ball, filed on Jan. 23, 2001, and hereby incorporated by reference. Alternatively, the golf ball 20 is a three-piece golf ball as shown in FIG. 1 A. Such a three-piece golf ball 20 is disclosed in U.S. Pat. No. 6,117,024, which is hereby incorporated by reference. However, those skilled in the pertinent art will recognize that the aerodynamic pattern of the present invention may by utilized on other two-piece or three-piece golf balls, one-piece golf balls, or multiple-layer golf balls without departing from the scope and spirit of the present invention.
A cover 21 or 21 a of the golf ball 20 may be any suitable material. A preferred cover 21 is composed of a thermoplastic material such as an ionomer material or a thermosetting material such as a polyurethane. However, those skilled in the pertinent art will recognize that other cover materials may be utilized without departing from the scope and spirit of the present invention. If the golf ball is a three-piece golf ball 20 , as shown in FIG. 1A , the intermediate layer 21 b is preferably composed of an ionomer material while the cover 21 a is composed of a softer material. The golf ball 20 may have a finish of a basecoat and/or top coat with a logo indicia. A core 23 of the golf ball is preferably composed of a polybutadiene material.
As shown in FIGS. 2-4 , the golf ball 20 has a surface 22 . The golf ball 20 also has an equator 24 dividing the golf ball 20 into a first hemisphere 26 and a second hemisphere 28 . A first pole 30 is located ninety degrees along a longitudinal arc from the equator 24 in the first hemisphere 26 . A second pole 32 is located ninety degrees along a longitudinal arc from the equator 24 in the second hemisphere 28 .
On the surface 22 , in both hemispheres 26 and 28 , are a plurality of dimples partitioned into multiple different sets of dimples. In a preferred embodiment, the number of dimples is 382, and there are eleven different sets of dimples, as partitioned by diameter of the dimple. Sets of dimples also vary by entry radius, entry angle and chord depth. In an alternative embodiment, there are eighteen different sets of dimples by entry radius.
In a preferred embodiment, there is a first plurality of dimples 40 , a second plurality of dimples 42 , a third plurality of dimples 44 , a fourth plurality of dimples 46 (including 46 a - 46 f ), a fifth plurality of dimples 48 , a sixth plurality of dimples 50 (including 50 a ), a seventh plurality of dimples 52 , an eighth plurality of dimples 54 , a ninth plurality of dimples 56 , a tenth plurality of dimples 58 , and an eleventh plurality of dimples 60 .
In the preferred embodiment, each of the first plurality of dimples 40 has the largest diameter dimple, and each of the eleventh plurality of dimples 60 has the smallest diameter dimples. The diameter of a dimple is measured from a surface inflection point 100 across the center of the dimple to an opposite surface inflection point 100 . The surface inflection points 100 are where the land surface 22 ends and where the dimples begin. Each of the second plurality of dimples 42 has a smaller diameter than the diameter of each of the first plurality of dimples 40 . Each of the third plurality of dimples 44 has a smaller diameter than the diameter of each of the second plurality of dimples 42 . Each of the fourth plurality of dimples 46 (including 46 a - 46 f ) has a smaller diameter than the diameter of each of the third plurality of dimples 44 . Each of the fifth plurality of dimples 48 has a diameter that is equal to or smaller than the diameter of each of the fourth plurality of dimples 46 . Each of the sixth plurality of dimples 50 (including 50 a ) has a smaller diameter than the diameter of each of the fifth plurality of dimples 48 . Each of the seventh plurality of dimples 52 has a smaller diameter than the diameter of each of the sixth plurality of dimples 50 . Each of the eighth plurality of dimples 54 has a smaller diameter than the diameter of each of the seventh plurality of dimples 52 . Each of the ninth plurality of dimples 56 has a smaller diameter than the diameter of each of the eighth plurality of dimples 54 . Each of the tenth plurality of dimples 58 has a smaller diameter than the diameter of each of the ninth plurality of dimples 56 . Each of the eleventh plurality of dimples 60 has a smaller diameter than the diameter of each of the tenth plurality of dimples 58 .
In a preferred embodiment, the fourth plurality of dimples 46 (including 46 a - 46 f ) are the most numerous. The second plurality of dimples 42 , the third plurality of dimples 44 , and the fifth plurality of dimples 48 are equally the second most numerous. The eleventh plurality of dimples 60 is the least.
Table One provides a description of the preferred embodiment. Table One includes the dimple diameter (in inches from inflection point to inflection point), chord depth (in inches measured from the inflection point to the bottom of the dimple at the center), entry angle for each dimple, entry radius for each dimple (in inches) and number of dimples.
TABLE ONE
Dimple
# of
Dimple
Chord
Entry
Entry
Reference
Dimples
Diameter
Depth
Angle
Radius
40
10
0.1838
0.0056
15.01
0.0385
42
60
0.1678
0.0054
13.37
0.0351
44
60
0.1668
0.0056
14.09
0.0338
46
20
0.1648
0.0054
14.85
0.0332
46a
10
0.1648
0.0056
15.33
0.0375
46b
10
0.1648
0.0054
14.56
0.0365
46c
20
0.1648
0.0056
14.71
0.0343
46d
20
0.1648
0.0057
14.44
0.0340
46e
10
0.1648
0.0054
14.77
0.0321
46f
10
0.1648
0.0056
14.35
0.0320
48
60
0.159
0.0059
14.85
0.0314
50
10
0.1586
0.0054
15.27
0.0258
50a
10
0.1586
0.0052
14.69
0.0376
52
20
0.156
0.0055
14.73
0.0428
54
20
0.1462
0.0055
13.80
0.0364
56
10
0.1422
0.0054
14.12
0.0293
58
20
0.1224
0.0054
15.14
0.0295
60
2
0.1008
0.0057
20.35
0.0270
The two dimples of the eleventh set of dimples 60 are each disposed on respective poles 30 and 32 . Each of the ninth set of dimples 56 is adjacent one of the eleventh set of dimples 60 . The five dimples of the ninth set of dimples 56 that are disposed within the first hemisphere 26 are each an equal distance from the equator 24 and the first pole 30 . The five dimples of the ninth set of dimples 56 that are disposed within the second hemisphere 28 are each an equal distance from the equator 24 and the second pole 32 . These polar dimples 60 and 56 account for approximately 2% of the surface area of the golf ball 20 .
Unlike the use of the term “entry radius” or “edge radius” in the prior art, the edge radius as defined herein is a value utilized in conjunction with the entry angle to delimit the concave and convex segments of the dimple contour. The first and second derivatives of the two Bézier curves are forced to be equal at this point defined by the edge radius and the entry angle, as shown in FIG. 5A. A more detailed description of the contour of the dimples is set forth in U.S. Pat. No. 6,331,150, filed on Sep. 16, 1999, entitled Golf Ball Dimples With Curvature Continuity, which is hereby incorporated by reference in its entirety.
FIGS. 6-10 illustrate the half cross-sectional views of dimples for some of the different sets of dimples. A half cross-sectional view of a typical dimple of the fourth set of dimples 46 c is shown in FIG. 6 . The radius R d46c of the dimple 46 c is approximately 0.0824 inch, the chord depth CD—CD is approximately 0.0056 inch, the entry angle EA 46c is approximately 14.7068 degrees, and the entry radius ER 46c is approximately 0.0343 inch.
A half cross-sectional view of a dimple of the eleventh set of dimples 60 is shown in FIG. 7 . The dimple radius R d60 of the dimple 60 is approximately 0.0504 inch, the entry angle EA 60 is approximately 20.3487 degrees, and the entry radius ER 60 is approximately 0.027 inch. The entry angle for each of the two dimples 60 of the eleventh set of dimples is the largest entry angle for a dimple in the preferred embodiment.
A half cross-sectional view of a dimple of the second set of dimples 42 is shown in FIG. 8 . The dimple radius R d42 of the dimple 42 is approximately 0.0839 inch, the entry angle EA 42 is approximately 13.3718 degrees, and the entry radius ER 42 is approximately 0.0351 inch. The entry angle for each of the sixty dimples 42 of the second set of dimples is the smallest entry angle for a dimple in the preferred embodiment.
A half cross-sectional view of a dimple of the seventh set of dimples 52 is shown in FIG. 9 . The dimple radius R 52 of the dimple 52 is approximately 0.0780 inch, the entry angle EA 52 is approximately 14.7334 degrees, and the entry radius ER 52 is approximately 0.0428 inch. The entry radius for each of the twenty dimples 52 of the seventh set of dimples is the largest entry radius for a dimple in the preferred embodiment. The ten dimples of the seventh set of dimples 52 that are disposed within the first hemisphere 26 are each an equal distance from the equator 24 and the first pole 30 . The ten dimples of the seventh set of dimples 52 that are disposed within the second hemisphere 28 are each an equal distance from the equator 24 and the second pole 32 .
A half cross-sectional view of a dimple of the sixth set of dimples 50 is shown in FIG. 10 . The dimple radius R d50 of the dimple 50 is approximately 0.0793 inch, the entry angle EA 50 is approximately 15.2711 degrees, and the entry radius ER 50 is approximately 0.0258 inch. The entry radius for each of the ten dimples 50 of the seventh set of dimples is the smallest entry radius for a dimple in the preferred embodiment.
Alternative embodiments of the dimple pattern of the present invention may vary in the number of dimples, diameters, depths, entry angle and/or entry radius. Most common alternatives will not have any dimples at the poles 30 and 32 . Other common alternatives will have the same number of dimples, but with less variation in the diameters.
The force acting on a golf ball in flight is calculated by the following trajectory equation:
F=F L +F D +G (A)
wherein F is the force acting on the golf ball; F L is the lift; F D is the drag; and G is gravity. The lift and the drag in equation A are calculated by the following equations:
F L =0.5 C L Aρν 2 (B)
F D =0.5 C D Aρν 2 (C)
wherein C L is the lift coefficient; C D is the drag coefficient; A is the maximum cross-sectional area of the golf ball; ρ is the density of the air; and ν is the golf ball airspeed.
The drag coefficient, C D , and the lift coefficient, C L , may be calculated using the following equations:
C D=2 F D /Aρν 2 (D)
C L=2 F L /Aρν 2 (E)
The Reynolds number R is a dimensionless parameter that quantifies the ratio of inertial to viscous forces acting on an object moving in a fluid. Turbulent flow for a dimpled golf ball occurs when R is greater than 40000. If R is less than 40000, the flow may be laminar. The turbulent flow of air about a dimpled golf ball in flight allows it to travel farther than a smooth golf ball.
The Reynolds number R is calculated from the following equation:
R=νDρ/μ (F)
wherein ν is the average velocity of the golf ball; D is the diameter of the golf ball (usually 1.68 inches); ρ is the density of air (0.00238 slugs/ft 3 at standard atmospheric conditions); and μ is the absolute viscosity of air (3.74×10 −7 lb*sec/ft 2 at standard atmospheric conditions). A Reynolds number, R, of 180,000 for a golf ball having a USGA approved diameter of 1.68 inches, at standard atmospheric conditions, approximately corresponds to a golf ball hit from the tee at 200 ft/s or 136 mph, which is the point in time during the flight of a golf ball when the golf ball attains its highest speed. A Reynolds number, R, of 70,000 for a golf ball having a USGA approved diameter of 1.68 inches, at standard atmospheric conditions, approximately corresponds to a golf ball at its apex in its flight, 78 ft/s or 53 mph, which is the point in time during the flight of the golf ball when the golf ball travels at its slowest speed. Gravity will increase the speed of a golf ball after its reaches its apex.
FIG. 11 is a graph of the lift coefficient for a Reynolds number of 70,000 at 2000 rotations per minute versus the drag coefficient for a Reynolds number of 180,000 at 3000 rotations per minute for a golf ball 20 with the dimple pattern of the present invention thereon as compared to the Titlelist HP DISTANCE 202, the Titlelist HP ECLIPSE 204, the SRI Maxfli HI-BRD (from Japan) 206, the Wilson CYBERCORE PRO DISTANCE 208, the Titleist PRO V1 210, the Bridgestone TOUR STAGE MC392 (from Japan) 212, the Precept MC LADY 214, the Nike TOUR ACCURACY 216, and the Titlelist DT DISTANCE 218.
The golf balls 20 with the dimple pattern of the present invention were constructed as set forth in co-pending U.S. patent application Ser. No. 09/768,846, as previously referenced. The aerodynamics of the dimple pattern of the present invention provides a greater lift with a reduced drag thereby translating into a golf ball 20 that travels a greater distance than golf balls of similar constructions.
As compared to other golf balls, the golf ball 20 of the present invention is the only one that combines a lower drag coefficient at high speeds, and a greater lift coefficient at low speeds. Specifically, as shown in FIG. 11 , none of the other golf balls have a lift coefficient, C L , greater than 0.19 at a Reynolds number of 70,000, and a drag coefficient C D less than 0.232 at a Reynolds number of 180,000. For example, while the Nike TOUR ACCURACY 216 has a C L greater than 0.19 at a Reynolds number of 70,000, its C D is greater than 0.232 at a Reynolds number of 180,000. Also, while the Titleist DT DISTANCE 218 has a drag coefficient C D less than 0.232 at a Reynolds number of 180,000, its C L is less than 0.19 at a Reynolds number of 70,000. Further, the golf ball 20 of the present invention is the only golf ball that has a lift coefficient, C L , greater than 0.20 at a Reynolds number of 70,000, and a drag coefficient C D less than 0.235 at a Reynolds number of 180,000. Yet further, the golf ball 20 of the present invention is the only golf ball that has a lift coefficient, C L , greater than 0.19 at a Reynolds number of 70,000, and a drag coefficient C D less than 0.229 at a Reynolds number of 180,000. More specifically, the golf ball 20 of the present invention is the only golf ball that has a lift coefficient, C L , greater than 0.21 at a Reynolds number of 70,000, and a drag coefficient C D less than 0.230 at a Reynolds number of 180,000. Even more specifically, the golf ball 20 of the present invention is the only golf ball that has a lift coefficient, C L , greater than 0.22 at a Reynolds number of 70,000, and a drag coefficient C D less than 0.230 at a Reynolds number of 180,000.
In this regard, the Rules of Golf, approved by the United States Golf Association (“USGA”) and The Royal and Ancient Golf Club of Saint Andrews, limits the initial velocity of a golf ball to 250 feet (76.2 m) per second (a two percent maximum tolerance allows for an initial velocity of 255 per second) and the overall distance to 280 yards (256 m) plus a six percent tolerance for a total distance of 296.8 yards (the six percent tolerance may be lowered to four percent). A complete description of the Rules of Golf are available on the USGA web page at www.usga.org. Thus, the initial velocity and overall distance of a golf ball must not exceed these limits in order to conform to the Rules of Golf. Therefore, the golf ball 20 has a dimple pattern that enables the golf ball 20 to meet, yet not exceed, these limits.
From the foregoing it is believed that those skilled in the pertinent art will recognize the meritorious advancement of this invention and will readily understand that while the present invention has been described in association with a preferred embodiment thereof, and other embodiments illustrated in the accompanying drawings, numerous changes, modifications and substitutions of equivalents may be made therein without departing from the spirit and scope of this invention which is intended to be unlimited by the foregoing except as may appear in the following appended claims. Therefore, the embodiments of the invention in which an exclusive property or privilege is claimed are defined in the following appended claims. | A dimple pattern for a golf ball with multiple sets of dimples is disclosed herein. Each of the multiple sets of dimples has a different entry radius. A preferred set of dimples is eighteen different dimples. The dimples may cover as much as eighty-seven percent of the surface of the golf ball. The unique dimple pattern allows a golf ball to have shallow dimples with steeper entry angles. In a preferred embodiment, the golf ball has 382 dimples with eleven different diameters and eighteen different entry radii. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This divisional application claims the benefit under 35 U.S.C. §121 of application Ser. No. 10/982,346, filed on Nov. 5, 2004, which in turn claims the benefit under 35 U.S.C. §119(e) of Provisional Patent Application No. 60/561,745, filed on Apr. 13, 2004, the contents all of which are incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to a device and method for treating wounds. More specifically, the present invention relates to a therapeutic wound contact device.
BACKGROUND OF THE INVENTION
Wound healing is a basic reparative process of the human body. It has been known throughout time that dressing wounds with appropriate materials aids the body's natural regenerative process. Historically, such materials have been made from cotton fibers; e.g. gauze. These dressings are beneficial to the healing process because they insulate damaged tissue from external contaminants and because they remove potentially deleterious wound exudates.
Numerous studies suggest that wound healing depends on the interplay of complex mechanisms involving cell proliferation, migration and adhesion coupled with angiogenesis. Application of traditional gauze or other essentially flat materials are essentially sub-optimal with respect to these mechanisms. Wound healing studies In-vitro carried out in cell culture vehicles that permit cellular function. It is therefore desirable in the practice of wound healing to provide the equivalent of cell culture or a bioreactor system to allow the optimal interplay of cell functions of proliferation, migration and adhesion. Additionally, it is essential to incorporate other bodily functions that encourage the supply of fibronectins, plasma proteins, oxygen, platelets, growth factors, immunochemicals and so forth.
As science and medicine have advanced, the technology incorporated into wound healing devices has improved substantially. Highly absorbent wound dressings capable of absorbing many times their weight in liquids are available. Systems that temporarily seal wounds and utilize suction to remove exudates have found widespread utilization. Dressings incorporating anti-microbial agents and biologic healing agents are common. Devices that provide a moist wound environment for improved healing have been found to be useful.
In spite of the technological gains in wound healing devices and dressings, millions of people still suffer from the chronic wounds. Such chronic wounds are debilitating and can last for years, greatly diminishing the individual's quality of life. Often such wounds result in the loss of a limb. Individuals may even die from complications such as infection.
As such, there is dire need for more effective wound healing devices and methods.
SUMMARY OF INVENTION
To provide for improved wound healing, the present invention is a wound contact material, a method for making the wound contact material, and a method of treatment employing the wound contact material.
According to an exemplary embodiment of the present invention, a therapeutic device for promoting the healing of a wound in a mammal is provided. The device comprises a permeable substrate or structure having a plurality of depressions formed in a surface thereof, wherein said surface having said depressions is disposed in surface contact with the wound.
According to a further exemplary embodiment of the present invention, a therapeutic device for promoting the healing of a wound in a mammal is provided. The device comprises a permeable structure having a plurality of wound surface contact elements disposed between end portions of the structure, and a plurality of voids defined by the contact elements.
According to an additional exemplary embodiment of the present invention, a therapeutic device for promoting the healing of a wound in a mammal, the device comprising a permeable structure comprising a plurality of fibers coupled to one another having a plurality of wound surface contact elements disposed between end portions of the structure and a plurality of voids defined by the contact elements is provided.
According to a yet further exemplary embodiment of the present invention, a therapeutic device for promoting the healing of a wound in a mammal, the device comprising a polyester felt having a plurality of wound surface contact elements disposed between end portions of the structure and a plurality of voids defined by the contact elements is provided.
According to an additional exemplary embodiment of the present invention, a method of manufacturing a therapeutic device for promoting the healing of a wound in a mammal comprises the steps of providing a molten substrate material providing a mold defining a plurality of depressions and a plurality of contact elements and applying the molten substrate material to the mold.
According to an even further exemplary embodiment of the present invention, a method of manufacturing a therapeutic device for promoting the healing of a wound in a mammal comprises the steps of providing a permeable structure and forming a plurality of depressions into a surface of the permeable structure.
According to another exemplary embodiment of the present invention, a method of treating a wound comprises the steps of providing a permeable structure comprising i) a plurality of wound surface contact elements disposed between end portions of the structure, and ii) a plurality of voids defined by the contact elements, and applying the permeable structure to at least one surface of the wound and applying a force to the structure to maintain the structure in intimate contact with the wound surface.
These and other aspects and objects will become apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is best understood from the following detailed description when read in connection with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not to scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Included in the drawings are the following Figures:
FIG. 1 is a perspective view of a channeled wound contact dressing according to a first exemplary embodiment of the present invention;
FIG. 2A is a perspective view of a channeled wound contact composite according to a second exemplary embodiment of the present invention;
FIG. 2B is a cross section of the channeled wound contact composite according to the second exemplary embodiment of FIG. 2A ;
FIG. 3A is a perspective view of a dimpled wound dressing according to a third exemplary embodiment of the present invention;
FIG. 3B is a top view of the dimpled wound dressing illustrated in FIG. 3A ;
FIG. 3C is a bottom view of the dimpled wound dressing illustrated in FIG. 3A ;
FIG. 3D is a cross sectional view of the dimpled wound dressing illustrated in FIG. 3A ;
FIGS. 4A , 4 B and 4 C are illustrations of the dimpled wound dressing of FIG. 3A in use;
FIG. 5A is a perspective view of an irregular wound contact dressing according to a fourth exemplary embodiment of the present invention;
FIG. 5B is a cross sectional view of the irregular wound contact dressing illustrated in FIG. 5A ; and
FIG. 6 is a cross sectional view of an exemplary wound contact device in use on a wound.
DETAILED DESCRIPTION OF THE INVENTION
A wound dressing with a discontinuous contact layer surface has the advantages of promoting tissue growth with wound surface contact elements and permitting tissue growth by providing void volume for the subsequent tissue growth within the discontinuities. Desirably, the structure of the contact material is sufficiently physically rugged to resist flattening when forces required to press the material against the wound surface are applied to the material.
It is desirable for the material to retain its structure when exposed to aqueous or other bodily fluids. Many traditional dressing materials soften as then moisten so that their geometry changes. The contact layer is permeable, permitting the underlying wound to breathe and allowing for fluids to be drawn from the wound. The contact layer should not be too absorbent as this might result in a loss of structure. The layer is comprised of base materials that are resistant to change in the presence of moisture and aqueous liquids.
In the current embodiment, the extent of the voids remaining above the wound surface is preferably at least 0.1 mm when the structure is pressed against the surface of the wound. The width of the voids, as defined by contact elements adjacent the voids, is preferably greater than 0.1 mm. A more preferred width is between about 0.5 to 10 mm and a more preferred height is between about 0.2 to 5 mm.
Wound healing is recognized as a complex process. When a wound contact material as described is forced against a wound surface, a number of biological processes are believed to occur. Mechanical stress is applied to the underlying tissue. The discontinuities in the contact surface impose a force resulting in a catenary shape on the tissue. These mechanical forces encourage cellular activities as well as angiogenesis, and the discontinuities begin to fill with granular tissue. Excess fluid is conveyed away from the wound and tissue develops in a manner and pattern whereby disruption of the newly developed tissue is minimized upon removal of the contact surface.
A fibrous substrate or structure has all the flexibilities provided by the textile arts. Fibrous textiles can be formed into a structure for the invention by a number of the methods known in the art. Among these methods are knitting, weaving, embroidering, braiding, felting, spunbonding, meltblowing, and meltspinning. Each of these methods can be further adapted to produce a material whose structure matches that of the present invention. The desired structure can be imparted during production of the structure by, for example, applying molten material directly to a mold as in meltblowing. Alternatively, the structure can be formed by working a formed structure after production by, for example, heat stamping or vacuum forming. Further, fibers can be mixed with an adhesive and sprayed onto a textured surface.
The versatility of fibrous textiles also extends to their easy adaptation to composite applications. Individual fiber materials may be varied to optimize a physical parameter such as rigidity or flexibility. Individual fiber materials can also be selected for their known ability to assist in wound healing. Examples of such fiber materials are calcium alginate, and collagen. Alternatively, fibers may be treated with known wound healing agents such as hyaluronic acid and antimicrobial silver. The ratio of the fiber materials can be varied to suit the requirements of the wound. According to one desirable aspect of the invention, different fibers with various wound healing properties may be added as desired.
Other fibrous structures that are anticipated as beneficial additions include:
1. Fluid absorbing fibers
2. Non-adsorbent fibers
3. Bio-absorbable fibers
4. Wicking fibers to wick fluid away from the surface of the wound
5. Fibers with known healing effects, such as calcium alginate
6. Bio-erodable fibers for the controlled release of curative agent
7. Conductive fibers for the delivery of an electric charge or current
8. Adherent fibers for the selective removal of undesirable tissues, substances or microorganisms
9. Non-adherent fibers for the protection of delicate tissue
An exemplary embodiment of the present invention is illustrated in FIG. 1 . As shown in FIG. 1 , channeled wound dressing 100 is comprised of a generally conformable polyester felt material 102 . An alternative polyester textile such as knit, weave, or braid may also be suitable for most applications. Polyolefins, such as polyethylene or polypropylene, and polyamides, such as nylon, with similar physical properties are also contemplated. Creep resistance, as exhibited by polyester, is particularly desirable. Void channels 104 are cut into felt material 102 to provide a discontinuity that promotes the upward growth of new tissue. In use, the channeled wound dressing 100 is pressed against a wound in intimate contact with injured tissue. A force of 0.1 psi or more is desirably applied to the contact layer to press the contact elements against the surface of the wound. Wound contact elements 106 are thus in intimate contact with injured tissue.
FIGS. 2A and 2B illustrate a wound dressing composite 200 comprised of channeled dressing 100 and a vapor permeable adhesive backed sheet 202 . Adhesive backed vapor permeable sheets, in general, are known in the art and are believed to contribute to wound healing by maintaining a moisture level that is optimal for some wounds. In use, dressing composite 200 is placed onto the surface of the wound with its channeled dressing 100 portion in contact with the wound. Adhesive sheet 202 covers channeled dressing 100 and adheres to skin adjacent the wound. Composite 200 offers the advantages of channeled dressing 100 . Additionally, adhesive sheet 202 secures composite 200 and protects the wound from bacteria, etc. while allowing for the transmission of moisture vapor.
Another desirable embodiment of the present invention is illustrated in FIGS. 3A , 3 B and 3 C and 3 D. The substrate or structure for dimpled wound dressing 300 can be constructed from similar materials and production methods employed for channeled dressing 100 . FIG. 3A depicts a perspective view of dimpled dressing 300 with contact surface 320 on top. FIG. 3D shows a cross section of the dimpled dressing 300 which best illustrates the plurality of contact elements 322 and dimple voids 330 . Preferably, the total dimple void area comprises at least about 25% of the total dressing area. More preferably, the total dimple void area comprises at least about 50% of the total dressing area. Dimple voids 330 are partially defined by sidewalls 332 . Sidewalls 332 are partially responsible for providing rigidity necessary to resist compaction of dimple dressing 300 . Contact elements are preferably constructed to provide an arcuate contact surface. In a preferred embodiment, the radius of contact is between about 0.1 mm to 1 mm.
Dimple voids 330 can be formed in a variety of regular or irregular shapes. Preferably, dimple voids are constructed so that they are not “undercut” such that each aperture circumference is smaller than the corresponding inner void circumference. An “undercut” or reticulated void structure can cause tissue disruption when the dressing 300 is removed because any tissue that has grown into the void may be torn away when the material is removed from the wound. Additionally, undercut or reticulated void structures are more likely to result in shedding of the dressing material into the newly developing wound tissue.
In one preferred embodiment, a base material for dressing 300 is Masterflo RTM manufactured by BBA group of Wakefield, Mass. In this exemplary embodiment, the base material has a thickness of about 1.0 mm. Dimple voids 330 are heat stamped into the base material having a depth of about 0.75 mm and a diameter of about 2 mm.
Because the contact layer is generally replaced every few days it is important to account for the possibility of alignment of newly formed tissue with the voids of a new contact layer. Thus, according to exemplary embodiments of the present invention 1) dimple voids 300 can be arranged randomly so that they don't line up with the new tissue growth after each dressing change, 2) different contact layers with different diameter dimples may be provided, or 3) a different spacing of the dimples can be used every time the material is changed.
FIG. 3B and 3C illustrate the corresponding top and bottom views, respectively, of dimpled dressing 300 . One variation of this embodiment is also contemplated having dimple voids 330 and/or contact elements 322 disposed on both the top and bottom of dimpled dressing 300 . A second variation on dimpled wound dressing 300 is also contemplated wherein some or all of the dimple voids 330 are replaced with holes traversing the structure's entire thickness such that the top and bottom views of the variation would appear similar to FIG. 3B .
In one exemplary embodiment, dimple voids 330 can be partially filled with therapeutic substances. For example, antiseptic substances might be placed in voids 330 for treating infected wounds. Further, biologic healing agents could be delivered in the voids to improve the rate of new tissue formation. In yet another exemplary embodiment, the layer of dressing 300 could have a different function on each side. For example, one side of dressing 300 could be optimized for the growth of new tissue, while the other side could be optimized for the delivery of anti-microbial agents, for example.
Use of dimpled dressing 300 is illustrated by FIGS. 4A , 4 B and 4 C. FIG. 4A shows a wound surface 400 . Note that wound surface 400 may represent the majority of a shallow surface wound or a small interior portion of a deep tissue wound. FIG. 4B shows application of dimpled dressing 300 to wound surface 400 and corresponding tissue growth 410 within dimple voids 330 . Finally, removal of dimpled dressing 300 leaving tissue growth 410 is illustrated in FIG. 4C . As will be addressed in detail below, it is desirable to provide an external force for keeping dressing 300 pressed against the surface of the wound.
FIGS. 5A and 5B illustrate another embodiment of the present invention; a rough irregular dressing 500 . From a perspective view, FIG. 5A depicts how irregular dressing 500 has irregular voids 510 and irregular contact elements 520 acting as “hook-like” members that are able to contact and stick to necrotic tissue when the substrate is placed in the wound. When the substrate is removed from the wound, necrotic tissue is stuck to hook like protrusions 520 and is thus removed from the wound. Removal of the substrate debrides the wound. Removal of necrotic tissue is an important part of healing wounds. The substrate of dressing 500 may be made from polyester felt or batting. In one exemplary embodiment, the felt is singed with hot air so that a percentage of the fibers melt to form a textured surface with a number of hook like elements 520 . Another suitable configuration can be the hook material such as that used with hook and loop fabric.
After adequate removal of the necrotic tissue, the wound may still be considered infected and can be treated with the substrate including antimicrobial silver, for example, which is useful in killing bacteria, while the substrate and method of use facilitate the growth of new tissue.
The phase of wound healing where new tissue is forming is generally referred to as the proliferative phase. Once the wound is adequately healed in the proliferative phase and the bacterial load is adequately reduced, a substrate without antimicrobial silver and optionally with the addition of growth enhancing materials is used to facilitate the continued proliferation of new cells and tissue.
FIG. 5B shows the random cross section of irregular dressing 500 . The roughened surface of irregular dressing 500 can be formed by passing a suitable substrate under convective heat at or about the melting point of the substrate's component material. For example, polyester materials typically melt in a range from about 250 degrees Celsius to about 290 degrees Celsius. A polyester felt material passed briefly under a convective heat source operating in this range will experience surface melting and subsequent fusing of the polyester strands at its surface. The degree of surface melting can be controlled with temperature and exposure time to yield a surface of desired roughness exhibiting irregular voids 510 and irregular contact elements. Although irregular dressing 500 is illustrated as having only one roughened surface the invention is not so limited in that both upper and lower surfaces may be similarly roughened. Such a dressing would be useful in the treatment of an undermined wound.
As described above, treatment with the present wound dressing invention comprises forcing the inventive dressing into intimate contact with the wound surface. Generally the force should be at least 0.1 psi. Various methods and systems for maintaining this intimate contact are contemplated. These methods and systems may include: applying an adhesive film over the inventive dressing and adjacent the wound surface; wrapping a bandage over the dressing and around the injured area; and securing a balloon or another inflatable bladder to the structure and inflating the bladder with air or a liquid. In one exemplary embodiment, the application of pressure to the bladder is provided intermittently. A conformable seal may be placed over the wound and contact structure, a rigid seal is then secured over the wound, contact structure imparting a force on the contact structure. A pressure is then applied between the rigid seal and the flexible seal forcing the contact structure against the wound surface. The intimate contact may be augmented by sealing the wound area with a conformable cover and applying suction. When suction is used, dimpled wound dressing 300 is particularly well-adapted for this application. In general the range of suction levels is between 0.25 psi and 5 psi. The suction use can be further improved by applying a wound packaging material to the back of the dressing. One such suitable wound packaging material is described in U.S. Provisional Patent Application No. 60/554,158, filed on Mar. 18, 2004.
FIG. 6 illustrates therapeutic device 600 in use in wound W. As shown in FIG. 6 , therapeutic device 600 with depressions 604 , such as dimple void for example, is placed in wound W with depressions 604 placed adjacent wound surface 700 . Wound W and therapeutic device 600 are desirably covered with wound cover 606 , such as an adhesive back polyurethane film for example. In one exemplary embodiment, suction from a suction source (not shown) may be applied to wound W via suction tube 608 and coupling 610 . As healing progresses, tissue 702 in the wound bed grows into depressions 604 .
The depressions 604 remain intact even when the device is placed in a wound and suction is applied. Additionally, where the material of the device is comprised of generally non-absorbent fibers, the material does not get soggy when in a wet wound. This allows the wound fluids to be pulled out of the wound by suction, for example, and additionally ensures that depressions 604 remain. It is critical that the depressions remain, so that voids exist where new tissue can grow filling the wound cavity.
While the above described configuration uses depressions having a dimpled shape, other 3 dimensional structures can be fabricated such that there is a void for tissue to grow in to. One such non-limiting alternative configuration would be a woven waffle pattern.
Case Study 1
Patient A is a 70 year old male with a Stage IV decubitus ulcer on the right hip with significant undermining. The contact structure of the present invention was applied to the wound and an adhesive film was placed over the wound and the contact structure. A suction of 1.1 psi was applied beneath the adhesive film to impart a force upon the contact structure. The suction was maintained generally continuously. The contact material was replaced every two to four days. After use of the device for 30 days the undermined portion of the wound had virtually healed and the area of the wound opening had decreased from 66 square cm to 45 square cm. A split thickness skin graft was applied to the wound.
Case Study 2
Patient B is a 50 year old male with a fracture of the right ankle with exposed bone. A plate was used to reduce the fracture and a rectus abdominus free flap was performed to cover the exposed bone and hardware. The flap only partially survived resulting in an open wound with exposed bone and hardware. The contact structure of the present invention was applied to the wound and an adhesive film was placed over the wound and the contact structure. A force was applied to the contact structure by the application of an ace bandage wrapped around the ankle or by the application of suction. The suction force was generally applied for about half of the day and the force of the bandage wrap was maintained for the remainder of the day. For a number of days, the bandage wrap was solely used to impart the force. When the force was imparted by suction a suction of between 1 and 2 psi was used. In less than 2 weeks new tissue had grown over the exposed hardware. In a period of 7 weeks the wound area was reduced from 50 square cm to 28 square cm.
While preferred embodiments of the invention have been shown and described herein, it will be understood that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will occur to those skilled in the art without departing from the spirit of the invention. Accordingly, it is intended that the appended claims cover all such variations as fall within the spirit and scope of the invention. | A therapeutic device for promoting the healing of a wound in a mammal is disclosed. An exemplary device comprises a permeable structure having a plurality of depressions formed in a surface thereof. In use, the surface having the depressions is disposed adjacent a surface of the wound. A method of treating a wound comprises the steps of providing a permeable structure comprising a plurality of randomly disposed fibers and having i) a plurality of wound surface contact elements disposed between end portions of the structure, and ii) a plurality of voids defined by the contact elements; and applying the permeable structure to at least one surface of the wound. | 8 |
[0001] This application is a continuation of U.S. patent application Ser. No. 14/291,455, filed May 30, 2014, new U.S. Pat. No. 9,170,061, which is a continuation of U.S. patent application Ser. No. 12/929,928, filed Feb. 24, 2011, now U.S. Pat. No. 8,752,473, which is a continuation of U.S. patent application Ser. No. 12/220,725, filed Jul. 28, 2008, the disclosure of each of which is incorporated herein by reference, and hereby claims priority thereof to which it is entitled.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This present invention generally relates to self loading firearms, specifically to gas blocks for self loading firearms which facilitate user adjustment of the gas flow from the barrel into the operating system.
[0004] 2. Description of the Related Art
[0005] The need to regulate the gas flow between the barrel and operating system of a firearm has been a concern since the introduction of autoloading firearms. Gas is generated during the combustion of gun powder present in the cartridges used in modern firearms. This gas expands violently to push the bullet out of the firearm's barrel. These expanding gases are utilized as a means to operate the action of the host firearm. In modern firearms the preferred method of facilitating the function of an autoloading weapon is as follows. A hole is placed thru the barrel, generally on the top. Location of this hole or gas port varies between operating systems. Generally a gas port size is chosen to allow a broad range of ammunition to be utilized while guaranteeing the reliable function of the host firearm.
[0006] Unfortunately due to varying lengths of barrels, ammunition variance, and other factors it is very difficult to choose a gas port size which universally works under all conditions. A popular way of dealing with these problems is to incorporate an adjustable gas block into the operating system.
[0007] An adjustable gas block allows for the flow of gas between the gas port in the barrel and the operating system of the firearm to be increased or decreased based on mitigating factors present at the time of use. These systems typically work by utilizing an oversized gas port with means to adjust the flow of gas into the operating system and by venting the unneeded gases from the barrel into the atmosphere thus generating flash and sound. Further, adjustment of the gas system typically requires a special tool and offers no way for the user to index the system and make adjustments due to mitigating circumstances quickly. Designs such as these are well known in the prior art and can be found on the Belgium FAL, Soviet SVD and the Yugoslavian M76 rifle.
[0008] Recent firearm designs such as the FN SCAR rifles have incorporated adjustable gas blocks to be used in conjunction with noise suppressors. Noise suppressors provide a means to redirect, cool and slow the expanding gases generated from the discharge of a firearm so that the resulting flash and sound generated by the firearm is minimized or eliminated. As a result, back pressure is generated forcing more gas into the firearm's operating system. This extra gas, or back pressure increases the firing rate of a weapon during its full auto function, fouls the weapon leading to premature malfunction and to a variety of feeding and extraction problems.
[0009] Modern rifle designs such as the FN SCAR rifles incorporate adjustable gas blocks which have selectable pre-set positions. Typically two or three positions of adjustment are afforded the user. A reduced gas flow setting on an adjustable gas block is generally present due to military and government agency requirements. Reducing the standard gas flow is desirable when a silencer is to be used. Silencers increase back pressure and the cyclic rate of the host firearm. By reducing the amount of gas directed to the operating system under normal circumstances, the silencer, with the increased pressure it generates, should not affect the weapon's operation adversely. While designs with an adjustable gas block mitigate the potential problems associated with the increase of back pressure and fouling a noise suppressor generate, gases are still vented out of the gas block thus generating flash and sound. Generating flash and sound from the gas block is counterproductive to the function of the silencer which is attempting to reduce the flash and sound from the muzzle of the host firearm.
[0010] The present invention offers several advantages over the prior art. Four positions of adjustment are provided for. Position one offers a “standard” flow of gas. This position is optimized for the firearm's barrel length and caliber. Position two reduces the flow of gas into the indirect gas operating system so that with the addition of a silencer the indirect gas operating system is still receiving an equivalent amount of gas as was being provided by position one when no silencer was being utilized. Position three blocks the flow of gas between the barrel gas port and the indirect operating system. This position optimizes the sound reduction capability of an attached noise suppressor. Position four increases the amount of gas being communicated to the operating system so that the firearm may operate properly while dirty or when underpowered ammunition is being utilized. Each of the aforementioned positions of adjustment are indexed with a spring and ball detent, and are pre-set at the factory. No tool is required to rotate the adjustment cylinder into one of the four positions. There is no vent in the gas block which allows for excess gas or un-burnt powder to exit.
SUMMARY OF THE INVENTION
[0011] Accordingly several objects and advantages of the present invention are
[0012] (a) To provide the user an indexing means to adjust the flow of gas into the operating system of a firearm.
[0013] (b) To provide a device which restricts the flow of gas into the operating system without venting excess gas from the gas block.
[0014] (c) To provide an adjustment mechanism which does not require the use of special tools.
[0015] (d) To provide an adjustable gas block that may be utilized with an indirect gas system.
[0016] (e) To provide an adjustable gas block with a means to provide gas that is in excess of what is required to help the weapon function in adverse conditions or with underpowered ammunition.
[0017] In accordance with one embodiment of the present invention, a firearm is provided comprising a receiver, a barrel, an adjustable gas block for an indirect gas operated firearm and an indirect gas system. The adjustable gas block is fixedly secured to the barrel and aligned with the gas port hole located thereon. A rotating cylinder provides an indexing, adjustment means for the gas block. By rotating the provided cylinder the flow of gas between the barrel and the indirect gas system is either increased or decreased. Four positions of adjustment are afforded the user: A standard gas flow, suppressed gas flow, no gas flow, and an adverse conditions gas flow setting. For adverse conditions the gas flow is increased over what the host weapon would typically require to compensate for a dirty operating system.
[0018] Still further objects and advantages will become apparent from a consideration of the ensuing description and drawings.
DESCRIPTION OF THE DRAWINGS
[0019] The novel features believed to be characteristic of the present invention, together with further advantages thereof, will be better understood from the following description considered in connection with the accompanying drawings in which a preferred embodiment of the present invention is illustrated by way of example. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended to define the limits of the invention.
[0020] FIG. 1 is a side perspective view of an adjustable gas block for an indirect gas operated firearm in accordance with the present invention;
[0021] FIG. 2 is an exploded view of the gas block shown in FIG. 1 ;
[0022] FIG. 3 is a partial cutaway view of the nozzle assembly and adjustment knob which are parts of the gas block shown in FIGS. 1 and 2 ;
[0023] FIG. 4 is a side cutaway view of the adjustable gas block for an indirect gas operated firearm shown in FIG. 1 ;
[0024] FIG. 5 is a side perspective view of the adjustable gas block for an indirect gas operated firearm shown with the firearm receiver and barrel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] The adjustable gas block, generally designated by reference numeral 1 , for an indirect gas operated firearm is designed to provide four positions of adjustment, each of which affects the flow of gas from the barrel gas port into the operating system of the host firearm. The herein disclosed device is designed for an indirect gas operating system, but it should be noted that this device is not limited to such operating systems and in fact could be utilized with a gas impingement operating system such as is found on the M16 family of firearms.
[0026] As shown in FIG. 1 , which illustrates the preferred embodiment of the present invention, the adjustable gas block 1 for an indirect gas operated firearm is a replacement for a standard gas block, well known in the prior art, for an autoloading firearm. The adjustable gas block 1 for an indirect gas operated firearm is comprised of a housing 10 , an adjustment knob 20 , a nozzle assembly 30 , also referred to as a gas nozzle, and a front sight 60 .
[0027] In FIG. 2 , there is illustrated an exploded view of the adjustable gas block 1 for an indirect gas operated firearm and all of its components. The housing 10 has a gas nozzle receiving channel 13 which is located above the barrel receiving channel 12 . Near the distal end of the housing 10 is located a groove 14 for the adjustment knob 20 . The groove is transverse to the longitudinal axis of the barrel and is bounded on one side by a front surface of the gas block adjacent the gas nozzle receiving channel and on the other side by a solid rearwardly facing surface of the gas block. Located along the bottom of the housing 10 are two thru pin placements 15 which receive two taper pins that are utilized to secure the unit as a whole about the barrel 101 (see FIG. 5 ). A front sight 60 is provided for on the distal end of the housing 10 along with a bayonet lug 70 .
[0028] The preferred embodiment gas nozzle 30 consists of a front end 33 , a back end and a middle portion. The front end 33 of the gas nozzle 30 , which does not have an opening, protrudes from the front of the gas nozzle receiving channel 13 and into the groove 14 . The back end protrudes from the rear of the housing and has an opening 31 into the gas nozzle which is in communication with gas ports 35 , 36 and 37 (shown in FIG. 3 ). The middle area consists of the structural features between the front end 33 and the opening 31 at the back end. Structural features found on the middle area are the connecting member 39 , the radial flange 40 , an opening 34 for a pin 21 and the diameter-reducing transition portion 41 .
[0029] The adjustment knob 20 has a front face, a rear face, and a generally annular body surrounding a central opening or bore 29 , said rotatable knob being received within said transverse groove with the knob rear face adjacent the front side of the gas nozzle receiving channel cylindrical bore and the knob front face adjacent a rearwardly facing surface of the housing. The adjustment knob 20 includes a series of slots 25 - 28 located about the periphery of the rear face of the adjustment knob 20 . The central opening or bore 29 of the adjustment knob 20 receives a front portion of the gas nozzle 30 . An opening 24 is present on the exterior of the adjustment knob 20 and is designed to receive a pin 21 .
[0030] In FIG. 3 there is illustrated a view of the adjustment knob 20 assembled with the gas nozzle 30 . The gas nozzle 30 is partially cut away to reveal the three gas ports 35 , 36 and 37 . Gas port 36 is at a 90 degree angle with respect to each of gas ports 35 and 37 , and gas ports 35 and 37 are positioned 180 degrees from one another. Gas port one 35 , gas port two 36 , and gas port three 37 are each unique in size. These gas ports 35 - 37 all intersect in the center of the gas nozzle 30 . Each of the gas ports is in communication with the opening 31 located at the front of the gas nozzle 30 and the bore 38 therethrough.
[0031] FIG. 4 illustrates a cutaway view of the adjustable gas block 1 . The housing 10 houses a spring 22 and ball detent 23 in a void 19 . A gas port 44 thru the housing 10 is in communication with both the gas nozzle 30 and the gas port of the barrel 101 . The gas nozzle 30 has a bore 38 which is in communication with an opening 31 of the gas nozzle 30 and the gas port 44 located in the housing 10 . The adjustment knob 20 is secured about the gas nozzle 30 by means of a pin 21 which is inserted through an opening 24 in the adjustment knob 20 and then through the opening 34 located on the gas nozzle 30 .
[0032] FIG. 5 illustrates a perspective view of a firearm receiver 90 connected to a barrel 101 utilizing a removable rail 91 (also referred to as a handguard) which incorporates an indirect gas operating system 100 and the adjustable gas block 1 .
[0033] As used herein, the word “front” or “forward” corresponds to the direction right of the adjustable gas block 1 as shown in FIGS. 1 thru 5 ; “rear” or “rearward” or “back” corresponds to the direction opposite the front direction of the adjustable gas block 1 , i.e., to the left as shown in FIGS. 1 thru 5 ; “longitudinal” means the direction along or parallel to the longitudinal axis of the adjustable gas block 1 ; and “transverse” means a direction perpendicular to the longitudinal direction.
[0034] The adjustable gas block 1 is assembled as follows. The spring 22 and ball detent 23 are inserted in the void 19 located within the housing 10 . A placement area or groove 14 formed in the housing 10 receives the adjustment knob 20 therein and retains the spring 22 and ball detent 23 in place. The spring 22 provides a force to the ball detent 23 which interacts with the indexing notches 25 , 26 , 27 and 28 located about the adjustment knob 20 and provides an indexing means for the orientation of the gas nozzle 30 . The interaction between the ball detent 23 and the indexing notches 25 - 28 prevents the unintentional rotation of the adjustment knob 20 during routine use of the host firearm. The gas nozzle 30 is inserted through the gas nozzle receiving channel 13 and through the central opening 29 in the adjustment knob 20 . The gas nozzle 30 is initially oriented such that the openings 34 align with the openings 24 on the adjustment knob 20 where a pin 21 , preferably a roll pin type, is pushed through. This retains the adjustment knob 20 and the gas nozzle 30 in place. A portion of the barrel 101 is received by the barrel receiving channel 12 located on the housing 10 . Once the through pin placements 15 are aligned with the existing openings on the barrel 101 , two pins are then used to secure the adjustable gas block 1 to the barrel 101 and thus prevent the rotation and longitudinal movement of the housing 10 .
[0035] When a firearm is discharged, expanding gases travel down the barrel 101 with a small amount of this gas being vented through a gas port located on the top of the barrel 101 . This gas then travels through the gas port 44 located in the housing 10 into the bore 38 and out of the opening 31 of the gas nozzle 30 into the operating system 100 . A firearm equipped with the adjustable gas block 1 disclosed herein, through the use of the adjustment knob 20 , can rotate the gas nozzle 30 into a position which blocks gas from entering the bore 38 . This occurs when the adjustment knob 20 is rotated such that indexing notch 28 is in contact with the ball detent 23 thereby placing a non-ported portion of the gas nozzle 30 over the gas port 44 of the housing 10 . If the adjustment knob 20 and thereby the gas nozzle 30 are rotated in such a manner as to allow the flow of gas into the operating system 100 , one of the three gas ports 35 - 37 will be in direct communication with the gas port 44 located in the housing 10 .
[0036] Once the adjustable gas block 1 is fully assembled onto a rifle as shown in FIG. 5 , the adjustment knob 20 is received within the transverse groove 14 with the rear face of the knob adjacent the front end of the gas nozzle receiving channel cylindrical bore and the knob front face adjacent a rearwardly facing surface of the housing. When coupled to the gas nozzle 30 , the adjustment knob 20 may be used to regulate the flow of gas between the barrel 101 and the operating system 100 . In the preferred embodiment of the herein disclosed design, the adjustment knob 20 has four indexed positions 25 , 26 , 27 and 28 . Also provided are the three gas ports 35 , 36 and 37 which regulate the flow of gas into the bore 38 , through the gas nozzle 30 , and into the operating system 100 . The adjustment knob 20 and the gas nozzle 30 , when attached by the provided pin 21 , form an assembly where the rotation of the adjustment knob 20 rotates the gas nozzle 30 within the housing 10 . When the indexing notches 25 - 27 are in contact with the ball detent 23 , a specific gas port 35 - 37 of the gas nozzle 30 is in communication with the gas port 44 of the housing 10 . When indexing notch 28 is in contact with the ball detent 23 , the gas nozzle 30 is rotated to a position where there is no gas port to communicate with the gas port 44 of the housing 10 . Gas port three provides a flow of gas which is optimized for the proper functioning of the rifle based on its barrel length, caliber and operation under optimal conditions. Gas port three 37 is also referred to as the “standard” setting. Gas port one 35 has an opening which is larger than the opening of gas port three 37 , thereby providing an increased quantity of gas to the operating system 100 of the host firearm. Gas port one 35 is used when the host weapon is dirty or the firearm's rate of fire needs be increased. Gas port one 35 is also referred to as the “adverse condition setting”. The third gas port 36 , generally referred to as gas port two, has an opening which is smaller in diameter than the opening of the “standard” gas port 37 . Gas port two 36 is for use when a silencer is affixed to the muzzle of the barrel 101 . This gas port 36 is also referred to as the “silencer setting”.
[0037] In sum, an adjustable gas block is provided for an autoloading firearm which utilizes an indirect gas operating system. Four pre-set positions are afforded the user of this device. Gas settings which are optimized for suppressor use, harsh environments, dirty weapons or when firing under ideal circumstances are also provided for. A position which prevents the flow of gas into the operating system is provided for. This system does not vent excess gas from the gas block into the atmosphere around it. Instead excess gas is trapped within the barrel and vented from the muzzle where a flash hider or silencer might allow the gasses to expand and cool.
[0038] Another embodiment of the adjustable gas block could eliminate the increased gas flow setting or the setting which blocks the flow of gas.
[0039] Still another embodiment of the adjustable gas block could be adapted to work with a direct gas impingement system such as found on M16 style rifles. The nozzle assembled could be modified to receive the gas tube found on such system and thereby regulate the flow of gas from the barrel into the operating system.
[0040] While the above drawings and description contain much specificity, these should not be construed as limitations on the scope of the invention, but rather as an exemplification of one preferred embodiment thereof.
[0041] Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents. | A firearm including a barrel, receiver, indirect gas system and an adjustable gas block designed to interface with the indirect gas system is provided. Four indexable positions of adjustment are provided for on the adjustable gas block. Positions of adjustment are selected based on the use of a silencer, use of under-powered ammunition, the presence of un-burnt powder and debris in the host firearms operating system, or if the weapon is being fired under “ideal” circumstances. The provided gas block is designed to function with an indirect gas operating system. Excess gas from the operating system is not vented from the gas block thereby generating excess flash and sound. No tool is required to manipulate the adjustment mechanism of the gas. | 5 |
This application is a 371 of PCT/US97/19211 filed Oct. 24, 1997 which claims benefit of Prov. No. 60/029,109 filed Oct. 24, 1996.
BACKGROUND OF THE INVENTION
Didemins were isolated from the Caribbean tunicate Trididemnum solidum 1 . These cyclic depsipeptides possess a variety of biological activities including in vitro and in vivo antiviral, antitumor, and immunosuppressive activities. 2-5 They are potent inhibitors of L1210 leukemia cells in vitro, and are also active in vivo against P388 leukemia and B16 melanoma. 3 Didemnin B, a more active compound of this class, is approximately twenty times more cytotoxic than didemnin A in vitro and has undergone phase II clinical trials for antitumor activity. 3 Both didemnins A and B exhibit antiviral activity against DNA and RNA viruses, with didemnin B being more active. 4 The structures of didemnins A and B have been established as 1 and 2, respectively. 6
Structure activity relationship studies have been somewhat limited due to the restricted number of available modifications of the extracted natural compounds. Although the bioactivity of didemnin B has been attributed to its side chain, 1b few other structural features have been examined. An X-ray crystal structure of didemnin B by Hossain, et al., 7 shows that the β-turn side chain, the isostatine hydroxyl group, and the tyrosine residue extend outward from the rest of the molecule, leading to speculation about their importance for liological activity. Structural changes in those areas have shown these features to be essential for activity. 8
Although many studies have shed light on the pharmacology and chemistry of didemnins, little is known about their mechanism of action. However, recent biochemical studies of possible binding sites have provided promising results. Studies performed by Shen, et al., 9 have shown that didemnin B binds to a site on Nb2 node lymphoma cells and that this binding may b responsible for the immunosuppressive activity. Schreiber and co-workers 10 have reported that didemnin A binds elongation factor 1α (EF-1α) in a GTP-dependent manner which suggests EF-1α may be the target responsible for the ability of didemnins to inhibit protein synthesis.
SUMMARY OF THE INVENTION
We present here synthetic studies toward a modified macrocycle which possesses an amide bond in place of an ester bond (3). A modification such as, this is likely to result in an increase in hydrogen bonding at the active site, and thus, provide more active compound. In addition, the facile nature of the C—O bond leads us to believe replacement of these C—O bonds with C—N bonds may improve the stability of these compounds.
Synthetic Strategy.
The retrosynthetic disconnections which formed the basis of our plan for the preparation amino-Hip analogue 3 of didemnin A are illustrated in Scheme I. We envisaged disconnection of the amide function between N,O—Me 2 -L-tyrosine and L-proline to give the linear heptapeptide 4 and disconnection between L-threonine and isostatine (3S, 4R, 5S) to afford the two units: a tripeptide unit 5 comprised of N—Me-leucine, threonine, and N,O—Me 2 -tyrosine; and a tetrapeptide unit 6 comprised of isostatine, α-α′ amino-isovaleryl) propionyl (Aip), leucine, and proline.
Synthesis of Tripeptide 5.
Preparation of the diprotected tripeptide unit is shown in Scheme II. Our approach began with methylation of the uncommon amino acid, Cbz-D-leucine, 7, with CH 3 I/NaH 11 . Coupling of the derivative Cbz-D-MeLeuOH with the hydroxyl group of the threonine derivative L-TheOEt 12 was accomplished with dicyclohexylcarbodiimide (DCC) 13 to provide the dipeptide E8. Ester hydrolysis with potassium hydroxide afforded the desired carboxylic acid which was then protected as a phenacyl (Pac) ester 9. Coupling with the tyrosine derivative BocMe 2 TryOH 14 followed by removal of the Boc protecting group 15 afforded 10. Removal of the phenacyl function 17 provided the key fragment 5.
Reagents: a) (i) CH 3 I, NaH, THF; (ii) L-ThrOEt, DCC. CH 2 Cl 2 ; b) (i) KOH, MeOH; (ii) phenacylBr, Et 3 N, EtOAc; c) BocMe 2 TryOH, DCC, DMAP, CH 2 Cl 2 ; d) Zn, HOAc/H 2 O.
Synthesis of Tetrapeptide 6.
The construction of fragment 6 involves two novel subunits (2S,4S)-aminoisovalerylpropionic acid (Aip) and (3S, 4R, 5S)-isostatine (Ist). The synthesis of the required isostatine derivative involves (2R, 3S)-allo-isoleucine. The expensive conversion to the hydroxy acid with retention and its conversion in two steps to the amino acid with inversion (Scheme III). 18 Conversion of (2S, 3S)-isoleucine to the corresponding α-hydroxy acid 12 was accomplished by using a well-known procedure 19 that allows overall retention of configuration via a double inversion. Esterification was carried out with acetyl chloride in methanol, and the corresponding α-hydroxy methyl ester was transformed into the tosloxy methyl ester 13. Treatment of the tosylate with sodium azide in DMF provided the α-azido ester 14 stereoselectively. Saponification of the ester afforded the α-azido acid 15. Hydorgenation of the azide to the free amine proceeded readily in methanol as atmospheric pressure using Pearlman's catalyst (20% palladium hydroxide on carbon), 20 to afford (2S, 3S)-allo-isoleucine 16.
The major portion of the isostatine subunit, D-allo-isoleucine, 16, was transformed into the tert-butoxycarbonyl (Boc) acid under standard conditions. 16 After activation of its carboxyl group as the imidazolide by use of carbonyldiimidazole, treatment with the magnesium enolate of ethyl hydrogen malonate afforded the required β-keto ester 18. The reduction by NaBH 4 of the carbonyl group of the β-keto ester was effectively stereospecific, generating the desired (3S, 4R, 5S)-19a as the major product (>10:1) after chromatographic separation. As shown in Scheme IV, saponification afforded the required Boc-(3S, 4R, 5S)-Ist-OH, 20.
The next step toward the synthesis of the tripeptide fragment (6) involved formation of the amino Hip subunit. This unit was synthesized from Cbz-L-valine, 21, utilizing a procedure based in part on the work of Nagarajan. 21 After activation of its carboxyl group as the imidazolide by use of carbonyl-diimidazole, treatment with the magnesium enolate of ethyl hydrogen methyl malonate (EHMM) afforded the required β-keto ester 22. Sodium borohydride reduction of the β-keto ester produced a diastereomeric mixture of alcohols which were separable by column chromatography. Following saponification and coupling with L-leucine methyl ester (L-LeuOMe), flash chromatography afforded the desired (Pac) bromide provided the protected derivative 24. Oxidation of the secondary alcohol with pyridinium chlorochromate on alumina 22 provided the β-keto amide. Removal of the phenacyl protecting group provided the free acid which was coupled with L-proline trimethylsilylester. Catalytic hydrogenation removed the Cbz protecting group and coupling of the isostating subunit 20 with the amine produced the diprotected tetrapeptide. As shown in Scheme V, the Boc protecting group was then removed under standard conditions 15 to afford the key tetrapeptide unit 6.
Reagents: a)(i) CO(imid) 2 , THF; (ii) EHMM, iPrMgBr; b) (i) NaBH 4 , EtOH; (ii) KOH, MeOH; (iii) LeuOMe, DCC, CH 2 Cl 2 ; c) (i) KOH, MeOH; (ii) phenacylBr, Et 3 N, EtOAc; (iii) PCC, Al 2 O 3 , CH 2 Cl 2 ; d) (i) Zn/HOAc; (ii) ProOTMSe, DCC, CH 2 Cl 2 ; (iii) H 2 , Pd/C, MeOH; (iv) BocIstOH 16, DCC, CH 2 Cl 2 ; (v) HCl, dioxane.
Synthesis of Linear Heptapeptide 4.
The synthesis of the linear heptapeptide 4 involved coupling of the two subunits, Cbz-D-MeLeuThe(OMe 2 TyrBoc)OH, 5, and H-IstAipLeuProOTMSe, 6. A variety of coupling methods (BopCl, 24 DCC,EEDQ 25 ) were attempted, however, the EDCI method 26 was shown to be the most efficient for the formation of the triprotected compound 4. Deprotections of the trimethylsilyl ester and the Boc functions were performed under standard conditions to give the monoprotected linear heptapeptide 7. As shown in Scheme VI, cyclization of 7 was achieved by treatment with EDCI to yield the protected compound 3, and catalytic hydrogenation provided the unprotected amino Hip (Aip) analog of didemnin A, 8.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a LRFAB mass spectrum of deprotected tripeptide (5).
FIG. 2 is a LRFAB mass spectrum of deprotected tripeptide (6).
FIG. 3 is a reversed phase HPLC trace of the fully protected heptapeptide (4).
FIG. 4 is a LRFAB mass spectrum of the fully protected heptapeptide (4).
FIG. 5 is a LRFAB mass spectrum of fully deprotected heptapeptide (4).
FIG. 6 is a reversed phase HPLC trace of the deprotected linear heptapeptide (7).
FIG. 7 is a LRFAB mass spectrum of deprotected heptapeptide (7).
FIG. 8 is a LRFAB mass spectrum of protected amino Hip analog (3).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
We have described the total syntheses of the amino Hip analogue of didemnin A. Previous studies have shown that didemnins are subject to hydrolysis and undergo decomposition due to the instability of the ester bonds. Replacement of the ester bond with an amide linkage should increase the maintenance of the active cyclic conformation and, thus, provide a compound of greater activity.
General Experimental Procedures.
1 H NMR spectra were recorded on Varian XL-200, General Electric QE-300, Varian XL-400, and General Electric QN-500 spectrometers. 1 H chemical shifts are references in CDCl 3 and methanol-d 4 to residual CHCl 3 (7.26 ppm) and CD 2 HOD (3.34 ppm). Electron impact (EI) mass spectra were recorded on a Finnigan MAT CH-5 DF spectrometer. High resolution (HRFAB) and fast atom bombardment (FAB) mass spectra were recorded on a VG ZAB-SE mass spectrometer operating in the FAB mode sing magic bullet matrix. 27 Microanalytical results were obtained from the School of Chemical Sciences Microanalytical Laboratory. Infrared (IR) spectra were obtained on an IR/32 FTIR spectrophotometer. Solid samples were analyzed as chloroform solutions in sodium chloride cells. Liquids or oils were analyzed as neat films between sodium chloride plates.
Optical rotations (in degrees) were measures with a DIP 360 or a DIP 370 digital polarimeter with an Na lamp (589 nm) using a 5×0.33-cm (1.0 mL) cell. Melting points were determined on a capillary melting point apparatus and are not corrected. Normal phase column chromatography was performed using Merck-kieselgel silica gel (70-230 mesh). Fuji-Davison C18 gel (100-200 mesh was used for reversed phase column chromatography. All solvents were spectral grade. Analytical thin layer chromatography was performed on precoated plates (Merck, F-254 indicator). These plates were developed by various methods including exposure to ninhydrin, iodine, and UV light (254 nm). HPLC was performed with a Waters 900 instrument and an Econosil C 18 column (Alltech/Applied Science) and a Phenomenex C 18 column.
THF was distilled from sodium benzophenone ketyl and CH 2 Cl 2 from P 2 O 5 . Dimethylformamide (DMF), triethylamine (Et 3 N), and N-methylmorpholine (NMM) were distilled from calcium hydride and stored over KOH pellets. Pyridine was distilled from KOH and stored over molecular sieves. Other solvents used in reactions were reagent grade without purification. Di-tert-butyl dicarbonate [(BocO) 2 O], dicyclohexycarboniimide (DCC), I-(3-dimethylaminopropyl)-3-ethylcarboniimide hydrochloride (EDCI), dimethylaminophtidine (DMAP). I-hydrozybenzotriazole (HOBT), D- and L-isoleucine, L-tyrosine, L-isoleucine, L-threonin, D-valine, and L-proline were obtained from the Aldrich Chemical Company. All reactions requiring anhydrous conditions were performed under an atmosphere of nitrogen.
N-Benzyloxycarbonyl-N-methyl=D-leucine (Cbz-D-MeLeuOH).
Sodium hydride (60% dispersion, 6.47 g, 162.9 mmol) was added portionwise, with cooling, to a solution of Cbz-D-LeuOH (14.4 g, 54.3 mmol) in THF (21.4 mL) was added portionwise, with cooling. Methyl iodide (27.0 mL, 435 mmol) was then added via a dropping funnel. The reaction was allowed to stand at room temperature for 24 hours. Ethyl acetate (70 mL) was slowly added to the reaction mixture, followed by water, to destroy the excess sodium hydride. The solution was then evaporated to dryness and theoily residue partitioned between ether (30 mL) and water (60 mL). The ether layer was washed the aqueous sodium bicarbonate (5 mL) and the combined aqueous layers were acidified with 4N HCl to pH 3. The solution was extracted with ethyl acetate (3×15 mL) and the extract was washed with 5% aqueous sodium thiosulfate (2×10 mL) and water (10 mL). The solution was dried over sodium sulfate and the solvent evaporated to give an oily residue which crystallized overnight. Recrystallization from petroleum ether produced a white solid (12.7 g, 84%); [α] 29 Na+24.7° (c 0.02, CHCl 3 ), Lit. 11b [α] 29 D+26.9° (c 0.02, CHCl 3 ); m.p. 71-72° C. (Lit. 11b 72-73° C.); 1 H NMR (300 MHz, CDCl 3 δ 7.40-7.27 (5H,m), 5.17 (2H,s), 4.74 (1H,m), 2.87 (3H,s), 1.78-1.76 (2H,m), 1.62-1.57 (1H,m), 0.92-0.80 (6H,m); FABMS 280.2 (M+H), 236.2 (M−CO 2 ); HRFABMS Cacd for C 15 H 22 NO 4 (M+H) 280.1549, Found 280.1556; Anal. Calcd for C 15 H 21 NO 4 ; C, 64.48; H, 7.58; N,5.02. Found: C,64.30; H, 7.65; N, 4.93.
L-Threonine Ethyl Ester (L-ThrOEt).
A current of dry HCl was passed through a suspension of L-threonine (35.0 g, 0.29 mol) in absolute ethanol (350 ml), with shaking, until a clear solution formed. The solution then refluxed for 30 minutes, and was evaporated to dryness under reduced pressure, and the oily residue was taken up in absolute ethanol (175 mL) and, again, taken to dryness under reduced pressure. The oily residue was then treated with a saturated solution of ammonia in chloroform. The ammonium chloride was filtered off and the filtrate was taken to dryness at 0° C. under reduced pressure. A yellow solid was isolated (36.2 g. 85%); [α] 29 Na+0.82° (c 5.0, EtOH). Lit. 12 [α] 29 D+0.95° (C 5.0 EtOH); m.p. 51-53° C. (Lit 12 52-54° C.); 1 H NMR (200 MHz, CDCl 3 w/TMS) δ 4.82 (1H.m), 4.40 (1H,d), 4.05 (2H,q), 1.62 (3H,d), 1.21 (3H;t); FABMS 148.2 (M+H); HRFABMS Calcd for C 6 H 14 NO 3 (M+H) 148-0974, found 148.0972.
Z-D-Methylleucylthreonine Ethyl Ester (8).
Z-D-MeLeuOH (2.12 g. 7.59 mmol) was dissolved in 100 mL of CH 2 Cl 2 and cooled to 0° C. DCC (1.72 g, 8.35 mmol) was added and the solution was stirred at 0° C. for 10 minutes. L-ThrOEt (1.12 g. 7.59 mmol) in a mL of CH 2 Cl 2 was added and the solution was allowed to warm to rt. After approximately 15 hours, dicyclohexylurea was removed by filtration and washed with CH 2 Cl 2 . The filtrate was washed with 10% citric acid, 5% sodium bicarbonate, and water and dried over sodium sulfate. The solution was evaporated to dryness and the product purified by silica gel column chromatography (hexane/EtOAc=65/35) to afford the product as a yellow oil (2.35 g. 76%); 1 H NMR (400 MHz, CDCl 3 ) δ 7.36-7.42 (5H,m), 6.73 (1H.d), 6.50 (1H, br s), 5.18 (2H, s), 4.83 (1H,m), 4.51 (1H,m), 4.30 (1H,m), 4.17 (2H,q), 2.81 (3H,s), 1.74 (2H,m), 1.70 (3H,d), 1.68 (2H,m), 1.20 (3H,t), 0.82-0.90 (6H,m); FABMS 431.4 (M+Na), 409.2 (M+H); HBFABMS calcd for C 21 H 33 N 2 O 6 (M+H) 409.2344. Found 409.2339; Anal. Calcd for C 21 H 32 N 2 O 6 : C,61.73; H, 7.90; N,6.86. Found=: C, 62.00; H, 8.08; N,7.07.
Z-D Methylleucylthreonine (Z-D-MeLeuThrOH)
Z-D-MeLeuThrOEt (1.80 g, 4.42 mmol) was dissolved in methanol and 2N KOH was slowly added to the mixture at 0° C. The solution was stirred for 2 hours. TLC analysis (CHCl 3 /MeOH 95:5) showed the reaction to be complete. The mixture was neutralized using 2N CHI. The solvent was then evaporated. The solution was partitioned between ethyl acetate and water and the organic layer separated. Aqueous HCl was added to the aqueous layer to pH 3. This was extracted with ethyl acetate and all o the ethyl acetate extracts were combined. The solution was dried over MgSO 4 and the solvent evaporated to give a dark orange oil (1.77 g. 98%) which was used for the next reaction without purification; 1 H NMR (200 MHz, CDCl 3 ) α 7.36-7.41 (5H,m), 6.72 (1H,s), 6.52 (1H, br s), 5.18 (2H,s), 4.83 (1H,m), 4.51 (1H.,m), 4.30 (1H,m) 2.81 (3H,s), 1.74 (2H,m), 1.70 (3H,d), 1.68 (1H,m), 0.82-0.90 (6H,m); FABMS 381.2 (M+H); HRFABMS Calcd for C 19 H 29 N 2 O 6 (M+H) 381.2026, Found 381.2021; Anal. Calcd for C 19 H 28 N 2 O 6 : C, 59.97; H, 7.42; N, 7.37, Found. C, 60.53; H, 7.06; N, 7.11.
Z-D-Methylleucylthreonine Phenacyl Ester (9).
Z-D-MeLeuThrOH (1.50 g. 3.95 mmol) was dissolved in ethyl acetate (25 mL). Triethylamine (0.39 g. 3.95 mmol) and phenacyl bromide (0.079 g., 3.98 mmol) were added and, within a few minutes, a precipitate formed. The mixture was stirred overnight. At this time, water and ether were added and the two layers separated. The organic layer was washed with 0.1N HCl, saturated sodium bicarbonate, and brine, and then dried over MgSO 4 . The residue was chromatographed on silica gel (hexane/EtOAc=4/1) to give a clear oil (1.71 g, 87%); 1 H NMR (200 MHz, CDCl 3 ) δ 7.34-7.41 (10H,m), 6.71 (1H,s), 6.52 (1H,br s), 5.27 (2H,s), 5.18 (2H,s), 4.83 (1H,m), 4.61 (1H,m), 4.50 (1H,m)., 2.81 (3H,s), 1.74 (2H.m), 1.70 (3H,d), 1.68 (1H,m), 0.82-0.90 (6H,m); FABMS 537.1 (M+K), 499.1 (M+H); HRFABMS Calcd for C 27 H 35 N 2 O 7 (M+H) 499.2444. Found 499.2450.
N-tert-Butoxycarbonyl-tyrosine (BocTyrOH). 16
Tyrosine ethyl ester (5.06 g, 25 mmol) was dissolved in 25 mL of water and solid sodium hydroxide was added until litmus paper indicated a neutral pH. Diozane (50 mL) and (Boc) 2 O (6.12 g, 27.5 mmol) were added with cooling. The reaction was allowed to stir for 2 hours. Water and ether were added and the two layers separated. The organic layer was extracted three times with aqueous sodium hydroxide (IN). The aqueous layers were allowed to sit overnight then neutralized with aqueous HCl and extracted with ether, which was washed with brine and dried over MgSO 4 . A yellow oil was obtained (6.02 g, 86%); 1 H NMR (200 MHz, CDCl 3 ) δ 7.10 (2H,d), 6.84 (2H,d), 4.92-5.00 (1H,m), 4.47-4.52 (1H,m), 3.00-3.12 (2H,m), 1.43 (9H,s); EIMS 282.0.
N-tert-Butoxycarbonyl-N,O-dimethyltyrosine (BocMe 2 TryOH).
A solution of BocTyrOH (5.30 g, 18.8 mmol) and methyl iodide (2.57 mL, 41.4 mmol) in 80 mL of dry THF was cooled at 0° C. and sodium hydride (60% dispersion, 2.47 g, 62.0 mmol) was added. The reaction was allowed to stir at 0° C. for 1 hour, then at rt overnight. Excess sodium hydride was quenched by the dropwise addition of 10 mL of THF/H 2 O (1:1) and the solvents were removed in vacuo. After removal of the solvents, the deep orange gel was diluted with 30 mL of water and washed with pentane (2×30 mL). The aqueous phase was acidified with solid citric acrd (pH 2). Ethyl acetate was used for extraction. The combined extracts were washed with brine, dried (MgSO 4 ) and concentrated in vacuo. The crude residue was purified by silica gel column chromatography eluting with ethyl ether to afford the desired compound as a yellow oil (5.22 g, 90%); [α] 29 D-15.7° (c 1.0, MeOH), Lit. 14b [α] 22 D-16.9° (c 1.0, MeOH) 1 H NMR 300 MHz, CDCl 3 ) δ 7.18 & 7.12 (2H, two d), 6.85 (2H,d), 4,58 (1H, two t), 3.80 (3H, s), 3.24 & 3.13 (1H, 2dd), 2.76 & 2.68 (3H, 2s), 1.43 & 1.38 (9H, 2s); FABMS 619.3 (2M+H), 310.2 (M+H), 210.2 (M−Boc); HRFABMS Calcd for C 16 H 24 MO 5 (M+H) 310.1654, Found 310.1648.
Cbz-D-MeLeu-Thr(OMe 2 TyrBoc)-OPac (10).
BocMe 2 TyrOH (0.27 g, 0.91 mmol) in CH 2 Cl 2 (20 mL), DCC (19.5 mg, 0.95 mmol) and DMAP (41.3 mg) were added at 0° to a solution of Cbz-D-MeLeuThrOPac (0.45 g, 0.91 mmol). The solution was allowed to warm to room temperature and stirred for 12 h. Dicycloheylurea was filtered and washed with ethyl acetate. The filtrate and washings were combined and washed with 10% citric acid, 5% sodium bicarbonate and water, dried over MgSO 4 and concentrated. The crude residue was purified by flash column chromatography eluting with hexane and ethyl acetate (4:1) to obtain the product (0.53 g, 74%) as an orange oil; 1 H NMR (500 MHz, CDCl 3 δ 7.30-8.00(10H,m), 6.82 & 7.10 (2H, d), 5.31(1H, s), 5.20-4.8.5(1H, m), 3.74(3H, s), 3.10 & 3.07(1H, 2 dd) 2.92(3H, s), 2.73 (3H, s), 1.71 (3H, d), 1.44 & 1.37 (9H, 2 s), 0.92 (6H, m); FABMS 828.4 (M+K), 812.4 (M+Na), 790.3 (M+H), 690.4 M−Boc); HRFABMS Calcd for D 43 H 57 N 3 O 11 (M+H) 790.3915, Found 790.3916.
Cbs-D-MeLeu-Thr(OMe 2 TyBoc)-OH (5).
The tripeptide 10 (30.0 mg, 38.0 μmol) was treated with Zn (60 mg) in AcOH/H 2 O (70:30) and the mixture was stirred at rt overnight, Zn was filtered off using celite and the solution was partitioned between ether and water. The organic layer was separated and dried over Na 2 SO 4 . Purification by reversed phase column chromatography (CH 3 CH/H 2 O gradient system) afforded the product as a clear oil (21.3 mg, 92%); FABMS 710.4 (M+K), 694.3 (M+Na), 672.3 (M+H), 572.3 (M−Boc), see FIG. 1; HRFABMS Calcd for C 35 H 52 N 4 O 9 (M+H) 672.3734, Found 672,3674.
Methyl (2S,3S)-2-Hydroxy-3-methylpentanoate.
Acetyl chloride (6.13 mL) was added dropwise to MeOH (90 mL) cooled in an ice bath. After addition was complete, a solution of the α-hydroxy acid (23.0 g, 0. 17 mol) in MeOH (60 mL) was added. The solution was stirred at 0° C. for 1 h, then at rt oversight, concentrated and diluted with ether. The either solution was washed with saturated NaHCO 3 , brine, bried over MgSO 4 and concentrated to give a yellow oil (19.8 g, 80%); [α] 29 D+27.3 (c 0.95, CHCl 3 ), Lit. 18 [λ] 20 D+28.5(c 0.95, CHCl 3 ); 1 H NMR(300 Mhz, CDCl 3 ) δ 0.91 (t, 3H), 0.97 (d, 3H), 1.21 & 1.37 (m, 2H), 1.78 (m,1H), 2.92 (br s, 1H), 3.82 (s, 3H), 4.08 (d, 1H); CIMS 147.1 (M+H).
Methyl (2S, 3S)-2-Tosyloxy-3-methylpentanoate(13).
The hydroxypentanoate (4.44 g, 30.6 mmol) was dissolved in dry CH 2 Cl 2 and cooled in an ice bath to 0° C. Pyridine (45.0 mL) was added followed by p-toluenesulfonyl chloride (11.5 g, 60.8 mmol) in small portions with constant stirring. The mixture was stirred at rt overnight, then heated at 40° C. for 1 h. The solvent was evaporated and the residue dissolved in EtOAc and washed with 1N H 2 SO 4 and 1N KHCO 3 . The extracts were dried over MgSO 4 and evaporated in vacuo to give a dark orange oil (8.32 g, 88%); 1 H NMR (300 MHz, CDCl 3 ) δ 0.93 (t, 3H), 0.97 (d, 3H), 1.21 & 1.41 (m, 1H), 1.91 (m, 1H), 2.41 (s, 2H), 3.60 (s, 3H), 4.63 (d, 2H), 7.24 & 7.80 (d, 2H); FABMS 339.2 (M+K), 323.2 (M+Na), 301.1 (M+H), 241.2 (M−CO 2 CH 3 ); HRFABMS Calcd for C 14 H 21 O 5 S (M+H) 301.11 10, Found 301.1109.
Methyl (2R, 3S)-2-Azido-3-methylpentanoate (14).
Sodium azide (1.20 g, 18.6 mmol) was added to a stirred solution of methyl 2-tosyloxy-3-methylpentanoate (3.29 g, 10.9 mmol) in DMF (30 mL). The solution was kept at 50° C. for 24 h, then partitioned between EtOAc and water. The aqueous layer was separated and extracted with EtOAc (3×50 mL). The combined organic layers were dried over MgSO 4 and concentrated in vacuo to give a deep yellow oil (1.51 g, 81%), IR (neat) v 3500-3000 (very br m), 2970 (s), 2939 (br m), 2111 (s), 1736 (s), 1472 (w), 1387 (w), 1225 (br m), 1175 (w), 1086 (w), 732 (s) cm −1 ; 1 H NMR (300 MHz, CDCl 3 ) δ 0.93 (t, 3H), 0.97 (d, 3H), 1.22 & 1.43 (m, 1H), 1.96 (m, 1H), 3.78 (s, 3H), 3.85 (d, 2H); CIMS 172.1 (M+H).
(2R, 3S)-2-Azido-3-methylpentanoic acid (15).
To a solution of a α-azido ester (6.56 g, 38.3 mmol) in THF (58 mL) at 0° C. was added 1N NaOH (52 mL). The reaction mixture was stirred at 0° C. for 1 h and then at rt overnight. The mixture was diluted with ether (30 mL), the organic layer separated, and the aqueous phase extracted with ether (30 mL). The aqueous layer was then cooled to 0° C., acidified to pH 2 by dropwise addition of conc. HCl, and extracted with ethyl acetate (3×25 mL). The combined ethyl acetate extracts were dried (MgSO 4 ) and concentrated in vacuo to furnish 10.9 g (95%); IR (neat) v max 3500-3000 (very br m), 2974 (s), 2942 (br m), 2090 (s), 1464 (w), 1382 (w), 1222 (br m), 1168 (w), 1088 (w), 721 (s) cm −1 ; 1 H NMR (300 MHz, CDCl 3 ) δ 0.93 (3H, t), 0.97 (3H, d), 1.21 & 1.41 (1H, m), 1.97 (1H, m), 3.90 (2H, m); FABMS 158.2 (M+H); HRFABMS Calcd for C 14 H 21 O 5 S (M+H),301.1110, Found 301.1109.
D-allo-isoleucine (16).
To a solution of the α-azido acid (6.01 g, 38.2 mmol) in MeOH (25 mL) was added 20% Pd(OH) 2 on carbon (1.89 g). The reaction flask was purged with H 2 gas and the contents vigorously stirred at rt and atmospheric pressure for 15 h, filtered and the filter pad washed with distilled water and ethanol. The filtrate was concentrated in vacuo to afford the product as a white solid. Recrystallization from EtOAc provided the compound as colorless needles (4.75 g, 95%); 1 H NMR (300 MHz, MeOH-d 4 ) δ 0.93 (t, 3H), 0.97 (d, 3H), 1.32 & 1.46 (m, 1H), 2.47 (m, 1H), 3.58 (d, 2H); FABMS 132.1 (M+H); Anal. Calcd for C 6 H 13 NO 2 : C, 54.92; H, 9.99; N, 10.64. Found: C, 54.79; H, 10.17; N, 10.26
N-tert-Butoxycarbonyl-D-allo-isoleucine (17).
A solution of D-allo-isoleucine (120 mg, 0.916 mmol) was dissolved in water (2.5 mL) and 1N NaOH (1.83 mL) and stirred at rt for 48 h. Di-tert-butyl dicarbonate (200 mg, 0.916 mmol) in dioxane (5,00 mL) was added to the stirred mixture at 0° C. After 12 h the dioxane was evaporated, the aqueous residue washed with Et 2 O, mixed with EtOAc, and the rapidly stirred mixture acidified with 2 N H 2 SO 4 at 0° C. This solution was extracted with EtOAc. and the combined organic extracts were dried (Na 2 SO 4 ) and coned in vacuo to a crystalline material (179 mg, 85%); mp 35-37° C. (Lit. 28 34-36° C.); [α] 29 D −42.7° (c 2.04, CHCl 3 ), [Lit. 28 [α] 27 D−40.7° (c 2.06, CHCl 3 ]); 1 H NMR (300 MHz. CDCl 3 ) δ 5.52 (br s, 1H), 3.72-3.54 (m, 1H), 1.92-2.01 (m, 1H), 1.43 (s, 9H). 1.37-1.12 (m, 3H), 0.97 (t, 3H), 0.93 (d, 3H); FABMS 463.2 (2M+H), 232.1 (M+H), 132.1 M−Boc); HRFABMS Calcd for C: 1 H 21 NO 4 (M+H) 232.1551, Found 232.1548.
Ethyl Hydrogen Malonate.
A previously reported procedure was used. 29 Potassium hydroxide (10.02 g, 85% KOH, 156 mmol) in ethanol (99 mL) was added dropwise to a stirred solution of diethyl malonate (23.69 mL, 156 mmol) in ethanol (108 mL), and the solution was stirred at rt overnight. The mixture refluxed for 1 h and the solid was filtered off. The ethanolic solution on cooling gave the monopotassium salt. Water (5 mL) was added to the dried potassium salt, and the solution was cooled to 0° C. Concentrated hydrochloric acid (3.45 mL) was added, keeping the temperature below 5° C. The solid was filtered and washed with ether. The filtrate was extracted with CH 2 Cl 2 , dried (MgSO 4 ), and concentrated to give a yellow oil (9.96 g, 48%; Lit. 29b 51%); 1 H NMR (300 MHz, CDCl 3 ) δ 4.37 (s, 2H), 4.24 (q, 2H), 1.34 (t, 3H); FABMS 133.0 (M+H).
Ethyl (4R,5S)-3-tert-Butoxycarbonylamino-5-methyl-3-oxoheptanoate (18).
A tetrahydrofuran solution of isoproprylmagnesium chloride (1.42 mL, 13.5 mmol) was added dropwise to a solution of ethyl hydrogen malonate (891 mg, 6.75 mmol) in dry CH 2 Cl 2 (5.62 mL). The reaction was then cooled in an ice-salt bath while a solution of Boc-D-allo-isoleucine (520 mg, 2.25 mmol) and N,N′-carbonyldiimidazole (360 mg, 2.25 mmol) in dry THF (1.20 mL) was added. The mixture was stirred overnight at rt, then poured into cold hydrochloric acid (10%, 100 mL). The ethyl ester was extracted with ether, washed with aqueous NaHCO 3 , dried (MgSO 4 ) and concentrated to give 475 mg (70%) of a pale yellow oil; IR (neat) v max 3355, 1750, 1700cm −1 ; 1 H NMR (300 MHz, CDCl 3 ) δ 4.98 (d, 1H), 3.90-4.57 (m, 1H), 4.18 (q, 2H), 3.46 (s, 2H), 0.70-2.00 (m, 6H), 1.43 (s, 9H), 1.26 (t, 3H), 0.78 (d, 3H); FABMS 302.2 (M+H), 202.2 (M−Boc).
(3S, 4R, 5S)-N-tert-Butoxycarbonyl-isostatine Ethyl Ester (19a).
To a stirred solution of 18 (500 mg, 1.66 mmol) in Et 2 O (2.90 mL) and EtOH (6.80 mL) cooled in an ice-salt bath was added NaBH 4 (60 mg, 1.58 mmol). The solution was allowed to stir at −20° C. for 2 h then poured into ice water. extracted with EtOAc and dried over MgSO 4 . The residue was chromatographed on silica gel (hexane/EtOAc=4/1) to give 325 mg (65%) of the desired isomer 19a and 25 mg (5%) of the minor isomer 19b. 19a: R f 0.20 (hexane/EtOAc=3/1); [α] 29 D−6.7° (c.0.5, MeOH), Lit. 30 [α] 23 D−6.4° (c 0.5, MeOH); IR (neat) v max 3350, 1740, 1700 cm −1 ; 1 H NMR (300 MHz, CDCl 3 ) δ 4.43 (d, 1H), 4.20 (q, 2H), 3.90-3.61 (m, 2H), 3.30 (br s, 1H), 2.50 (d, 2H), 1.90-1.98 (m, 1H), 1.41-1.30 (m, 2H), 1.40 (s, 9H), 1.24 (t, 3H), 0.97 (d, 3H), 0.90 (t, 3H); FABMS 304.2 (M+H) 204.2 (M−Boc); HRFABMS Calcd for C 15 H 29 NO 5 (M+H) 304.2117, Found 304.2123; Anal. Calcd for C 15 H 28 NO 5 : C, 59.37; H, 9.64; N, 4.62. Found: C, 59.03; H, 9.38; N, 4.88. 19b: R f 0.22 (hexane/EtOAc=3/1); [α] 29 D+26.9 (c 0.5, MeOH), Lit. 30 [α] 23 D+26.4 (c 0.5, MeOH); IR (neat) v max 3410, 1740, 1710.cm −1; 1 H NMR (300 MHz, CDCl 3 ) δ 4.42 (d, 1H), 4.20 (q, 2H), 3.87-3.61 (m, 2H), 3.32 (br s, 1H), 2.49 (d, 2H), 1.92-1.98 (m, 1H), 1.41-1.30 (m, 2H), 1.40 (s, 9H), 1.24 (t, 3H), 0.98 (d, 3H), 0.88 (t, 3H); FABMS 304.2 (M+H), 204.2 (M−Boc); HRFABMS Calcd for C 15 H 29 NO 5 (M+H) 304.2117, Found 304.2123; Anal. Calcd for C 15 H 28 NO 5 : C, 59.37; H, 9.64; N, 4.62. Found: C, 59.03; H, 9.38; N, 488.
(3S, 4R, 5S)-N-tert-Butoxycarbonyl-isostatine (20).
Boc-(3S, 4R, 5S)-Ist-OEt (300 mg, 1.00 mmol) was dissolved in methanol (5.00 mL) and 2N NaOH (2.00 mL) was alowly added to the mixture at 0° C. The solution was stirred at rt overnight at which time TLC analysis (hexane/EtOAc=4/1) showed the presence of a carboxylic acid. The mixture was neutralized using 2N HCl. The solvent was evaporated and the solution was partitioned between EtOAc and water and the organic layer separated. Aqueous HCl was added to the aqueous layer to pH 3. This was extracted with EtOAc and the EtOAc extracts were combined. The solution was dried over MgSO 4 and the solvent evaporated to give a yellow oil (215 mg, 78%) which was used for the next reaction without purification; [α] 29 D−4.6° (c 0.0014, CHCl 3 ), Lit. 11b [α] 20 D−57° (c 0.0014, CHCl 3 ); 1 H NMR (300 MHz, CDCl 3 ) 4.43 (d, 1H), 3.85-3.63 (m,2H), 2.76 (br, 1H), 2.41 (m, 2H), 2.00-1.93 (m, 1H), 1.43-1.35 (m, 2H), 1.43 (s, 9H), 0.91 (t, 3H), 0.87 (d, 3H); FABMS 276.1 (M+H), 176.1(M−Boc); HRFABMS Calcd for C 13 H 25 NO 5 (M+H) 276.1806, Found 276.1810.
Ethyl Hydrogen Methylmalonate.
Potassium hydroxide (3.53 g, 90% KOH, 57.4 mmol) in ethanol (35 mL) was added dropwise to a stirred solution of diethyl methylmalonate (9.87 mL, 57.4 mmol) in ethanol (40 mL), and the solution was stirred at rt overnight. The mixture was heated at reflux for 1 hr and the solid filtered off. The ethanolic solution on cooling gave the monopotassium salt. Water (5 mL) was added to the dried potassium salt, and the solution was cooled to 0° C. Concentrated hydrochloric acid (3.45 mL) was added, keeping the temperature below 5° C. The solid was filtered and washed with ether and the filtrate was extracted with CH 2 Cl 2 , then dried and concentrated to give a yellow oil (4.86 g, 58%, Lit. 29 60%); 1 H NMR (200 MHz, CDCl 3 ) δ 4.23 (q, 2H), 3.47 (q, 1H), 1.42 (d, 3H), 1.27 (t, 3H); FABMS 147.1 (M+H).
Cbz-AipOEt (22).
A tetrahydrofuran solution of isopropylmagensium chloride (9.57 mL, 90.8 mmol) was added dropwise to a solution of ethyl hydrogen methylmalonate (6.63 g, 45.4 mmol) in dry CH 2 Cl 2 (35 mL). The reaction was then cooled in an ice-salt bath while a solution of Cbz-L-valine (3.87 g, 15.1 mmol) and N,N′-carbonyldiimidazole (2.44 g, 15.1 mmol) in dry THF (15 mL) was added. The mixture was stirred overnight at rt, then poured into cold hydrochloric acid (10%, 200 mL). The ethyl ester was extracted with ether, washed with aqueous NaHCO 3 , brine, dried (MgSO 4 ) and concentrated. Purification by flash column chromatography (hexane/EtOAc=10/1) gave the desired product as a yellow oil (4.50 g, 89%); 1 H NMR (200 MHz, CDCl 3 ) δ 7.32-7.38 (s, 5H), 5.24-5.37 (m, 1H), 5.17 (s, 2H), 4.20 (q, 2H), 3.41 (q, 1H), 218-2.21 (m, 1H), 1.45 (d, 3H), 1.32-1.37 (m, 1H), 1.24 (t, 3H), 0.94 (d, 3H), 0.81 (d, 3H); FABMS 374.0 (M+K), 336.1 (M+H), 292.1 (M−OEt); HRFABMS Calcd for C 18 H 26 NO 5 (M+H) 336.1811, Found 336.1817; Anal. Calcd for C 18 H 25 NO 5 : C, 64.44; H, 7.52; N, 4.18. Found: C, 64.70; H, 7.62; N, 4.37.
Cbz-DihydroAipOEt.
To a stirred solution of Cbz-AipOEt (6.54 g, 19.5 mmol) in Et 2 O (15 mL) and EtOH (35 mL) at −20° C., NaBH 4 (0.74 g, 19.5 mmol) was added over a period of 15 min. The reactioin mixture was stirred 15 min at −20° C. and poured into ice water (50 mL). After extraction with ethyl acetate (30 mL), the combined organic extracts were dried (MgSO 4 ) and concentrated to give a yellow oil (6.12 g, 93%); 1 H NMR (300 MHz, CDCl 3 ) δ 7.39 (s, 5H), 7.01 (br s, 1H), 5.13 (s, 2H), 4.72 -4.53 (m, 1H), 4.18 (q, 2H), 3.80-3.71 (m, 1H), 3.38 (br s, 1H), 2.32-2.20 (m, 1H), 1.98 (m, 1H), 1.40 (d, 3H), 1.25 (t, 3H), 9.92-0.80 (m, 6H); FABMS 338.1 (M+H); Anal. Calcd for C 18 H 27 NO 5 : C, 64.06; H, 8.07; N, 4.15. Found : C, 64.21; H, 8.36; N, 4.29.
Cbz-DihydorAipOH.
Cbz-DihydroAipOEt (5.99 g, 17.7 mmol) was dissolved in methanol and 2N KOH was slowly added to the mixture at 0° C. The solution was allowed to stir for 2 h. TLC analysis (hexane/ethyl acetate 10:1) showed the reaction to be complete. At this time, 2N HCl was added to neutralization. The solvent was evaporated and the solution was partitioned between ethyl acetate and water. The organic layer was separated. Aqueous HCl was added to bring the aqueous layer to pH 3 which was then extracted with ethyl acetate. The ethyl acetate extracts were combined, the solution was dried over MgSO 4 and the solvent was evaporated to give a pale yellow oil (4.59 g, 84%); 1 H NMR (300 MHz, CDCl 3 ) δ 7.39 (s, 5H), 7.04 (br s, 1H), 5.13 (s, 2H), 4.40-4.20 (m. 1H), 3.92-3.71 (m, 1H), 3.33 (br s, 1H), 2.32-2.20 (m, 1H), 1.98 (m, 1H), 1.40 (d, 3H), 0.92-0.80 (m, 6H); FABMS 310.2 (M+H); HRFABMS Calcd for C 16 H 24 NO 5 (M+H) 310.1654, Found 310.1651; Anal. Calcd for C 16 H 23 NO 5 : C, 62.10; H, 7.51; N, 4.53. Found : C, 62.50; H, 7.71; N, 4.37.
Cbz-DihydroAip-LeuOMe (23). Cbz-DihydroAipOH (1.17 g, 3.82 mmol) was dissolved in dry CH 2 Cl 2 (25 mL) and cooled to 0° C. DDC (0.87 g, 4.20 mmol) and DMAP (0.32 g, 2.90 mmol) were added with stirring and the mixture was stirred for 1 h. After filtration of dicycloheylurea, leucine methyl ester (0.56 g, 3.82 mmol) was added and the mixture was stirred overnight. The residue was concentrated and taken up in ethyl acetate. The solution was washed with aqueous citric acid, aqueous sodium bicarbonate, dried over MgSO 4 , and concentrated. The residue was purified by column chromatography eluting with hexane/ethyl acetate (50:50) to give a clear oil (1.23 g, 74%); 1 H NMR (300 MHz, CDCl 3 ) δ 7.43 (s, 5H), 6.81 (br s, 1H), 6,42 (br s, 1H), 4.78-4.72 (m, 1H), 4.48-4.43 (m, 1H), 3.78-3.72 (m, 1H), 3.67 (s, 3H), 3.51 (br s, 1H), 2.50-2.40 (m, 1H), 2.37-2.20 (m, 1H), 1.40-1.30 (dd, 6H), 1.10-0.90 (m. 9H), FABMS 437.2 (M+H); HRFABMS Calcd for C 23 H 37 N 2 O 6 (M+H) 437.2652, Found 437.2653; Anal. Calcd for C 23 H 36 N 2 O 6 : C, 63.27; H, 8.32; N. 6.42. Found: C, 63.65; H, 8.35; N, 6.49.
Cbz-DihydroAip-LeuOH.
Cbz-DihydroAip-LeuOMe (303 mg, 0.70 mmol) was dissolved in MeOH and 2N KOH was slowly added with cooling. After approximately 3 h stirring, TLC analysis (hexane/ethyl acetate 6:1) showed reaction to be complete. The solution was neutralized with 2N HCl and extracted with ethyl actate. The aqueous layer was adjusted to pH 3 and extracted with ethyl acetate. The combined ethyl acetate extracts were then dried over MgSO 4 . Evaporation of the solvent left a yellow oil (270 mg, 92%); 1 H NMR (200 MHz, CDCl 3 ) δ 7.42 (s, 5H), 6.81 (br s, 1H), 6.42 (br s 1H), 4.78-4.72 (m, 1H), 4.48-4.42 (m, 1H), 3.78-3.72 (m, 1H), 3.51 (br s, 1H), 2.50-2.40 (m, 1H), 2.37-2.30 (m, 1H), 1.40-1.30 (dd, 6H), 1.10-0.90 (m, 9H); FABMS 423.2 (M+H); HRFABMS Calcd for C 22 H 35 N 2 O 6 (M+H) 423.2495, Found 423.2493.
Cbz-DihydroAip-Leu-OPac.
Cbz-DihydroAip-LeuOH (2.03 g, 4.81 mmol) was dissolved in ethyl acetate (33 mL), triethylamine (0.66 mL) and phenacyl (Pac) bromide (0.97 mg, 6.85 mmol) were added to the mixture was stirred at rt overnight. Water and ether were added and the two layers separated. The organic layer was washed with 0.1N HCl saturated sodium bicarbonate, and brine, then dried over MgSO 4 . Concentration by evaporation of the solvent gave a tan oil. The residue was chromatographed on silica gel (hexane/EtOAc=4/1) to give 1.27 g (53%) of one isomer and 0.96 g (40%) of the other isomer; a: R f 0.46 (hexane/EtOAc=1/1); 1 H NMR (300 MHz, CDCl 3 ) δ 7.90 (d, 2H), 7.61 (m, 1H), 7.50 (m, 2H), 7.40 (s, 5H), 6.03 (br s, 1H), 6.00 (br s, 1H), 5.40 (AB q, 2H), 5.10 (s, 2H), 4.78-4.72 (m, 1H), 4.45-4.53 (m, 1H), 4.05-4.10 (m, 1H), 3.70 (br s, 1H), 2.50 (q, 1H), 2.40-2.32 (n, 1H), 2.00-1.85 (m, 3H), 1.25 (dd, 6H), 1.06 (d, 3H), 1.02-0.80 (dd, 6H); FABMS 541.2 (M+H); HRFABMS Calcd for C 30 H 41 N 2 O 7 (M+H) 541.2916, Found 541.2916; Anal. Calcd for C 30 H 40 N 2 O 7 : C, 66.63; H, 7.46; N, 5.18. Found: C, 66.61; H, 7.44; N, 5.26. b: R f 0.30 (hexane/EtOAc=1/1); 1 H NMR (300 MHz, CDCl 3 ) δ 7.90 (d, 2H), 7.62 (m, 1H), 7.50 (m, 2H), 7.40 (s, 5H), 6.03 (br s, 1H), 6.00 (br s, 1H), 5.40 (AB q, 2H), 5.10 (s, 2H), 4.78-4.73 (m, 1H), 4.44-4.55 (m, 1H), 4.06-4.12 (m, 1H), 3.72 (br s, 1H), 2.51 (q 1H), 2.39 -2.31 (m, 1H), 2.00-1.85 (m, 3H), 1.24 (dd, 6H), 1.06 (d. 3H), 1.05-0.83 (dd, 6H); FABMS m/z 541.2 (M+H); HRFABMS Calcd for C 30 H 41 N 2 O 7 (M+H) 541.2916, Found 541.2914; Anal. Calcd for C 30 H 40 N 2 O 7 : C, 66.63; H, 7.46; N, 5.18. Found: C, 66.61; H, 7.44; N, 5.26.
Cbz-Aip-Leu-OPac (24).
A solution of Cbz-Dihydro-Aip-LeuO-Pac (0.44 g, 0.81 mmol) in CH 2 Cl 2 (2.10 mL) was stirred while pyridinium chlorochromate on alumina reagent 16 (1.57 g) was added. After 2 h stirring at rt, the solution was filtered and washed with ether. The combined filtrates were combined and the solvent evaporated. The residue was chromatographed on silica gel hexane/EtOAc=4/1) to give 0.37 g (87%) of the desired product as a white solid; R f 0.42 hexane/EtOAc=1/1); 1 H NMR (300 MHz, CDCl 3 ) δ 7.90 (d, 2H), 7.61 (m, 1H), 7.50 (m, 2H), 7.40 (s, 5H), 6.90 (br s, 1H), 6.88 (br s, 1H), 5.40 (AB q, 2H), 5.18 (s, 2H), 4.78-4.72 (m, 1H), 4.45-4.53 (m, 1H), 3.68 (q, 1H), 2.25-2.38 (m, 1H), 1.92-1.71 (m, 3H), 1.45 (d, 3H), 1.10-1.00 (dd, 6H), 0.80-0.75 (dd, 6H); FABMS 1077.3 (2M+H), 577.3 (M+K), 561.2 (M+Na), 539.3 (M+H); HRFABMS Calcd for C 30 H 39 N 2 O 7 (M+H) 539.2757, Found 539.2762; Anal. Calcd for C 30 H 38 N 2 O 7 : C, 66.88; H, 7.11; N, 5.18. Found: C, 66.92; H, 7.33; N, 478.
Cbz-Aip-Leu-OH.
The protected dipeptide (167 mg, 0.31 mmol) was treated with Zn (500 mg) in AcOH/H 2 O (70:30). The mixture was allowed to stir at rt overnight, Zn was filtered off using celite and the solution was partitioned between ether and water. The organic layer was separated and dried over Na 2 SO 4 . Purification by column chromatography (CHCl 3 /MeOH) afforded the product as a white powder. The reaction flask was protected with a CaCl 2 tube and the mixture allowed to stir at rt for 1½ h. Solvent was evaporated and the remaining oil was placed under vacuum to give a yellow solid (87.7 mg, 70%); 1 H NMR (300 MHz, CDCl 3 ) δ 7.42 (s, 5H), 6.88 (br s, 1H), 6.85 (br s, 1H), 5.42 (AB q, 2H), 5.15 (s, 2H), 4.79-4.72 (m, 1H), 4.55-4.47 (m, 1H), 3.67 (q, 1H), 2.37-2.26 (m, 1H), 1.94-1.75 (m, 3H), 1.46 (d, 3H), 1.12-1.01 (dd, 6H), 0.80-0.74 (dd, 6H); FABMS 460.3 (M+K), 443.2 (M+Na), 421.3 (M+H).
Cbz-Aip-Leu-Pro OTMSe.
Cbz-Aip-Leu-OH (36.7 mg, 85.0 μmol) was dissolved in dry CH 2 Cl 2 (1.0 mL) and the solution was cooled to 0° C. DCC (26.1 mg, 0.13 mmol) was added and the mixture was stirred for 30 min at 0° C. Pro-OTMSe (18.5 mg, 85.0 μmol) in CH 2 Cl 2 (1.0 mL) was added and the solution was stirred for 30 min at 0° C. and at rt overnight. The residue was concentrated and taken up in ethyl acetate. The solution was washed with aqueous citric acid, aqueous sodium bicarbonate, dried over MgSO 4 , and concentrated. The residue was purified by column chromatography, eluting with CH 2 Cl 2 /MeOH (95:5) to give a yellow oil (34.0 mg, 65%); 1 H NMR (300 MHz, CDCl 3 ) δ 7.47 (s, 5H), 6.85 (br s, 1H), 6.84 (br s, 1H), 5.45 (AB q, 2H), 5.13 (s 2H), 4.80-4.73 (m, 1H), 4.53-4.47 (m, 1H), 4.24-4.01 (dt, 4H), 3.63 (q, 1H), 2.35-2.23 (m, 1H), 1.94-1.75 (m, 3H), 1.46 (d, 3H), 1.12-1.01 (dd, 6H), 0.80-0.74 (dd, 6H), 0.00 (s, 9H); FABMS 656.3 (M+K), 640.2 (M+Na), 618.3 (M+H).
H-Aip-Leu-Pro-OTMSe.
The protected tripeptide (24.9 mg, 40.3 μmol) was dissolved in isopropyl alcohol (1.00 mL) and 10% Pd/C catalyst (0.99 mg) was added. The solution was hydrogenated for 3 h, the catalyst was removed by filtration over celite, and the solvent removed to afford the desired product (15.6 mg. 82%), 1 H NMR (300 MHz, CDCl 3 ) δ 6.84 (br s, 1H). 6.82 (br s, 1H), 5.41 (AB q, 2H), 5.09 (s, 2H), 4.82-4.71 (m, 1H), 4.56-4.48 (m, 1H), 4.25-4.00 (dt, 4H), 3.62 (q, 1H), 2.37-2.23 (m, 1H), 1.95-1.75 (m, 3H), 1.47 (d, 3H), 1.14-1.01 (dd, 6H), 0.82-0.74 (dd, 6H), 0.00 (s, 9H); FABMS m/z 506.3 (M+Na); 484.3 (M+H).
Bos-Ist-Aip-Leu-Pro-OTMSe.
Boc-Ist-OH (7.51 mg, 27.3 μmol) was dissolved in dry CH 2 Cl 2 (1.0 mL) and the solution was cooled to 0° C. DCC (10.52 mg, 0.089 mmol) was added and then mixture was stirred for 30 min at 0° C. H-Aip-Leu-Pro-OTMSe (3.28 mg, 27.3 μmol) in CH 2 Cl 2 (1.0 mL) was added and the solution was stirred for 30 min at 0° C. and at rt overnight. The residue was concentrated and taken up in ethyl acetate. The solution was washed with aqueous citric acid, aqueous sodium bicarbonate, dried over MgSO 4 , and concentrated. The residue was purified by reversed phase HPLC using a gradient system of CH 3 CH/H 2 O (45.0 mg, 83%); FABMS 741.5 (M+H), 641.5 (M−Boc).
H-Ist-Aip-Leu-Pro-OTMSe (6).
The protected tetrapeptide (30.0 mg, 0.045 mmol) was dissolved in MeOH (2 mL) and a steady current of HCl was passed through the solution for approximately 20 min. Evaporation of the solvent produced a yellow oil which was purified by reversed phase column chromatography eluting with CH 3 CN/H 2 O (gradient system) to give 22.0 mg (87%) of the compound as a yellow powder; FABMS 641.5 (M+H), see FIG. 2 .
Cbz-D-MeLeu-Thr[O-N,O—Me 2 TyrBoc)]-Ist-Aip-Leu-Pro-OTMSe (4).
Acid 5 (21.9 mg, 28.4 μmol) and N-methylmorpholine (6.4 μL) were dissolved in dry THF (0.4 mL), and the solution was cooled to 0° C. A solution of amine 6 (16.2 mg, 28.4 μmol) and HOBT (0.81 mg) in 1.5 mL of the dry THF were added. This suspension was mixed with a cold solution of EDCI (9.76 mg, 51.1 μmol) in 0.5 mL of THF. The reaction mixture was stirred at 0° C. for ½ h. The solution was then concentrated to 0.50 mL, kept at 0° C. for 24 h, the diluted with ether. The organic layer was washed with 10% HCl, 5% NaHCO 3 , and saturated NaCl solutions. The organic layer was dried (Na 2 SO 4 ), filtered, and concentrated. The crude oil was purified by reversed phase HPLC using a gradient system of CH 3 CN/H 2 O to give 11.6 mg (32%) of the linear heptapeptide, see FIG. 3; FABMS 1294.2 (M+H); 1194/2 (M−Boc), see FIG. 4; HRFABMS Calcd for C 67 H 108 N 7 O 16 Si (M+H) 1294.7649, Found 1294.7644.
Cbs-D-MeLeu-Thr-N,O—MeTyr-Ist-Aip-Leu-ProOH (7).
1M TBAF (2.1 μL) was added to a solution of the fully protected linear heptapeptide (5.80 mg, 4.50 μmol) in dry THF. After 2 h stirring at 0° C., the mixture was diluted with distilled water and concentrated to a small volume. The remaining solution was diluted with EtOAc and 2N HCl was added to render the aqueous layer acidic. The EtOAc layer was washed three times with water and dried with Na 2 SO 4 . Evaporation of the solvent gave the deprotected heptapeptide in quantitative yield (4.3 mg); FABMS 1194.2 (M+H); 1094.2 (M−Boc), see FIG. 5; HRFABMS Calcd for C 62 H 100 N 7 O 14 Si (M+H) 1194.7098, Found 1194.7089. The deprotected heptapeptide was subjected to a solution of 1M TFA (9.57) μL). After 1 h stirring at room temperature, the solvent was evaporated. Water was added to the residue and the aqueous solution was extracted with EtOAc. The extract was washed with 5% NaHCO 3 and water, and dried over Na 2 SO 4 . The compound was purified by reversed phase HPLC using a gradient system of CH 3 CN/H 2 O see FIG. 6) to give 3.58 mg (91%); FABMS 1094.2 (M+H), see FIG. 7 .
AipDidemnin A (8).
The linear heptapeptide 7 (3.58 mg, 3.28 μmol) was dissolved in dry THF (0.08 mL), and the solution was cooled to 0° C. EDCI (0.63 mg, 3.28 μmol) in 1.0 mL of THF was added, and the reaction mixture was stirred at 0° C. for 2 h. After storage in the freezer overnight, the solution was diluted with ether. The organic layer was washed with 10% HCl, 5% NaHCO 3 , and saturated NaCl solutions. The organic layer was dried (Na 2 SO 4 ), filtered, and concentrated. The crude oil was purified by reversed phase HPLC using a gradient system of CH 3 CN/H 2 O to give 1.41 mg (40%) of the protected analogue 3; FABMS 1076.7 (M+H), see FIG. 8; HRFABMS Calcd for C 57 H 86 N 7 O 13 (M+H) 1076.6284, Found 1076.6283. The protected compound 3 (1.41 mg) was dissolved in isopropyl alcohol (0.50 mL) and 10% Pd/C catalyst (0.50 mg) was added. The solution was hydrogenated for 3 h. At this time, the catalyst was removed by filtration over celite and the solvent removed to afford the desired compound 8, AipDidemnin A.
TABLE I
Antiviral Activities of Amino Hip Didemnin Analogues a
HSV/CV-1
Compound
ng/mL
Cytotoxicity b
Activity c
Cbz-[Aip 3 ]-Didemnin A
100
10
+
(new compound)
50
8
+
20
0
+
10
0
−
Didemnin A (1)
100
0
+
50
0
+
20
0
+
10
0
−
Footnotes: a Test performed by Dr. G. R. Wilson in this laboratory; b 0-least toxic to 16 (toxic); c +++ complete inhibition, ++ strong inhibition, + moderate inhibition, − no inhibition.
TABLE II
L1210 Cytotoxicity of Amino Hip Didemnin Analogues a
Dose (ng/mL)
Compounds
250
25
2.5
0.25
Inhibition
(%)
IC 50 (ng/mL)
Didemnin A (1)
100
70
0
0
75
Cbz-[Aip 3 ]-
100
87
0
0
85
Didemnin A (3) b
[Aip 3 ]-
98
20
0
0
100
Didemnin A (8) b
Footnotes: a Test performed by Dr. G. R. Wilson in this laboratory; b new compounds.
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30. Hamada, Y.; Kondo, Y.; Shibata, M.; Shiori, T. J. Am. Chem. Soc ., 1989, 111, 669. | Disclosed is a synthetic method for the preparation of analogs of Didemnin A (1), particularly the Amino-Hip analog of Didemnin A, also known as “AipDidemnin A” (8). These compounds have the following structures: | 2 |
FIELD OF THE INVENTION
This invention relates to azeotrope-like mixtures of 1,1,2-trichloro-1,2,2-trifluoroethane, methanol, nitromethane and at least 14.5 weight percent dimethoxymethane (also known as methylal). These mixtures are useful as vapor degreasing agents and as solvents in a variety of industrial cleaning applications including defluxing of printed circuit boards.
BACKGROUND OF THE INVENTION
Vapor degreasing and solvent cleaning with fluorocarbon based solvents have found widespread use in industry for the degreasing and otherwise cleaning of solid surfaces, especially intricate parts and difficult to remove soils.
In its simplest form, vapor degreasing or solvent cleaning consists of exposing a room-temperature object to be cleaned to the vapors of a boiling solvent. Vapors condensing on the object provide clean distilled solvent to wash away grease or other contamination. Final evaporation of solvent from the object leaves behind no residue as would be the case where the object is simply washed in liquid solvent.
For difficult to remove soils where elevated temperature is necessary to improve the cleaning action of the solvent, or for large volume assembly line operations where the cleaning of metal parts and assemblies must be done efficiently and quickly, the conventional operation of a vapor degreaser consists of immersing the part to be cleaned in a sump of boiling solvent which removes the bulk of the soil, thereafter immersing the part in a sump containing freshly distilled solvent near room temperature, and finally exposing the part to solvent vapors over the boiling sump which condense on the cleaned part. In addition, the part can also be sprayed with distilled solvent before final rinsing.
Vapor degreasers suitable in the above-described operations are well known in the art. For example, Sherliker et al. in U.S. Pat. No. 3,085,918 disclose such suitable vapor degreasers comprising a boiling sump, a clean sump, a water separator, and other ancillary equipment.
Fluorocarbon solvents, such as trichlorotrifluoroethane, have attained widespread use in recent years as effective, nontoxic, and nonflammable agents useful in degreasing applications and other solvent cleaning applications. Trichlorotrifluoroethane has been found to have satisfactory solvent power for greases, oils, waxes and the like. It has therefore found widespread use for cleaning electric motors, compressors, heavy metal parts, delicate precision metal parts, printed circuit boards, gyroscopes, guidance systems, aerospace and missile hardware, aluminum parts and the like.
The art has looked towards azeotropic compositions including the desired fluorocarbon components such as trichlorotrifluoroethane which include components which contribute additionally desired characteristics, such as polar functionality, increased solvency power, and stabilizers. Azeotropic compositions are desired because they exhibit a minimum boiling point and do not fractionate upon boiling. This is desirable because in the previously described vapor degreasing equipment with which these solvents are employed, redistilled material is generated for final rinse-cleaning. Thus, the vapor degreasing system acts as a still. Unless the solvent composition exhibits a constant boiling point, i.e., is an azeotrope or is azeotrope-like, fractionation will occur and undesirable solvent distribution may act to upset the cleaning and safety of processing. Preferential evaporation of the more volatile components of the solvent mixtures, which would be the case if they were not azeotrope or azeotrope-like, would result in mixtures with changed compositions which may have less desirable properties, such as lower solvency towards soils, less inertness towards metal, plastic or elastomer components, and increased flammability and toxicity.
A number of 1,1,2-trichloro-1,2,2-trifluoroethane based azeotrope compositions have been discovered which have been tested and in some cases employed as solvents for miscellaneous vapor degreasing and defluxing applications. For example, U.S. Pat. No. 3,573,213 discloses the azeotrope of 1,1,2-trichloro-1,2,2-trifluoroethane and nitromethane; U.S. Pat. No. 2,999,816 discloses an azeotropic composition of 1,1,2-trichloro-1,2,2-trifluoroethane and methyl alcohol; U.S. Pat. No. 3,960,746 discloses azeotrope-like compositions of 1,1,2-trichloro-1,2,2-trifluoroethane, methanol and nitromethane. U.S. Pat. No. 4,096,083 discloses azeotrope-like compositions containing 1,1,2-trichloro-1,2,2-trifluoroethane, dimethoxymethane and acetone.
The art is continually seeking new fluorocarbon based azeotropic mixtures or azeotrope-like mixtures which offer alternatives for new and special applications for vapor degreasing and other cleaning applications.
It is accordingly an object of this invention to provide novel azeotrope-like compositions based on 1,1,2-trichloro-1,2,2-trifluoroethane which have good solvency power and other desirable properties for vapor degreasing and other solvent cleaning applications.
Another object of the invention is to provide novel constant boiling or essentially constant boiling solvents which are liquid at room temperature, will not fractionate under conditions of use and also have the foregoing advantages.
A further object is to provide azeotrope-like compositions which are nonflammable both in the liquid phase and the vapor phase. These and other objects and features of the invention will become more evident from the description which follows.
DESCRIPTION OF THE INVENTION
In accordance with the invention, novel azeotrope-like compositions have been discovered comprising 1,1,2-trichloro-1,2,2-trifluoroethane, methanol, nitromethane and dimethoxymethane.
In a preferred embodiment of the invention, the azeotrope-like compositions comprise from about 73.8 to about 80.4 weight percent of 1,1,2-trichloro-1,2,2-trifluoroethane, from about 4.9 to about 5.8 weight percent of methanol, from about 0.02 to about 0.2 weight percent of nitromethane and from about 14.5 to about 20.3 weight percent of dimethoxymethane.
In another preferred embodiment of the invention, the azeotrope-like compositions comprise from about 76.5 to about 80.3 weight percent of 1,1,2-trichloro-1,2,2-trifluoroethane, from about 5.0 to about 5.3 weight percent of methanol, from about 0.02 to about 0.2 weight percent of nitromethane and from about 14.5 to about 18.5 weight percent of dimethoxymethane.
In yet another preferred embodiment of the invention the azeotrope-like compositions comprise from about 79.2 to about 80.3 weight percent of 1,1,2-trichloro-1,2,2-trifluoroethane, from about 5.0 to about 5.3 weight percent of methanol, from about 0.02 to about 0.2 weight percent of nitromethane and from about 14.5 to about 15.2 weight percent of dimethoxymethane.
Such compositions possess constant or essentially constant boiling points of about 39.7° C. at 760 mm Hg. The precise azeotrope composition has not been determined but has been ascertained to be within the above ranges. Regardless of where the true azeotrope lies, all compositions within the indicated ranges, as well as certain compositions outside the indicated ranges, are azeotrope-like, as defined more particularly below.
It has been found that these azeotrope-like compositions are stable, safe to use and that the preferred compositions of the invention are nonflammable (exhibit no flash point when tested by the Tag Open Cup test method-ASTM D 1310-86) and exhibit excellent solvency power. These compositions have been found to be particularly effective when employed in conventional degreasing units for the dissolution of rosin fluxes and the cleaning of such fluxes from printed circuit boards.
From fundamental principles, the thermodynamic state of a system (pure fluid or mixture) is defined by four variables: pressure, temperature, liquid compositions and vapor compositions, or P-T-X-Y, respectively. An azeotrope is a unique characteristic of a system of two or more components where X and Y are equal at the stated P and T. In practice, this means that the components of a mixture cannot be separated during distillation or in vapor phase solvent cleaning when that distillation is carried out at a fixed T (the boiling point of the mixture) and a fixed P (atmospheric pressure).
For the purpose of this discussion, by azeotrope-like composition is intended to mean that the composition behaves like a true azeotrope in terms of its constant boiling characteristics or tendency not to fractionate upon boiling or evaporation. Such composition may or may not be a true azeotrope. Thus, in such compositions, the composition of the vapor formed during boiling or evaporation is identical or substantially identical to the original liquid composition. Hence, during boiling or evaporation, the liquid composition, if it changes at all, changes only to a minimal or negligible extent. This is to be contrasted with non-azeotrope-like compositions in which during boiling or evaporation, the liquid composition changes to a substantial degree.
Thus, in order to determine whether a candidate mixture is "azeotrope-like" within the meaning of this invention, one only has to distill a sample thereof under conditions (i.e. resolution--number of plates) which would be expected to separate the mixture into its separate components. If the mixture is non-azeotropic or non-azeotropic-like, the mixture will fractionate, i.e. separate into its various components with the lowest boiling component distilling off first, and so on. If the mixture is azeotrope-like, some finite amount of a first distillation cut will be obtained which contains all of the mixture components and which is constant boiling or behaves as a single substance. This phenomenon cannot occur if the mixture is not azeotrope-like i.e., it is not part of an azeotropic system. If the degree of fractionation of the candidate mixture is unduly great, then a composition closer to the true azeotrope must be selected to minimize fractionation. Of course, upon distillation of an azeotrope-like composition such as in a vapor degreaser, the true azeotrope will form and tend to concentrate.
It follows from the above that another characteristic of azeotrope-like compositions is that there is a range of compositions containing the same components in varying proportions which are azeotrope-like. All such compositions are intended to be covered by the term azeotrope-like as used herein. As an example, it is well known that at differing pressures, the composition of a given azeotrope will vary at least slightly and changes in distillation pressures also change, at least slightly, the distillation temperatures. Thus, an azeotrope of A and B represents a unique type of relationship but with a variable composition depending on temperature and/or pressure. Accordingly, another way of defining azeotrope-like within the meaning of this invention is to state that such mixtures boil within ±1° C. (at about 760 mm Hg) of the boiling point of the preferred compositions disclosed herein (i.e. closest to the boiling point of the true azeotrope of about 39.7° C. at about 760 mm Hg). The preferred azeotrope-like compositions boil within ±0.6° C. at about 760 mm Hg.
The 1,1,2-trichloro-1,2,2-trifluoroethane, methanol, nitromethane and dimethoxymethane components of the novel solvent azeotrope-like compositions of the invention are all commercially available. Preferably they should be used in sufficiently high purity so as to avoid the introduction of adverse influences upon the solvency properties or constant boiling properties of the system. A suitable grade of 1,1,2-trichloro-1,2,2-trifluoroethane, for example, is sold by Allied-Signal Inc. under the trademark GENESOLV® D.
EXAMPLES 1-2
The azeotrope-like compositions of the invention were determined through the use of distillation techniques designed to provide higher rectification of the distillate than found in most vapor degreaser systems. For this purpose a five theoretical plate Oldershaw distillation column was used with a cold water condensed, automatic liquid dividing head. Typically, approximately 350 cc of liquid were charged to the distillation pot. The liquid was a mixture comprised of various combinations of 1,1,2-trichloro-1,2,2-trifluoroethane, methanol, nitromethane and dimethoxymethane. The mixture was heated at total reflux for about one hour to ensure equilibration. For most of the runs, the distillate was obtained using a 3:1 reflux ratio at a boil-up rate of 250-300 grams per hour. Approximately 120 cc of product were distilled and 4 approximately equivalent sized overhead cuts were collected. The vapor temperature (of the distillate), pot temperature, and barometric pressure were monitored. A constant boiling fraction was collected and analyzed by gas chromatography to determine the weight percentages of its components.
To normalize observed boiling points during different days to 760 mm of mercury pressure, the approximate normal boiling points of 1,1,2-trichloro-1,2,2-trifluoroethane rich mixtures were estimated by applying a barometric correction factor of about 26 mm Hg/°C., to the observed values. However, it is to be noted that this corrected boiling point is generally accurate up to ±0.4° C. and serves only as a rough comparison of boiling points determined on different days. By the above-described method, it was discovered that a constant boiling mixture boiling at ±0.1° C. at 760 mm Hg was formed for compositions comprising about 76.5 to about 80.3 weight percent 1,1,2-trichloro-1,2,2-trifluoroethane (FC-113), about 5.0 to about 5.2 weight percent methanol (MeOH), about 0.05 to about 0.2 weight percent nitromethane, and about 14.5 to about 18.5 weight percent dimethoxymethane. Supporting distillation data for the mixtures studied are shown in Table I.
TABLE I______________________________________Starting Material (wt. %)Example(Distil-lation) FC-113 MeOH Dimethoxymethane Nitromethane______________________________________1 73.8 5.8 20.3 0.22 79.8 4.9 15.1 0.3______________________________________Distillate(Distil-lation) FC-113 MeOH Dimethoxymethane Nitromethane______________________________________1 76.5 5.0 18.5 0.022 80.3 5.2 14.5 0.05______________________________________ Boiling Point(Distil- Boiling Barometric Corrected tolation) Point (°C.) Pressure (mm Hg) 760 mm Hg______________________________________1 39.5 736.9 39.82 39.2 742.0 39.5 Mean 39.7° C. ± 0.2______________________________________
From the above examples, it is readily apparent that additional constant boiling or essentially constant boiling mixtures of the same components can readily be identified by any one of ordinary skill in this art by the method described. No attempt was made to fully characterize and define the true azeotrope in the system comprising 1,1,2-trichloro-1,2,2-trifluoroethane, methanol, nitromethane and dimethoxymethane, nor the outer limits of its compositional ranges which are constant boiling. Anyone skilled in the art can readily ascertain other constant boiling or essentially constant boiling mixtures.
EXAMPLE 3
To illustrate the azeotrope-like nature of the mixtures of this invention under conditions of actual use in vapor degreasing operation, a vapor phase degreasing machine was charged with a preferred azeotrope-like mixture in accordance with the invention, comprising about 79.1 weight percent 1,1,2-trichloro-1,2,2-trifluoroethane (FC-113), about 5.1 weight percent methanol, about 15.2 weight percent dimethoxymethane, and about 0.2 weight percent nitromethane. The mixture was evaluated for its constant boiling or non-segregating characteristics. The vapor phase degreasing machine utilized was a small water-cooled, three-sump vapor phase degreaser, which represents a type of system configuration comparable to machine types in the field today which would present the most rigorous test of solvent segregating behavior. Specifically, the degreaser employed to demonstrate the invention contains two overflowing rinse-sumps and a boil-sump. The boil-sump is electrically heated, and contains a low-level shut-off switch. Solvent vapors in the degreaser are condensed on water-cooled stainless-steel coils. The still is fed by gravity from the boil-sump. Condensate from the still is returned to the first rinse-sump, also by gravity. The capacity of the unit is approximately 1.5 gallons. This degreaser is very similar to Baron Blakeslee 2 LLV 3-sump degreasers which are quite commonly used in commercial establishments.
The solvent charge was brought to reflux and the compositions in the rinse sump containing the clear condensate from the still, the work sump containing the overflow from the rinse sump, and the boil sump where the overflow from the work sump is brought to the mixture boiling point were determined with a Perkin Elmer Sigma 3 gas chromatograph. The temperature of the liquid in the boil sump and still was monitored with a thermocouple temperature sensing device accurate to ±0.2° C. Refluxing was continued for 48 hours and sump compositions were monitored throughout this time. If the mixture was not azeotrope-like, the high boiling components would very quickly concentrate in the still and be depleted in the rinse sump. This did not happen. This result indicates that the compositions of this invention will not segregate in any types of large-scale commercial vapor degreasers, thereby avoiding potential safety, performance, and handling problems. The preferred composition tested was also found to not have a flash point according to recommended procedures ASTM D-56 (Tag Closed Cup) and ASTM D-1310 (Tag Open Cup). | Azeotrope-like compositions comprising 1,1,2-trichloro-1,2,2-trifluoroethane, methanol, nitromethane and dimethoxymethane are stable and have utility as degreasing agents and as solvents in a variety of industrial cleaning applications including the defluxing of printed circuit boards. | 2 |
INDEX TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 09/945,908 filed Sep. 4, 2001.
FIELD OF THE INVENTION
[0002] An apparatus and method for detecting the clandestine placement of an illicit chemical present in a beverage is disclosed and described. More particularly, an apparatus and method by which an individual may safely and rapidly perform a qualitative assay to determine if a beverage has been subject to unwanted addition of extraneous chemical entities.
BACKGROUND OF THE INVENTION
[0003] There is growing concern over a relatively new crime, date rape. The perpetrators of this heinous act have resorted to approaching their victims at parties, bars and social gatherings, and succeeded in the clandestine placement of various chemical entities into the beverages of their victims. The victim, unaware that tampering has taken place, consumes the beverage and is rendered into a state such that defense against their attacker is a virtual impossibility. There are many such chemical entities at the disposal of the rapist. They have been collectively termed date rape drugs. These include, but are not limited to: Flunitrazepam (also known as Rohypnol), Ketamine, and Gamma hyroxybutyrate (GHB). These and many others can greatly affect the victims' consciousness and ability to defend in the event of an attack. Chemical testing for these substances is very well documented. However, what is not available is an apparatus and means for individuals to test their beverages, in their social setting, if they suspect tampering has taken place.
[0004] It is the object of the invention to provide an apparatus and method for detecting a clandestine chemical entity in a beverage that is easy to use, reliable, safe, and inexpensive to mass-produce.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0005] The apparatus is intended for the rapid, easy and reliable testing of date rape drugs. Date rape drugs are defined as those substances, which are used by an assailant to render the victim into a state of consciousness, which may be conscious, semi-conscious or unconscious, such that the victim loses the ability of self-defense. These date rape drugs can include but are not limited to: Flunitrazepam, which is commonly known as Rohypnol or “Ruffies,” 4-Hydroxybutanoic acid, also known as gamma hydroxy butyrate (GHB) and Ketamine. The apparatus is composed with one or more solid, chemical calorimetric indicators embedded in the surface of the invention. The apparatus should be of suitable porosity so as to allow the flow of the test solution to reach said colorimetric indicator. The invention can be used in, but are not limited to: a cocktail napkin, beverage coaster, placemat, menu, match book, drink carrier, flyer, coupon, personal test kit or even a business card. The manufacturing of the apparatus is to be in a manner such that the test regions are clearly discernable to the user. The apparatus can even be manufactured in a manner to include an advertisement or a logo. The method of use would comprise the steps of: locating a specific region on the apparatus, removing a drop of beverage, placing the drop within a marked region on the apparatus, observing a colorimetric indication within the region wherein the drop was placed. The removal can be done using a straw, a swizzle stick or even one's finger. Each region would be specific for an individual compound. The invention may contain one or more marked regions in order to test for more than one illicit substance. A qualitative calorimetric result would then instantly be observed. These calorimetric indicator test spots provide for colors that are bright and distinctive. In doing so, the test result would not be confused with being a byproduct of the beverage color.
[0006] The testing for illicit substances is well known in the chemical arts. Flunitrazepam, which is commonly known as Rohypnol or “Ruffies” is a member of the class of compounds known as benzodiazopines. Either a reaction with Zimmermann's reagent, or reacting with a platinum/potassium iodide test system can detect this class of compound. 4-Hydroxybutanoic acid, also known as gamma hydroxy butyrate (GHB) is a commonly known anesthetic. It can be identified in a reaction system with bromo cresol purple. Ketamine is another anesthetic for which the current invention can be applied. It can be identified using cobalt thiocyanate.
[0007] Another embodiment provides for the test material to be deposited on a solid, non-porous substrate, such as a plate or glass.
[0008] These are provided by way of example and are in no means intended to be limiting the scope of the invention.
[0009] While the invention has been described in its preferred form or embodiment with some degree of particularity, it is understood that this description has been given only by way of example and that numerous changes in the details of construction, fabrication, and use, including the combination and arrangement of parts, may be made without departing from the spirit and scope of the invention. | An apparatus and method for detecting the clandestine placement of an illicit chemical present in a beverage is disclosed and described. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of co-pending Ser. No. 309,146 filed Nov. 24, 1972.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to feeding groups of articles. In one of its aspects, the invention relates to an improved system for filling containers with predetermined articles to preclude dumping incomplete groups of articles into the containers.
2. State of the Prior Art
Produce, such as carrots, are commonly sold in bags which contain a predetermined weight of the produce. For example, carrots are commonly sold in one pound plastic bags. The bagging of produce in one pound bags creates certain efficiencies in a supermarket but requires the wholesaler to package his products.
Weighing and bagging the produce is tedious, time consuming and costly for the wholesaler. Machines are presently available for bagging the produce when the produce can be fed in weighted quantities in a timed sequence to the bagging apparatus. An example of such a machine is the Formost Produce Bagger manufactured by Formost Packaging Machines, Inc., Seattle, Wash. However, weighing of the product by hand labor and feeding the same to a conveyor for the bagging operation is also tedious, time consuming and costly.
It has been proposed to use a weighing machine which could weigh the product until a desired weight is obtained and then dump the same into containers on a conveyor for feeding through the packaging machine. However, difficulty is encountered in keeping up with the packaging machine when a single weigh hopper is used. When plural weigh hoppers are used, difficulties are encountered in dropping more than one load of produce into a given container and in having some containers on the conveyor without any product.
In U.S. Pat. No. 2,698,692 to Jones, et al., there is disclosed a system for feeding articles to a plurality of retainers on a conveyor which is moved beneath a plurality of separate stacking means. Each of the stacking means collects a predetermined number of articles in a given stack and thereafter moves the stack of articles into one of two storage compartments. The articles are dropped from the storage compartment in synchronized movement with preselected containers on the conveyor. Positioning cams extending from the bottom of the conveyor which is beneath the storage compartments and actuate release of a stack of articles from a given storage compartment into a particular conveyor retainer.
U.S. Pat. No. 3,807,123 to Kihnke discloses a system for filling bags with a predetermined weight of articles, such as carrots, by feeding the articles seriatim to a weighing means and thereafter dumping the articles into the bag after a predetermined weight has been received in the weighing means. A gate extends across the path of articles fed to the weighing means as soon as a predetermined weight has been received therein.
In copending U.S. Patent Application Ser. No. 309,146, there is disclosed and claimed an article feeding apparatus wherein articles fed through a plurality of weighing hoppers are discharged into empty containers which pass therebeneath. In the disclosed embodiment, the hoppers dump in only preselected containers. In this system, occasionally hoppers will not be filled and the timing of the conveyor with the feed mechanism is such that the conveyor does not move at an optimum speed. Further, occasionally, a particular hopper will fill after the conveyor has stopped beneath the hopper and the hopper will thereafter discharge into the container. However, on occasion, sufficient time does not exist to complete the dump cycle which results in spilling of the articles and/or premature closing of the hoppers.
It has been suggested to put a photocell on the end hopper in the series to sense the presence of an empty container and to dump the hopper if the container is empty. However, if the photocell sees the article dumping in the hopper, it tends to cause the photocell operated switch to open and thereby prematurely terminate dumping of the hopper.
SUMMARY OF THE INVENTION
In accordance with the invention, there is provided an apparatus for feeding groups of articles to a packaging operation in a timed continuous sequence wherein each of the groups of articles have a minimum weight. The apparatus has a plurality of weighing means, each of the weighing means including a weigh hopper for holding a plurality of articles, means for weighing articles in the weigh hopper and means to dump articles from the weigh hopper. The weigh hoppers are aligned in a row along a predetermined path beneath which a conveyor moves with a plurality of containers adapted to hold and receive a quantity of the articles. Means are provided for feeding the articles seriatim to each of the weighing means to accumulate a minimal weight of the articles in the weigh hopper and means are provided for blocking further feeding of the articles to the weighing means after a minimum weight of the articles is present in each of the weigh hoppers. The conveyor is intermittently driven beneath the weigh hoppers. Means are provided for controlling each of the dumping means of the weighing means to dump articles in each of the weight hoppers only in an empty container so that only one group of articles is dumped into each of the containers and means are provided to prevent operation of the dumping means in a given hopper which has not attained the predetermined weight of the articles at the time that the conveyor stops. Further, a photocell is positioned beneath at least one hopper and preferably beneath all but the first hopper in the series to sense the presence of an empty container therebeneath. Means are provided to actuate dumping of the hopper, if full, responsive to sensing of the empty container. Further, means are provided to prevent premature termination of the dumping of the hopper due to the detection of an article falling into the container beneath the one weigh hopper at the commencement of the dumping operation.
The control means desirably includes a circuit having a switch means operated by the weighing means to close when the weight of the article reaches a predetermined minimum, a first actuating means in the circuit in series with the first switch to operate the dumping means when the current flows therethrough and a second switch means in the circuit in series with the first switch and the first actuating means, the second switch adapted to close when an empty container is beneath a given weigh hopper.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described with reference to the accompanying drawings in which:
FIG. 1 is a plan view of an apparatus for feeding and bagging articles such as carrots according to the invention;
FIG. 2 is a sectional view seen along lines 2--2 of FIG. 1;
FIG. 3 is an enlarged perspective view of a portion of the apparatus illustrating a diverter mechanism;
FIG. 4 is a partial sectional view taken along lines 4--4 of FIG. 2 and illustrating the dumping mechanism;
FIG. 5 is a perspective view of a portion of the conveyor illustrating the timing mechanism;
FIG. 6 is a schematic view of a portion of the electrical control system according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and to FIG. 1 in particular, there is illustrated an apparatus for feeding articles such as carrots to a bagging operation. For the sake of description of the apparatus, a carrot feeding and bagging operation will be described although it is to be understood that other articles or produce of similar nature can be fed and bagged in accordance with the invention.
Carrots 12 in a hopper 14 are taken therefrom by an elevator 16 and are deposited on a vibratory corrugated tray 18. Carrots 12 are singulated and divided into a plurality of different streams of carrots which are fed to six lanes 20, 22, 24, 26, 28 and 30. Each of the lanes has conveyor belts 32, 34, and 36 which are desirably driven at increasingly faster speeds to provide greater separation and singulation between the carrots fed to each lane. A conveyor belt 36 in each lane feeds the carrots to a weighing and dumping station 38 which collects a predetermined weight of carrots, for example one pound, and then dumps the carrots into a container 42 on a continuous conveyor 40. Each container 42 is secured at either side to continuous chains 44. The containers 42 are moved intermittently in timed relationship beneath each of the weighing and dumping stations 38 and the dumping from each of the weighing and dumping stations 38 is controlled so that the carrots at a given dumping station are dumped into a predetermined container or group of containers. One and only one load of carrots is dumped in each container 42. At an opposite end of the conveyor 40, a bagging apparatus 46 is provided for bagging the carrots. The bagging apparatus 46 can be any suitable bagging apparatus, but preferably is the type of bagging apparatus sold by Formost Packaging Machines, Inc., of Seattle, Wash.. Such an apparatus includes a pusher arm 48 which pushes the carrots from the containers 42 into a bag and carries the bag to a conveyor 50. The bags are then tied with a bag tier 52 as the filled bags move along the conveyor 50.
A diverter mechanism 54 is provided at each of the lanes 20 through 30 at the weighing and dumping stations 38 to divert the carrots on the conveyor belts 36 after a predetermined weight of carrots has been received by the weighing and dumping stations 38 and prior to the time when the carrots are dumped into the containers 42 on the conveyor 40.
Reference is now made to FIG. 2 for a more detailed discussion of the carrot feeding mechanism. The hopper 14 includes a container 56 which is partially filled with water 58. Water is withdrawn from a front bottom portion of the container 56 and pumped through a line 59 to a plurality of discharge nozzles 60 at the back part of the hopper, to cause flow of the water toward the elevator 16. The carrots are thus dumped into the container 56 and are moved by the water flow to the elevator 16.
The elevator 16 comprises a continuous flexible web 62 formed, for example, of open mesh metal material, and having a plurality of transverse projecting wooden cleats 64. The cleats are sufficiently wide to support a single width of carrots transverse to the length of the web 62. A pair of sprockets 66 and 68 support the web 62 for continuous movement in the direction of the arrows. Conventional means (not shown) are provided for driving the sprocket 68 to move the flexible web 62 in the desired direction.
The vibratory corrugated tray 18 is formed from a corrugated plate 70 and is supported by arms 74 and 76 which are driven by a conventional vibratory motor 72. The motor drives the corrugated plate 70 in a vibratory manner to separate the carrots into six paths formed by the various corrugations and to move the carrots down the plate 70 to the conveyor belts 32.
As seen in FIG. 2, conveyor belt 32 is supported by rollers 80 and 82, one of which may be driven by suitable driving means (not shown). Conveyor belt 34 is a continuous web which is supported by rollers 86 and 88, one of which may also be driven by suitable means (not shown). Similarly, the conveyor belt 36 is a continuous web supported by rollers 92 and 94 which are driven by suitable means (not shown). Retaining guides 96 and 98 are provided along the conveyor belts 32, 34, and 36 to retain the carrots thereon as they move down the lanes to the weighing and dumping stations 38.
A carrot return plate 100 is provided beneath the conveyor belt 36 and has upstanding projections 102 which extend into areas between each of the lanes 20 through 30. A return conveyor 104 is provided at the bottom of the carrot return plate 100 to receive the carrots sliding down the plate 100 and to convey them to a second carrot return conveyor 106. The carrots are dumped from the return conveyor 104 onto the return conveyor 106 which moves the carrots to still a third return conveyor 108, which returns the carrots to the hopper 14.
Reference is now made to FIG. 3 for a description of a diverter mechanism. For purposes of simplicity and brevity, only one such diverter mechanism will be described. It is to be understood, however, that each of the lanes 20 through 30 has a similar diverter mechanism which operates in a substantially identical manner.
The diverter mechanism 54 comprises fence 110 which is pivotably supported on a vertical pivot pin 112 alongside of the conveyor belt 36. The fence is movable on pin 112 from a position adjacent to the conveyor belt 36, allowing passage of carrots thereby, to a position across the conveyor belt 36, diverting the carrots to the side into contact with the upstanding projection 102 of the carrot return plate 100. This latter position is illustrated in FIG. 3. An upstanding plate 114 at the upper porion of the fence 100 is pivotably secured to the outer end of an extendible rod 118 of fluid cylinder 116 through a pivotable coupling 120. The cylinder 116 is rigidly supported by the supports 122 on frame members 123. In operation, then fence 110 normally is positioned alongside of the conveyor belt 36 to permit carrots to pass into the weighing and dumping station 38. When the weighing station is full, the extendible rod 118 is extended from the cylinder 116 to rotate the fence 110 about its pivotable mounting 112 across the conveyor belt 36. The carrots passing along the lanes thereafter contact the fence 110 and are diverted to plate 102 which guides the carrots to the conveyor 104.
Reference is now made to FIG. 4 for a description of the dumping and loading mechanism. The dumping and weighing stations 38 can be any suitable means to receive and accumulate a plurality of articles, to weigh the same, and to produce an output signal when a predetermined weight of articles is positioned in the accumulator. The apparatus in addition has means for dumping the accumulated articles into containers of conveyor 40. A suitable weighing mechanism is a GR-10 by the Pennsylvania Scale Company.
Reference is now made to FIG. 5 which shows a dumping and weighing station. Typically, each weighing and dumping station 38 includes a weigh hopper 124 comprising vertical side walls 126, inclined bottom walls 128 and 130 and an end wall 127. A hinge 132 secures the bottom wall 130 to the side wall 126. The bottom wall 130 has an angular flange 131 positioned along the end wall 131. A support bracket 138 is secured to the side wall 126 and pivotably mounts one corner of plate 136 on pin 137. A fluid cylinder 140 is pivotably mounted at a bottom portion to the support bracket 138 through a suitable pivot mounting 142 and has an extendible rod 144 pivotably mounted at its end to the other corner of the triangular plate 136. The position of the triangular plate 136 and thus of the inclined bottom wall 130 is controlled by a cylinder 140. When the extendible rod 144 is forced downwardly as illustrated in FIG. 4, the triangular plate 136 retains the bottom wall 130 in its closed position. Retracting of the extendible rod 144 will rotate the plate 136 in a clockwise direction about its pivotable mounting on the support plate 138 and thus rotate the bottom wall 130 about hinge 132 to dump the contents of the hopper 124 into a conveyor container 42 positioned therebeneath.
A normally closed limit switch 186 is mounted on end wall 127 and has an actuator 174 which is positioned for actuation by the edge of flange 131. The switch 186 is thus actuated by rotation of the bottom wall 130 in a clockwise direction to dump the hopper. The switch is thus open when the hopper is closed and closed when the hopper is dumping.
The containers 42 are U-shaped plates which are open at either end for removal of the carrots. A guide fence 146 is positioned along the upper run of the conveyor on each side of the containers 42 between the weighing and dumping stations 48 and the bagger 160 to retain the carrots within the containers 42. However, beneath each of the weighing and dumping stations 48, except the first such station, the fence 146 is cut away at 147. A photocell 149 is positioned adjacent the fence 146 to view through the cut away portion 147 at a light (not shown) at the other side of the containers 42. The light beam to the photocell 149 will be broken when the container is full.
As illustrated in FIGS. 2 and 5, the conveyor 40 is supported by uprights 148 and has elongated side braces 150. Uprights 153 extend upwardly from side braces 150 to support the weighing and dumping stations 38.
The chains 44 of the conveyor 40 are supported on sprockets 152 which are in turn secured to drive shafts 154. The drive shaft 154 is journalled in the uprights 148. The drive shaft 154 is driven intermittently by a Geneva drive 158 through a sprocket 156 on the drive shaft 154, a sprocket 160 on the Geneva drive 158 and a chain 162 which is wound around sprockets 160 and 156. The Geneva drive 158 is powered by the power means (not shown) for the bagger 46 to drive the conveyor intermittently.
Drive shaft 154 drives a chain 164 through a sprocket (not shown) and in turn drives a cam shaft 166 through sprocket 168. A timing cam 170 is positioned on the cam shaft 160. A cam follower 172 is provided for the cams 170. As the conveyor moves, the cam shaft 166 is rotated to operate the cam follower 172. A switch with multiple contacts is connected to the cam follower for a purpose which will be discussed hereinafter.
Reference is now made to FIG. 6 for a description of an electrical circuit used to operate a diverter 54 and a weighing and dumping station 38 in the same lane, it being understood that the same basic circuit (except as noted below) is used to control the feeding from each lane in the feeding mechanism. In FIG. 6, some parts described above are schematically shown with like numerals used to designate like parts.
A common b+ line 176 is connected to a common ground line 178 through connector lines 180 and 182. Lines 180 and 182 are connected together in a central portion by electrical line 184. The open line switch 186a and a diverter solenoid 188 are connected in line 180 between the b+ common 176 and the common ground 178. A normally open scale switch 190, a normally closed relay switch 190, a dump solenoid 194, a normally open photocell switch 216 and a normally open timing cam switch 218a are connected in line 182 between the b+ common 176 and the common ground 178. A normally open limit switch 186b is connected in parallel across the photocell switch 216 and is operative simultaneously with the limit switch 186a. The line 184 is coupled to the connector line 180 between the limit switch 186a and the diverter solenoid 188. At the other end, the line 184 is coupled to the connector line 182 between the scale switch 190 and the relay switch 212. The diverter solenoid 188 operates a valve 196 which supplies fluid pressure to either end of the fluid cylinder 116 for the diverter 154. The dump solenoid 194 operates a valve 198 which controls the flow of fluid pressure to the fluid cylinder 140 for the weigh hopper 124.
Branch line 220 is connected to the electrical line 182 between the relay switch 212 and the dump solenoid 194 at one end and to the common line 178 at the other end. A relay coil 222 is connected in the branch line 220. A third electrical line 206 is provided between the b+ line 176 and the common line 178. A relay coil 224 and a normally closed relay switch 226 are connected in series in the electrical line 206. The relay coil 224 operates the normally closed relay switch 212 to open when current flows through line 206. Relay coil 222 opens the normally closed relay switch 226 when current flows through branch line 220.
The foregoing has been a description of the circuit for weighing and dumping stations in the second through sixth position as the conveyor moves (top to bottom in FIG. 1). The circuit for the first weighing and dumping station 38 is the same except that the photocell switch 216 and the limit switch 186b are eliminated. Thus, the first weighing and dumping station will dump at an approximate time whenever the hopper thereof has reached a predetermined weight before the conveyor has stopped. The second through the sixth weighing and dumping stations will discharge only when the containers therebeneath are empty as sensed by the photocells 149, and the hoppers are filled before the conveyor beings its stop cycle.
Operation
In operation, carrots are fed into the hopper 14 and are carried by the elevator 16 to the vibratory corrugated tray 18 and to the lines 20 through 30. The carrots are fed seriatim to each weighing and dumping station 38 where they are received by a weigh hopper 124. As the carrots accumulate in the weigh hopper 124, the weight of the contents are measured by the weighing and dumping station 38. When the contents of the hopper 124 reach a predetermined weight, for example one pound, a signal will be generated by the weighing and dumping station and the switch 190 will close. Current thus flows through switch 190, line 184 and diverter solenoid 188 to the common ground 178. When the current flows through the diverter solenoid 88, the valve 196 is operated to extend the extendible rod 118 for the cylinder 116 and to thereby move the fence 110 across the conveyor 36 for the particular weighing and dumping station 38 in which the proper weight is reached. Thereafter, all carrots passing along the conceyor belt 36 for the full dumping and weighing station are diverted by the fence 110 and are returned to the hopper 14 via carrot return plate 100, return conveyors 104, 106, and 108.
The dumping of the weigh hopper 124 is controlled so that one and only one group of carrots are deposited in one empty conveyor. The first weigh hopper will discharge in a container therebeneath whenever the weigh hopper is full. As the conveyor stops, the timing cam 170 will close the timing cam switches 218a and 218b. Current will then flow through switch 190, 212, dump solenoid 194 and switch 218 (there being no switches 216 and 186b in the circuit for the first weigh hopper). At the same time current will flow through line 220 and through relay coil 222 to open the normally closed switch 226. Current thus does not flow through line 206 and switch 212 remains closed. The valve 196 is actuated by the flow of current through dump solenoid 194 to control the flow of fluid pressure to the fluid cylinder 140 to retract the extendible rod 144. The inclined bottom wall 130 of the weigh hopper 124 is swung open to dump the carrots therein into the container therebeneath.
As the bottom wall 130 is opened, the flange 131 releases the switch actuator 174 to permit the limit switch 186a to close. Current will thereby flow through switch 186a and through solenoid 188 to maintain the valve 196 in its position operating diverter 54. As the hopper dumps, however, the scale switch 190 will be opened to cut off the current flowing therethrough. As the conveyor is moved another increment, the timing cam switch 218a will be deactivated so as to open the switch 218a, thereby de-energizing the dump solenoid 194. Thereafter, the valve 198 is switched to extend the extendible rod 144 of the fluid cylinder 140, thereby closing the bottom wall 130 of the weigh hopper 124. The return of the flange 131 to its initial position will move the switch actuator 174, and thereby open the switch 186a. Current flow through diverter solenoid 188 will thereafter cease and the valve 196 will return to its initial position, thereby returning the fence 110 of the diverter 54 to its initial position. The carrots will then begin to feed once again into the weigh hopper 124 and the cycle begins anew.
In the event that the weigh hopper is no full when the stop cycle begins, the switch 190 will be open. However, the timing cam switches 218a and 218b will close, permitting current to flow through line 206, thereby opening the normally closed switch 212. If the weigh hopper fills during the time the conveyor stops, the switch 190 closes the current flows through line 184, line 180 through diverter solenoid 188 to operate the diverter gate 110. However, due to the presence of the open switch 212, current does not flow through line 182 and through dump solenoid 194. At the end of the cycle, the timing cam switches 218a and 218b again open and switch 212 again closes. At the start of the next cycle, the first hopper will be in condition for dumping. The weigh hoppers are prevented from dumping during a given cycle if the weigh hopper is filled after the conveyor has commenced its stop cycle. This feature of the invention prevents incomplete dumping of a weigh hopper due to an insufficient time cycle for dumping.
The second through the sixth weigh hoppers operate in a manner similar to the first hopper described above. However, an additional condition is imposed on the dumping of these weigh hoppers. The containers beneath these weigh hoppers must be empty before dumping will occur. In the embodiment shown, the presence of an empty container is detected by the photocell 149. This condition causes photocell switch 216 to close to activate the dumping cycle (assuming the particular weigh hopper is full at the start of the cycle). As the hopper dumps, the falling of the carrots into the container may break the light beam, causing the photocell switch 216 to open. However, switch 186b is closed upon opening of the hopper in the same manner as the switch 186a so that the switch 186b latches the circuit in the dump position once the dump cycle commences. Thus, even if the photocell switch 216 should open during the cycle, such opening would not prematurely terminate the dumping operation.
The invention thus provides a system whereby a plurality of containers on a conveyor system can be filled with a minimum weight of material for packaging. Each container on the conveyor is filled to maintain a continuous operation of a bagging apparatus which removes the contents of the containers. Each container is thus filled separately and at a separate time. The feeding mechanism operates so that only a predetermined weight of articles such as carrots are positioned in each of the containers for bagging. The apparatus thus provides a simple and efficient way for continuously feeding a predetermined weight of articles to a bagging operation in a timed sequence.
The invention has been described above with respect to a feeding system which uses three conveyor belts 32, 34, and 36, each driven at a sequentially faster rate. It may be desirable to use more or less belts in feeding the carrots to the weigh hoppers. For example, a single belt can be used to feed the carrots to the weigh hoppers. Desirably, the carrots are fed to the weigh hoppers at a speed of about 250 feet per minute.
Reasonable variation and modification are possible within the foregoing disclosure, the drawings, and the appended claims without departing from the spirit of the invention. | An apparatus for feeding substantially equally weighted groups of articles to a packaging apparatus in a timed continuous sequence. The articles are initially fed individually to a plurality of hoppers, each of which has means to weigh the articles therein. Further feeding of articles to any given hopper is blocked or discontinued when a predetermined weight of the articles has been reached in the particular hopper. A conveyor having a plurality of containers passes beneath the hoppers to receive the articles therefrom as they are dumped from the hoppers. The dumping of the articles from the hopper is controlled with the movement of the containers beneath the hoppers so that each hopper dumps the articles only in empty containers. The control means prevents more than one group of articles from being dumped into any given container on the conveyor and ensures that each container on the conveyor is filled so that the packaging operation has a continuous supply of the groups of articles.
Means are provided to prevent dumping of a hopper in the event that the hopper fills after the conveyor has stopped for the dumping cycle. An electric eye is provided to sense the presence of an empty container beneath multiple weigh hoppers and means are provided for latching the dumping mechanism after commencement of dumping to prevent premature termination of the dumping due to detection of the articles falling into the container during dumping of the hoppers. | 1 |
This invention relates to fluid filled units and more particularly to a novel and improved plastic web of interconnected pouches for use in a machine for, and with a process of, converting the pouches to fluid filled units.
BACKGROUND OF THE INVENTION
U.S. Pat. No. Re 36,501 reissued Jan. 18, 2000 and U.S. Pat. No. RE 36,759 reissued Jul. 4, 2000 respectively entitled “Method for Producing Inflated Dunnage” and “Inflated Dunnage and Method for its Production” and based on original patents respectively issued Sep. 3, 1996 and Dec. 2, 1997 to Gregory A. Hoover et al. (the Hoover Patents) disclose a method for producing dunnage utilizing preopened bags on a roll. The preopened bags utilized in the Hoover patents are of a type disclose in U.S. Pat. No. 3,254,828 issued Jun. 2, 1966 to Hershey Lerner and entitled “Flexible Container Strips” (the Autobag Patent). The preferred bags of the Hoover patents are unique in that the so called tack of outer bag surfaces is greater than the tack of the inner surfaces to facilitate bag opening while producing dunnage units which stick to one another when in use.
U.S. Pat. No. 6,199,349 issued Mar. 13, 2001 under the title Dunnage Material and Process (the Lerner Patent) discloses a chain of interconnected plastic pouches which are fed along a path of travel to a fill and seal station. As each pouch is positioned at the fill station the pouches are sequentially opened by directing a flow of air through a pouch fill opening to open and then fill the pouch. Each filled pouch is then sealed to create an hermetically closed, inflated dunnage unit. Improvements on the pouches of the Lerner Patent are disclose in copending applications Ser. No. 09/735,345 filed Dec. 12, 2000 and Ser. No. 09/979,256 filed Nov. 21, 2001 and respectively is entitled Dunnage Inflation (the Lerner Applications). The system of the Lerner Patent and Applications is not suitable for packaging liquids. Moreover, since the production of dunnage units by the process described is relatively slow, an accumulator is desirable. An improved accumulator and dispenser for receiving dunnage units manufactured by a dunnage unit formation machine is disclose in U.S. application Ser. No. 09/735,111 filed Dec. 12, 2000 by Rick S. Wehrmann under the title Apparatus and Process for Dispensing Dunnage.
Accordingly, it would be desirable to provide an improved system for filling pouches with fluid to produce dunnage or liquid filled units at high rates of speed.
SUMMARY OF THE INVENTION
The present invention is embodied in a plastic web which enhances the production of fluid filled units which may be dunnage units similar to those produced by the systems of the Lerner Patent and Applications but at greatly improved production rates. Specifically, a novel and improved unit formation web is disclose for use with a novel machine and process. The machine and process are claimed in a concurrently filed application Ser. No. 10/408,947 by Hershey Lerner et al, issued as U.S. Pat. No. 6,889,739.
The machine includes a rotatable drum having a spaced pair of cylindrically contoured surfaces. An elongated nozzle extends generally tangentially between and from the cylindrical surfaces. In use, the nozzle is inserted into the novel web at a transversely centered position as the web is fed upwardly and around the drum. The web has hermetically closed side edges and longitudinally space pairs of transverse seals. The seals of each pair are spaced a distance equal to slightly more than one half the circumference of the nozzle with which it is intended to be used.
Each transverse seal extends from an associated side seal toward the center of the web such that successive side seals and the associate side edge together define three sides of a pouch to be fluid filled. When the units being formed are dunnage, as the web passes over the nozzle, web pouches are inflated and the web is separated into two chains of inflated pouches as the nozzle assembly separates the web along longitudinal lines of weakness.
The chains are fed by the drum and metal transport belts successively under a plurality of heating and cooling shoes. Each shoe has a spaced pair of arcuate web transport belts engaging surfaces which are complemental with the cylindrical drum surfaces. The shoes are effective to clamp the transport belt and the web against the rotating drum as spaced sets of seals are formed to seal the air inflated pouches and convert the inflated pouches into dunnage units. The dunnage units are separated following their exit from the last of the cooling shoes.
Tests have shown that with pouches having four inch square external dimensions, dunnage units are produced at the rate of eight cubic feet per minute. This contrasts sharply with the machine of the Lerner Patents which produces dunnage units at the rate of three cubic feet per minute.
Accordingly the objects of the invention are to provide a novel and improved web for dunnage formation and a process of dunnage formation.
IN THE DRAWINGS
FIG. 1 is an elevational view of the unit formation machine of the present invention;
FIG. 2 is a plan view of the machine of FIG. 1 as seen from the plane indicated by the line 2 — 2 of FIG. 1 showing a web being fed into the machine;
FIG. 3 is an enlarged sectional view of a heat shoe and a portion of the drum as seen from the plane indicated by the line 3 — 3 of FIG. 1 ;
FIG. 3A is a further enlarged view of the shoe and the drum as seen from the same plane as FIG. 3 ;
FIG. 4 is a view showing a dunnage embodiment of the machine with components which delineate a air flow path from a supply to and through the cooling shoes and then the inflation nozzle;
FIG. 5 is a perspective view of a section of the novel and improved web;
FIG. 6 is a perspective view showing a section of a web as the web pouches are inflated and the web is separated into parallel rows of inflated pouches;
FIG. 7 is an enlarged plan view of a portion of the web including a transverse pair of heat seals;
FIG. 8 is a further enlarged fragmentary view of a central part of the web as located by the circle in FIG. 7 ;
FIG. 9 is a perspective view showing a pair of completed fluid filled units following separation and as they exit the machine; and,
FIG. 10 is an enlarged view of a preferred support embodiment and a shoe which arrangement is for supporting the shoes in their use positions and for moving them to out of the way positions for machine set up and service.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
While the following description describes a dunnage formation system, it should be recognized the preferred embodiment of the machine is sterilzable so that beverages such as water and fruit juice may be packaged using the novel web, machine and process.
Referring now to the drawings and FIGS. 1 and 2 in particular, a dunnage formation machine is shown generally at 10 . The machine includes a rotatable drum 12 which is driven by a motor 14 via a gear box 15 and a belt and pulley arrangement 16 , FIG. 2 . In the preferred and disclose arrangement, the drum is comprised of spaced annular disks 18 .
When the machine is in use a web 20 is fed from a supply, not shown. As is best seen in FIG. 1 , the web 20 passes over a guide roll 22 and thence under a guide roll 24 to an inflation station 25 . The web 20 is fed around the disks 18 to pass under, in the disclose embodiment, three heat shoes 26 which shoes heat metal transport belts 27 to seal layers of the web. The heat softened web portions and the transport belts then pass under cooling shoes 28 which freeze the seals being formed. As the now inflated and sealed web passes from the cooling shoes individual dunnage units 30 are dispensed.
In practice the machine 10 will be housed within a cabinet which is not shown for clarity of illustration. The cabinet includes access doors with an electrical interlock. When the doors are open the machine may be jogged for set up, but the machine will not operate to produce dunnage units unless the doors are closed and latched.
The Web
Referring now to FIGS. 5-9 , the novel and improved web for forming dunnage units is disclose. The web is formed of a heat sealable plastic such as polyethylene. The web includes superposed top and bottom layers connected together at spaced side edges 32 . Each of the side edges is a selected one of a fold or a seal such that the superposed layers are hermetically connected along the side edges 32 .
A plurality of transverse seal pairs 34 are provided. As best seen in FIGS. 5-7 , each transverse seal extends from an associated side edge 32 toward a longitudinally extending pair of lines of weakness 35 . The longitudinal lines of weakness 35 are superposed one over the other in the top and bottom layers of the web and are located midway between the side edges. Each transverse seal 34 terminates in spaced relationship with the longitudinal lines of weakness which preferably are in the form of uniform, small perforations. The transverse seal pairs 34 together with the side edges 32 delineate two chains of centrally open side connected, inflatable pouches 37 .
As is best seen in FIGS. 7 and 8 , transverse lines of weakness 36 are provided. The pouches are separable along the transverse lines 36 . Like the longitudinal lines of weakness 35 the transverse lines are preferably perforations but in contrast to the to the longitudinal line perforations each has substantial length. The perforations of the transverse lines 36 , in a further contrast with the perforations of the longitudinal lines 35 , are not of uniform dimension longitudinally of the lines. Rather, as is best seen in FIG. 8 , a pair of small or short perforations 38 is provided in each line. The small perforations 38 of each pair are disposed on opposite sides of and closely spaced from the longitudinal lines 34 . Each transverse line of weakness also includes a pair of intermediate length perforations 40 which are spaced and positioned on opposite sides of the small perforations 38 . The intermediate perforations extend from unsealed portions of the superposed layers into the respective seals of the associated transverse seal pair. The remaining perforations of each line are longer than the intermediate perforations 40 .
The Machine
In the embodiment of FIG. 1 , the disks 18 are mounted on a tubular shaft 42 . The shaft 42 is journaled at 44 for rotation driven by the belt and pulley arrangement 16 . The shaft 42 carries a stationary, tubular, nozzle support 45 which extends from around the shaft 42 radially outwardly. A nozzle assembly 46 is carried by a support arm 45 A, FIG. 6 . The nozzle assembly 46 includes an inflation nozzle 48 . As is best seen in FIG. 6 , the nozzle 48 is an elongated tube with a closed, generally conical, lead end portion 49 . The nozzle 48 when in use extends into the web at a central location transversely speaking. The web transverse lines of weakness are spaced slightly more than a one half the circumference of the nozzle so that the web layers fit closely around the nozzle to minimize leakage of air exiting side passages 51 of the nozzle to inflate the pouches 37 .
The nozzle assembly 46 includes a web retainer 50 which guides the web against the nozzle 48 . The retainer also functions to cause the web to be longitudinally split along the longitudinal lines of weakness 35 into two strips of inflated pouches.
As is best seen in FIGS. 3 and 3A , each of the heat shoes 26 has a mirror image pair of heat conductive bodies 52 . The bodies 52 together define a cylindrical aperture 54 , which houses a heating element, not shown. Each heat body 52 includes a seal leg 55 having an arcuate surface substantially complemental with a cylindrical surface of an associated one of the disks 18 . In the disclose embodiment the disk surfaces are defined by thermally conductive silicone rubber inserts 18 s , FIG. 3 A. In the embodiment of FIGS. 3 and 3A , springs 56 bias the legs 55 against the transport belts 27 as the web passes under the heat shoes due to rotation of the drum 12 and its disks 18 . The cooling shoes 38 are mounted identically to the heat shoes.
Each cooling shoe 28 includes an expansion chamber 58 , FIG. 4 . An air supply, not shown, is connected to a chamber inlet 60 . Air under pressure is fed through the inlet 60 into the chamber 58 where the air expands absorbing heat and thus cooling the shoe. Exhaust air from the chamber passes through an exit 62 . Cooling shoe legs 63 are biased against the web to freeze the heat softened plastic and complete seals.
In the embodiment of FIGS. 1-4 cooling shoe exhaust air then passes through a conduit 64 to the tubular shaft 42 . Air from the cooling shoes is fed via the conduit 64 and the shaft 42 to a passage 65 in the nozzle support 45 . The passage 65 is connected to the nozzle 48 . Thus air from the cooling shoes is directed to and through the nozzle 48 and the exit passages 51 into the pouches.
With the now preferred and sterilizable embodiment, cooling shoes 28 ′ as shown in FIG. 10 are employed has a jacket 67 which surrounds a body having cooling fins shown in dotted lines in FIG. 10 . An inlet 60 ′ is provided at the top of the jacket. Air flowing from the inlet passes over the fins cooling them and the exits from the bottom of the jacket. Each of the shoes 28 ′ is vented to atmosphere through an outlet 67 . The nozzle 48 is directly connected to a supply of fluid under pressure and the shaft 42 may be made of solid material.
A pair of hold down belts 66 are mounted on a set of pulleys 68 . The belts 66 are reeved around a major portion of the disks 18 . As is best seen in FIGS. 3 and 3A , the belts 66 function to clamp portions of the web 20 against the disks on opposite sides of the shoe legs 55 . While test have shown that the machine is fully operable without the belts 66 , they are optionally provided to isolate pressurized air in the inflated pouches 37 from the heating and cooling shoes.
A fixed separator 69 is provided. As the inflated pouches approach the exit from the downstream cooling shoe the fixed separator functions to cam them radially outwardly sequentially to separate each dunnage unit from the next trailing unit along the connecting transverse line of weakness except for a small portion under the transport belts 27 .
A separator wheel 74 is provided, FIG. 1 . The wheel 74 is rotated clockwise as seen in FIG. 1 such that arms 76 are effective to engage completed dunnage units 30 sequentially to complete the separation of each dunnage unit from the web along its trailing transverse line of weakness 36 . Thus, the separator wheel is effective to tear the last small connection of each pouch which was under an associated one of the transport belts as the pouch was substantially separated by the fixed separator 69 .
In the embodiment of FIG. 1 , each of the shoes 26 , 28 is mounted on an associated radially disposed shaft 71 . Clamping arrangements shown generally at 72 are provided to fix each of the shafts 71 in an adjusted position radially of and relative to the drum 12 . As is best seen in FIG. 3 , each shaft 71 carries a yoke 73 . The springs 56 span between yoke pins 75 and shoe pins 75 to bias the shoes against a web 20 . A cylinder 70 is provided for elevating a connected yoke and shoe for machine set up and service.
In the now preferred embodiment of FIG. 10 , each shoe is pivotally mounted on an arm 78 . The arm is also pivotally mounted at 80 on a frame 82 . A cylinder 70 ′ spans between the arm and the frame for elevating the connected shoe for set up and service and for urging the shoes 28 into their operating positions. The heat shoes 26 are, in the now preferred arrangement, identically mounted.
Operation
In operation, the shoes are elevated by energizing the cylinders 70 of FIGS. 1 and 4 or 70 ′ of FIG. 10. A web 20 is fed along a path of travel over the guide roll 22 and under the guide roll 24 and thence threaded over the inflation nozzle 48 . The web is then fed under the transport belts and the retainer 50 . As the machine is jogged to feed the web around the discs 18 and the heating and cooling shoes 26 , 28 the web is split by the nozzle support 55 . The split of the web is along the longitudinal line of weakness but the transverse lines of weakness remain intact at this time. Thus, the web portions at opposite ends of the small perforations 38 are of sufficient size and strength to avoid a longitudinal split of the web as the web is fed over the nozzle. Since the transverse seals of each pair are spaced only very slightly more than one half the circumference of the nozzle the web closely surrounds the nozzle to minimize air leakage when the pouches are inflated.
Next the heating and cooling shoes are elevated by actuating either the cylinders 70 or 70 ′. The web is then fed sequentially, and one at a time, under the heating shoes 26 and the cooling shoes 28 . Since the web has been split by the nozzle support 55 , there are in fact two parallel paths of travel each with an associated transport belt 27 and chain of side connected and inflated pouches.
Once the web has been fed around the drum to an exit location near the separator wheel 74 and the machine has been jogged until the operator is satisfied the feed is complete and the machine is ready the heat shoe elements will be energized. Air will be supplied to the cooling shoes 28 and the nozzle 48 . Next the motor 14 will be energized to commence machine operation.
As we have suggested, one of the outstanding features of the invention is that the web closely surrounds and slides along the nozzle. The close surrounding is assured by the transverse seals being spaced a distance substantially equal to one half the circumference of the nozzle 48 . Thus, the two web layers together delineate a nozzle receiving space which will closely surround an inserted nozzle. As the web advances the pouches 37 on opposed sides of the nozzle will be filled efficiently by fluid under pressure exiting the nozzle passages 51 in opposed streams. Where dunnage units are being formed the fluid will be air. The web is then split by the nozzle support into two chains of side connected and fluid filled pouches respectively traveling along associated ones of the two paths of travel.
Each of the chains is fed under spaced legs 55 of the heating shoes 26 to effect heat seals. As the web passes under cooling shoe legs 63 the seals are frozen and the pouches are separated along most of the length of transverse lines of weakness by the separator. Facile separation is assured by the long perforations because the remaining connections of the web across the transverse seals are short in transverse dimension and few in number.
When the pouches exit the last of the cooling shoes, they have been formed into finished dunnage units 30 . The finished units 30 are sequentially completely separated from the web by the arms 76 of the separation wheel 74 .
While the system as disclosed and described in the detailed description is directed to dunnage, again, as previously indicated, units filled with fluids other than air such as water and fruit juices can be produced with the same machine, process and web.
Although the invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction, operation and the combination and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention as hereinafter claimed. | A web for the manufacture of fluid filled units with a novel machine and process is disclosed. The web includes an elongate heat sealable, flattened plastic tube comprised of face and back imperforate layers. The layers are imperforately joined together along spaced side edges. The layers include superposed longitudinal lines of weakness disposed generally transversely midway between the side edges. The web has longitudinally spaced, pairs of transverse seals. Each transverse seal extends from a respective side edge to an end near but spaced from the longitudinal lines of weakness. The transverse seal pairs include transverse lines of weakness extending from one side edge to the other generally centrally of each seal in a longitudinal direction. The side edges, transverse seals and lines of weakness together delineating two oppositely oriented strings of pouches with each pouch having three imperforate sides and a centrally located fill opening at its fourth side. The transverse lines of weakness are spaced slightly more than one half the circumference of a cylindrical fluid fill nozzle used to fill the pouches such that the web closely surrounds the nozzle during pouch fluid filling. | 1 |
BACKGROUND--FIELD OF INVENTION
This Invention relates to a ladder safety device. More specifically, such devices used to prevent a ladder from skidding in a direction away from the object on which it is resting. It also relates to devices which enable the ladder to be leveled on uneven surfaces.
BACKGROUND--DESCRIPTION OF PRIOR ART
The most widely used ladder safety devices are stabilizers, and levelers. Stabilizers consist of a pair of long tubular legs, one for each side of the ladder. They are attached to the ladder at a point near the top, and hinged so as to pivot outward and towards the object against which ladder is resting. When not in use they can be folded against the rails of the ladder. This system although very secure once deployed, can only be used if there is a large clear area surrounding the ladder. It is also very expensive. The cost can often be close to or even exceed the cost of the ladder itself. In addition, the stabilizer does not provide any means by which to level the ladder on uneven terrain.
To level the ladder, a separate device must be purchased by the consumer. This device is often referred to as a ladder leveler. The ladder leveler usually consists of a pair of telescoping rods, one for each side rail of the ladder and are attached to the ladder at a point near its base. At the end of each rod is attached some type of foot which is used to provide grip. The rods can be extended downward independently of one another, allowing the user to compensate for uneven terrain.
A similar leveling device has been proposed in U.S. Pat. No. 4,995,474 (1991) to Gauthier. The device comprises a ladder of at least two legs with leveling capabilities. The method of adjustment is by means of a threaded rod running in a longitudinal throughbore in the ladder's leg. In order to make adjustments to the leg height of the ladder, the user is required to manually spin the device. Since the device is an integral part of the ladder's leg, the user must purchase the entire ladder to posses the benefits of the leveling system. In addition, the device is constructed primarily of steel which would add considerable weight to the ladder. Although relatively inexpensive when compared to the stabilizers, the levelers do not provide protection should the ladder's feet loose traction with the surface and begin to slide in a direction away from the object on which the ladder is resting. Furthermore, the levelers must be adjusted with one hand while holding the ladder in a vertical position with the other hand. This can be difficult and even dangerous in windy conditions. Current leveling devices are aligned longitudinally with the side rails of the ladder, and therefor do not provide any increase in lateral stability.
All of the above mentioned devices do not provide the user with an accurate means of setting the ladder at the proper incline angle. The proper incline angle is often the most important safe guard the user should observe, since the ladder's resistance to skidding is greatly influenced by the angle at which it is set in relation to the surface. As an aid to the user, most ladder manufacturers place a sticker on the side rail of the ladder illustrating a vertical line. When the line is perpendicular to the surface the ladder is set at the proper incline angle. This method is not at all accurate since it relies on the user to approximate when the line is perpendicular to the surface.
OBJECTS AND ADVANTAGES
Accordingly, several objects of the invention are as follows:
1. To provide a device which will enable a ladder to resist skidding away from the object on which the ladder is resting.
2. To provide a device which will enable the ladder to be leveled on uneven terrain.
3. To provide a device which will increase the lateral stability of the ladder.
4. To provide a device which will allow the user to accurately determine the optimum incline angle of the ladder.
In keeping with these objects and with others that will follow, one feature of the invention briefly stated, is an anti-skid and leveling device for ladders, consisting of a pair of devices each including a guide rail, an upper carriage which travels along the guide rail, a lower carriage which travels along the guide rail, two end caps attached to the guide rail, an incline indicator attached to the guide rail, a brace detention element attached to the guide rail, a brace latch attached to the guide rail, a brace stay mount attached to the upper carriage, a brace stay attached to the brace stay mount, a flanged cylindrical element attached to the upper carriage, a brace attached to the upper carriage, a friction element attached to the brace, a foot detention element attached to the guide rail, a foot mount attached to the lower carriage, a foot attached to the foot mount, a foot stay attached to the foot, a mounting post attached to the foot, a footpad attached to the mounting post, and a friction element attached to the footpad.
Basing the construction of the invention on the guide rail, to which all other elements are affixed, results in a compact, narrow structure only slightly wider than the side rails of the ladder itself, thus keeping the ladder slim and easy to handle. The invention is permanently attached to the side rails of the ladder, thereby allowing for ease of portability. Since the guide rail's structural rigidity is enhanced by the side rails of the ladder, it can be made of a lightweight material such as plastic.
The sliding upper and lower carriages provide a sturdy yet simple means by which to adjust the inventions features.
The incline indicator provides the user with a quick, accurate means of attaining the proper incline angle of the ladder with respect to the surface.
The brace is hinged at the top and can be folded into a position parallel to the guide rail for efficient storage when not in use. The height adjustment mechanism for the brace is self locking which eliminates any possibility of human error. In addition, the self locking mechanism makes adjusting the brace quick and easy. Since the brace always remains parallel to the vertical plane of the ladder's side rail, it can be deployed even in confined areas.
The foot is designed to act as an outrigger which adds to the lateral stability of the ladder, and is adjustable in height to enable the ladder to be leveled on uneven terrain. The height adjustment mechanism for the foot is self locking, which eliminates any possibility of human error. In addition, the self locking mechanism makes adjusting the invention's foot quick and easy. The height of the invention's foot can be adjusted with pressure applied by the user's foot, enabling the user to keep both hands on the ladder. This is especially useful in conditions of high wind.
The footpad is designed to swivel in all directions, enabling it to adjust to the slope of the terrain. In addition, the footpad is round in shape and large in diameter. This helps to prevent the footpad from sinking into soft terrain, as well as provide exceptional grip on harder surfaces.
The invention can be made of lightweight materials such as plastic and aluminum, thereby contributing little additional weight to the ladder. It is self contained requiring no other parts or assembly once installed. Furthermore, the invention effectively combines the features of stability and levelability into a single device.
DESCRIPTION OF THE DRAWING FIGURES
FIG. 1--a perspective view of the guide rail assembly.
FIG. 1a--a cross section view of the upper carriage and guide rail.
FIG. 1b--a cross section view of the lower carriage and guide rail.
FIG. 2--a perspective view showing details of the upper carriage and brace assembly.
FIG. 3--a perspective view showing details of the lower carriage and foot assembly.
FIG. 4--a side view showing the brace in its stored and deployed position.
FIG. 5--a frontal view of the invention showing attachment to the side rails of a ladder.
LIST OF REFERENCE NUMERALS USED IN THE DRAWINGS
12--a guide rail of the anti-skid and leveling device for ladders 10
14--an upper carriage
16--a lower carriage
18a--an upper end cap
18b--a lower end cap
20--a tubular level vial
22--a vial mount
24--a flanged cylindrical element
26--a brace
28--a brace latch
30--a brace detention element
32--a brace stay
34--a brace stay mount
36--a hinge pin of the brace stay 32
38--an external retaining ring of the hinge pin 36
40--a friction element of the brace 26
42--a foot
44--a foot detention element
46--a foot stay
48--a foot mount
50--a hinge pin of the foot mount 48
52--an external retaining ring of the hinge pin 50
54--a footpad
56--a friction element of the footpad 54
58--a ball end
60--a ball end retainer
62--a mounting post
66--a spring
68--face of the guide rail 12
70--rear side of the guide rail 12
72--front side of the guide rail 12
74--front side upper groove of the guide rail 12
76--rear side upper groove of the guide rail 12
78--front side lower groove of the guide rail 12
80--rear side lower groove of the guide rail 12
82--brace detention element recess of the guide rail 12
84--foot detention element recess of the guide rail 12
86--incline indicator recess of the guide rail 12
88--upper flange of the guide rail 12
90--lower flange of the guide rail 12
92--rear side surface of the upper carriage 14
94--face of the upper carriage 14
95--cut-out of the upper carriage 14
96--guide flange of the upper carriage 14
98--other guide flange of the upper carriage 14
100--rear side surface of the lower carriage 16
102--face of the lower carriage 16
103--cut-out of the lower carriage 16
104--guide flange of the lower carriage 16
106--other guide flange of the lower carriage 16
108--sliding surface of the brace detention element 30
110--resting surface of the brace detention element 30
112--sliding surface of the foot detention element 44
114--resting surface of the foot detention element 44
116--face of the brace 26
118--front side of the brace 26
120--rear side of the brace 26
122--mounting post receptacle of the foot 42
124--spring receptacle of the foot 42
126--notch in the foot 42
127--concave recess in the footpad 54
128--flat surface of the ball end 58
130--internally tapped hole of the ball end 58
132--externally threaded area of the mounting post 62
134--flange of the mounting post 62
136--recess in the endcap 18a
138--recess in the endcap 18b
140--a plurality of screws
142--pivot point of the foot 42
144--pivot point of the brace 26
146--incline indicator assembly
148--left guide rail assembly
150--right guide rail assembly
152--left side rail of ladder
154--right side rail of ladder
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1-5, the invention consists of a pair of devices each including a guide rail 12, an upper carriage 14, a lower carriage 16, an upper and lower end cap 18a and 18b respectively, an incline indicator assembly 146, a flanged cylindrical element 24, a brace 26, a brace latch 28, a brace detention element 30, a brace stay 32, a brace stay mount 34, a brace stay hinge pin 36, two external retaining rings 38, and 52, a brace friction element 40, a foot 42, a foot detention element 44, a foot stay 46, a foot mount 48, a foot mount hinge pin 50 a footpad 54, a footpad friction element 56, a ball end 58, a ball end retainer 60, a mounting post 62, and a spring 66.
The guide rail 12 includes a face 68, a rear side 70, a front side 72, a front side upper groove 74, a rear side upper groove 76, a front side lower groove 78, a rear side lower groove 80, a brace detention element recess 82, a foot detention element recess 84, an incline indicator recess 86, an upper flange 88, and a lower flange 90; (FIGS. 1, 1a, 1b, 2, 3).
The upper carriage 14 includes a rear side surface 92, a face 94, a cut-out 95, and a pair of guide flanges 96 and 98 respectively; (FIGS. 1a, 2).
The upper carriage 14 is installed over the guide rail 12 by engaging the guide flanges 96 and 98 respectively, with the front and rear side upper grooves 74 and 76 respectively, of the guide rail 12; (FIGS. 1a).
The lower carriage 16 includes a rear side surface 100, a face 102, a cut-out 103, and a pair of guide flanges 104 and 106 respectively; (FIGS. 1b, 3).
The lower carriage 16 is installed over the guide rail 12 by engaging the guide flanges 104 and 106 respectively, with the front and rear side lower grooves 78 and 80 respectively, of the guide rail 12; (FIG. 1b).
The brace latch 28 is attached to the guide rail 12; (FIG. 1).
The upper and lower end caps 18a and 18b respectively, each include a recess 136 and 138 respectively; (FIG. 1).
The upper end cap 18a is attached to the upper side of guide rail 12 so that the recess 136 engages the upper flange 88 of the guide rail 12; (FIG. 1).
The lower end cap 18b is attached to the lower side of guide rail 12 so that the recess 138 engages the lower flange 90 of the guide rail 12; (FIG. 1).
The incline indicator assembly 146 includes a tubular level vial 20, and a vial mount 22.
The level vial 20 is attached to the vial mount 22. (FIG. 1)
The assembly 146 is installed into the incline indicator recess 86 located in the face 68 of the guide rail 12; (FIG. 1).
The brace detention element 30 includes a sliding surface 108, and a resting surface 110; (FIG. 2).
The brace detention element 30 is attached to the guide rail 12 at the brace detention recess 82; (FIG. 2). The slope of the sliding surface 108 of the brace detention element 30 is pointed in a direction towards the lower side of the guide rail 12; (FIG. 2).
The brace stay mount 34 is attached to the rear side surface 92 of the upper carriage 14; (FIG. 2).
The brace stay 32 is attached to the brace stay mount 34 by means of the hinge pin 36. The hinge pin 36 is secured in place by the retaining ring 38; (FIG. 2).
The brace 26 is rotatably mounted to the face 94 of the upper carriage 14 by means of the flanged cylindrical element 24; (FIG. 2).
The foot detention element 44 includes a sliding surface 112, and a resting surface 114; (FIG. 3).
The foot detention element 44 is attached to the guide rail 12 at the foot detention recess 84; (FIGS. 1, 3). The slope of the sliding surface 112 of the foot detention element 44 is pointed in a direction towards the lower side of the guide rail 12; (FIG. 3).
The foot mount 48 is attached to the face 102 of the lower carriage 16; (FIG. 3).
The foot 42 includes a mounting post receptacle 122, a spring receptacle 124, and a notch 126; (FIG. 3).
The spring 66 is inserted into the spring receptacle 124 of the foot 42; (FIG. 3).
The foot 42 is attached to the foot mount 48 by means of the hinge pin 50. The hinge pin 50 is secured in place by the retaining ring 52; (FIG. 3).
The foot stay 46 is attached to the top of the foot 42, and is allowed to contact the foot detention element 44 through the cut-out 103 of the lower carriage 16; (FIG. 3).
The footpad 54 includes a concave recess 127 in its upper surface; (FIG. 3).
The friction element 56 is attached to the bottom of the footpad 54; (FIG. 3).
The ball end 58 includes a flat surface 128, and an internally tapped hole 130; (FIG. 3).
The ball end 58 rests in the concave recess 127, and the ball end retainer 60 is attached to the top of the footpad 54; (FIG. 3).
The mounting post 62 includes an externally threaded area 132, and a flange 134; (FIG. 3)
The mounting post 62 is attached to the ball end 58 by means of the threaded area 132 of the mounting post 62. The mounting post 62 is inserted into the mounting post receptacle 122 in the bottom of the foot 42 until the flange 134 contacts the bottom of the foot 42. The mounting post 62 is secured to the bottom of the foot 42 by a plurality of screws 140; (FIG. 3).
The brace 26 includes a face 116, a front side 118, and a rear side 120; (FIG. 4).
The friction element 40 is attached to the lower side of the brace 26; (FIG. 4).
The complete invention comprising a pair of assemblies is shown in FIG. 5. The left assembly 148, is attached to the left side rail 152 of the ladder, and the right assembly 150, is attached to the fight side rail 154 of the ladder.
OPERATION
The ladder is rested against an object and adjusted for the proper incline angle by using the incline indicator 146. The optimum angle for safety has been achieved when the bubble in the level vial 20 is centered between the marks on the vial's surface as can be seen in FIG. 4. The user then determines the foot 42 which needs to be adjusted in order to level the ladder on uneven terrain. The notch 126 in the outer edge of the foot 42 provides a surface by which the user can insert his or her own foot so as to apply a simultaneous inward and downward pressure to the foot 42; (FIG. 3). The inward force causes the spring 66 to compress breaking the contact between the foot stay 46 and the resting surface 114 of the foot detention element 44. The downward force causes the lower carriage 16 to slide in a direction towards the lower side of the guide rail 12. Pressure is applied by the user until the friction element 56 of the footpad 54 contacts the surface. At this point, the user will remove his or her foot from the notch 126 thereby restoring the spring 66 to its uncompressed position. The pressure exerted by the spring 66 will cause the foot stay 46 to engage the resting surface 114 of the foot detention element 44. This will prevent the lower carriage 16 from sliding in a direction towards the upper side of the guide rail 12.
Upon contacting the surface, the ball end 58 will allow the footpad 54 to swivel in all directions, quickly adjusting to the slope of the terrain. The footpad 54 is round in shape and large in diameter to prevent it from sinking into soft terrain. The friction element 56, increases the grip between the footpad 54 and the surface on which it is resting; (FIG. 3).
As the user climbs the ladder, the pulling force of gravity on his body will cause the foot 42 to rotate about the hinge pin 50 at the pivot point 142; (FIG. 5). The resulting motion pushes the foot stay 46 against the foot detention element 44, thereby maintaining positive contact between the foot stay 46 and the foot detention element 44; (FIG. 3). Since the amount of force generated by the foot stay 46 against the foot detention element 44 is proportional to the pulling force of gravity on the user's body, the system as designed, will adjust the integrity of the contact between the foot stay 46 and the foot detention element 44 in relation to the weight of the user. The greater the weight of the user, the more force is generated to prevent the foot stay 46 from loosing contact with the foot detention element 44.
The foot 42 extends outward in a direction perpendicular to the face 102 of the lower carriage 16; (FIGS. 3, 5). This outrigger type foot 42, provides the ladder with a much wider footprint, thereby greatly increasing lateral stability.
The brace 26 is used to provide the ladder with anti-skid protection as illustrated in FIG. 4. In its stored position, the brace 26 is parallel to the guide rail 12, and the upper carriage 14 is at the upper limit of its travel. The brace 26 is held in the stowed position by the brace latch 28. The brace 26 is deployed by releasing the latch 28 and pulling the lower side of the brace 26 in a direction towards the object on which the ladder is resting. The brace 26 rotates about the flanged cylindrical element 24 at the pivot point 144, until a specified angle is achieved between the brace and the guide rail. Once the brace 26 has been fully extended, the upper carriage 14 is lowered until the friction element 40 of the brace 26 comes into contact with the surface; (FIG. 4).
The force of gravity always pulls an object downward in a straight line towards the center of the Earth. For this reason, contact between the footpad 54 and the surface on which it is resting is greatest when the user is positioned directly over the footpad 54. As the user climbs the ladder, the downward force of his or her weight moves away from the footpad, and is gradually transferred to the object on which the ladder is resting. If the remaining down force exerted on the footpad 54 is not sufficient to provide ample friction between the footpad 54 and the surface, the footpad 54 will begin to skid in a direction away from the object on which the ladder is resting; (FIG. 4).
The force of gravity on the user's body will provide the energy necessary to induce the skid. The motion of the skid is effectively stopped by transferring the energy of the skid from the footpad 54 to the brace 26. This is accomplished by the brace stay 32, which is responsible for locking the upper carriage 14 in a stationary position, as well as maintaining a constant angle between the brace 26 and the guide rail 12. During a skid, the ladder will begin to pivot about the flanged cylindrical element 24 at the pivot point 144; (FIG. 4). The brace stay 32 will use this pivoting action to wedge itself between the rear side 120 of the brace 26, and the brace detention element 30. The brace stay 32 contacts the brace detention element 30 by passing through the cut-out 95 in the rear side 92 of the upper carriage 14. As a result, the upper carriage 14 will be locked in a stationary position, and the angle established between the brace 26 and the guide rail 12 will be maintained. The forward motion of the skid is converted to downward pressure on the friction element 40 of the brace 26. The more the ladder tries to skid, the more downward pressure will be exerted on the friction element 40.
SUMMARY, RAMIFICATIONS, AND SCOPE
Accordingly, it can be seen that the anti-skid and leveling device of the present invention can be used to enable a ladder to resist skidding away from the object on which the ladder is resting, provide for the ability to level the ladder on uneven terrain, and provide the ladder with greater lateral stability. Furthermore the invention has the additional advantages in that;
1. Its construction is based on a guide rail to which all other elements are affixed, resulting in a compact, narrow structure only slightly wider than the side rails of the ladder itself, thus keeping the ladder slim and easy to handle.
2. It is permanently attached to the side rails of the ladder thereby allowing for ease of portability.
3. Since the guide rail's structural rigidity is enhanced by the side rails of the ladder, it can be made of a lightweight material such as plastic.
4. The sliding upper and lower carriages provide a sturdy yet simple means by which to adjust the invention's features.
5. The brace is hinged at the top and can be folded into a position parallel to the guide rail for efficient storage when not in use.
6. The height adjustment mechanism for the brace is self locking which eliminates any possibility of human error, while making adjustments to the brace quick and easy.
7. Since the brace remains parallel to the vertical plane of the ladder's side rail, it can be deployed in confined areas.
8. The foot is designed to act as an outrigger which adds to the lateral stability of the ladder.
9. The feet are independently adjustable in height enabling the ladder to be leveled on uneven terrain.
10. The height adjustment mechanism for the foot is self locking which eliminates any possibility of human error, while making adjustments to the invention's foot quick and easy.
11. The height of the invention's foot can be adjusted with pressure applied by the user's foot, enabling the user to keep both hands on the ladder.
12. The footpad is designed to swivel in all directions, enabling it to automatically adjust to the slope of the terrain.
13. The footpad is round in shape and large in diameter to help prevent it from sinking into soft terrain, as well as providing exceptional grip on harder surfaces.
14. The incline indicator provides the user with a quick, and accurate means for determining the proper incline angle of the ladder, which greatly affects its safety.
15. The device is self contained, requiring no other pans or assembly once installed.
16. The features of stability and levelability are effectively combined into a single device.
Although the above description includes many specificities, these should not be construed as limitations on the scope of the invention, but as merely providing an illustration of the preferred embodiment of this invention. For example:
1. The invention can be manufactured as an integral pan of the ladder.
2. The guide rail can be produced in two sections. The upper section would contain the anti-skid feature, while the lower section would contain the leveling feature. This allows the consumer greater flexibility at the time of purchase.
3. The feet can be fashioned so as to fold against the guide rail for more efficient storage.
Thus, the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given. | An anti-skid and leveling device for ladders is provided, containing a pair of devices, each consisting of a guide rail along which an upper carriage and a lower carriage slide independently. The upper carriage provides a mounting platform onto which a brace is rotatably mounted. When pivoted to a specified angle, and lowered so as to contact the ground, the brace will prevent the ladder from skidding in a direction away from the object on which the ladder is resting. A self locking mechanism employing a series of detents is used to secure the upper carriage in a stationary position. The lower carriage provides a mounting platform onto which an outrigger type foot is mounted. The design of the foot provides the ladder with greater lateral stability. The sliding motion of the lower carriage provides height adjustment for the foot, allowing the ladder to be leveled on uneven terrain. Once adjusted, a self locking mechanism employing a series of detents is used to secure the lower carriage in a stationary position. Each foot contains a large round footpad that swivels 360 degrees. An incline indicator is attached to the guide rail to assist in setting the ladder at the proper incline angle. | 4 |
[0001] This application is a national stage application under 35 U.S.C. §371(c) of prior-filed, co-pending, PCT application serial number PCT/US2013/066392, filed on Oct. 23, 2013, which claims priority to Provisional Patent Application Ser. No. 61/717,445 filed Oct. 23, 2012 and titled “PROPULSION SYSTEM ARCHITECTURE”, and is related to PCT application serial number PCT/US2013/066383, titled “UNDUCTED THRUST PRODUCING SYSTEM” filed on Oct. 23, 2013, and PCT application serial number PCT/US2013/066403, titled “VANE ASSEMBLY FOR AN UNDUCTED THRUST PRODUCING SYSTEM” filed on Oct. 23, 2013. All of the above listed applications are herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The technology described herein relates to an unducted thrust producing system, particularly architectures for such systems. The technology is of particular benefit when applied to “open rotor” gas turbine engines.
[0003] Gas turbine engines employing an open rotor design architecture are known. A turbofan engine operates on the principle that a central gas turbine core drives a bypass fan, the fan being located at a radial location between a nacelle of the engine and the engine core. An open rotor engine instead operates on the principle of having the bypass fan located outside of the engine nacelle. This permits the use of larger fan blades able to act upon a larger volume of air than for a turbofan engine, and thereby improves propulsive efficiency over conventional engine designs.
[0004] Optimum performance has been found with an open rotor design having a fan provided by two contra-rotating rotor assemblies, each rotor assembly carrying an array of airfoil blades located outside the engine nacelle. As used herein, “contra-rotational relationship” means that the blades of the first and second rotor assemblies are arranged to rotate in opposing directions to each other. Typically the blades of the first and second rotor assemblies are arranged to rotate about a common axis in opposing directions, and are axially spaced apart along that axis. For example, the respective blades of the first rotor assembly and second rotor assembly may be co-axially mounted and spaced apart, with the blades of the first rotor assembly configured to rotate clockwise about the axis and the blades of the second rotor assembly configured to rotate counter-clockwise about the axis (or vice versa). In appearance, the fan blades of an open rotor engine resemble the propeller blades of a conventional turboprop engine.
[0005] The use of contra-rotating rotor assemblies provides technical challenges in transmitting power from the power turbine to drive the blades of the respective two rotor assemblies in opposing directions.
[0006] It would be desirable to provide an open rotor propulsion system utilizing a single rotating propeller assembly analogous to a traditional bypass fan which reduces the complexity of the design, yet yields a level of propulsive efficiency comparable to contra-rotating propulsion designs with a significant weight and length reduction.
BRIEF DESCRIPTION OF THE INVENTION
[0007] An unducted thrust producing system has a rotating element with an axis of rotation and a stationary element. The rotating element includes a plurality of blades, and the stationary element has a plurality of vanes configured to impart a change in tangential velocity of the working fluid opposite to that imparted by the rotating element acted upon by the rotating element. The system includes an inlet forward of the rotating element and the stationary element.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate one or more embodiments and, together with the description, explain these embodiments. In the drawings:
[0009] FIG. 1 is a cross-sectional schematic illustration of an exemplary embodiment of an unducted thrust producing system;
[0010] FIG. 2 is an illustration of an alternative embodiment of an exemplary vane assembly for an unducted thrust producing system;
[0011] FIG. 3 is a partial cross-sectional schematic illustration of an exemplary embodiment of an unducted thrust producing system depicting an exemplary compound gearbox configuration;
[0012] FIG. 4 is a partial cross-sectional schematic illustration of an exemplary embodiment of an unducted thrust producing system depicting another exemplary gearbox configuration;
[0013] FIG. 5 is a cross-sectional schematic illustration of another exemplary embodiment of an unducted thrust producing system;
[0014] FIG. 6 is a cross-sectional schematic illustration of another exemplary embodiment of an unducted thrust producing system;
[0015] FIG. 7 is a cross-sectional schematic illustration of another exemplary embodiment of an unducted thrust producing system;
[0016] FIG. 8 is a cross-sectional schematic illustration of another exemplary embodiment of an unducted thrust producing system;
[0017] FIG. 9 is a cross-sectional schematic illustration of another exemplary embodiment of an unducted thrust producing system;
[0018] FIG. 10 is a cross-sectional schematic illustration of another exemplary embodiment of an unducted thrust producing system;
[0019] FIG. 11 is a cross-sectional schematic illustration of another exemplary embodiment of an unducted thrust producing system;
[0020] FIG. 12 is a cross-sectional schematic illustration of another exemplary embodiment of an unducted thrust producing system;
[0021] FIG. 13 is a cross-sectional schematic illustration of another exemplary embodiment of an unducted thrust producing system;
[0022] FIG. 14 is a cross-sectional schematic illustration of another exemplary embodiment of an unducted thrust producing system; and
[0023] FIG. 15 is a cross-sectional schematic illustration taken along lines 15 - 15 of FIG. 14 illustrating the inlet configuration of the unducted thrust producing system of FIG. 14 .
DETAILED DESCRIPTION OF THE INVENTION
[0024] In all of the Figures which follow, like reference numerals are utilized to refer to like elements throughout the various embodiments depicted in the Figures.
[0025] FIG. 1 shows an elevational cross-sectional view of an exemplary embodiment of an unducted thrust producing system 10 . As is seen from FIG. 1 , the unducted thrust producing system 10 takes the form of an open rotor propulsion system and has a rotating element 20 depicted as a propeller assembly which includes an array of airfoil blades 21 around a central longitudinal axis 11 of the unducted thrust producing system 10 . Blades 21 are arranged in typically equally spaced relation around the centreline 11 , and each blade 21 has a root 23 and a tip 24 and a span defined therebetween. Unducted thrust producing system 10 includes a gas turbine engine having a gas generator 40 and a low pressure turbine 50 . Left- or right-handed engine configurations can be achieved by mirroring the airfoils of 21 , 31 , and 50 . As an alternative, an optional reversing gearbox 55 (located in or behind the low pressure turbine 50 as shown in FIGS. 3 and 4 or combined or associated with power gearbox 60 as shown in FIG. 3 ) permits a common gas generator and low pressure turbine to be used to rotate the fan blades either clockwise or counterclockwise, i.e., to provide either left- or right-handed configurations, as desired, such as to provide a pair of oppositely-rotating engine assemblies as may be desired for certain aircraft installations. Unducted thrust producing system 10 in the embodiment shown in FIG. 1 also includes an integral drive (power gearbox) 60 which may include a gearset for decreasing the rotational speed of the propeller assembly relative to the low pressure turbine 50 .
[0026] Unducted thrust producing system 10 also includes in the exemplary embodiment a non-rotating stationary element 30 which includes an array of vanes 31 also disposed around central axis 11 , and each blade 31 has a root 33 and a tip 34 and a span defined therebetween. These vanes may be arranged such that they are not all equidistant from the rotating assembly, and may optionally include an annular shroud or duct 100 distally from axis 11 (as shown in FIG. 2 ) or may be unshrouded. These vanes are mounted to a stationary frame and do not rotate relative to the central axis 11 , but may include a mechanism for adjusting their orientation relative to their axis 90 and/or relative to the blades 21 . For reference purposes, FIG. 1 also depicts a Forward direction denoted with arrow F, which in turn defines the forward and aft portions of the system. As shown in FIG. 1 , the rotating element 20 is located forward of the gas generator 40 in a “puller” configuration, and the exhaust 80 is located aft of the stationary element 30 .
[0027] In addition to the noise reduction benefit, the duct 100 shown in FIG. 2 provides a benefit for vibratory response and structural integrity of the stationary vanes 31 by coupling them into an assembly forming an annular ring or one or more circumferential sectors, i.e., segments forming portions of an annular ring linking two or more vanes 31 such as pairs forming doublets. The duct 100 may allow the pitch of the vanes to be varied as desired.
[0028] A significant, perhaps even dominant, portion of the noise generated by the disclosed fan concept is associated with the interaction between wakes and turbulent flow generated by the upstream blade-row and its acceleration and impingement on the downstream blade-row surfaces. By introducing a partial duct acting as a shroud over the stationary vanes, the noise generated at the vane surface can be shielded to effectively create a shadow zone in the far field thereby reducing overall annoyance. As the duct is increased in axial length, the efficiency of acoustic radiation through the duct is further affected by the phenomenon of acoustic cut-off, which can be employed, as it is for conventional aircraft engines, to limit the sound radiating into the far-field. Furthermore, the introduction of the shroud allows for the opportunity to integrate acoustic treatment as it is currently done for conventional aircraft engines to attenuate sound as it reflects or otherwise interacts with the liner. By introducing acoustically treated surfaces on both the interior side of the shroud and the hub surfaces upstream and downstream of the stationary vanes, multiple reflections of acoustic waves emanating from the stationary vanes can be substantially attenuated.
[0029] In operation, the rotating blades 21 are driven by the low pressure turbine via gearbox 60 such that they rotate around the axis 11 and generate thrust to propel the unducted thrust producing system 10 , and hence an aircraft to which it is associated, in the forward direction F.
[0030] It may be desirable that either or both of the sets of blades 21 and 31 incorporate a pitch change mechanism such that the blades can be rotated with respect to an axis of pitch rotation either independently or in conjunction with one another. Such pitch change can be utilized to vary thrust and/or swirl effects under various operating conditions, including to provide a thrust reversing feature which may be useful in certain operating conditions such as upon landing an aircraft.
[0031] Blades 31 are sized, shaped, and configured to impart a counteracting swirl to the fluid so that in a downstream direction aft of both rows of blades the fluid has a greatly reduced degree of swirl, which translates to an increased level of induced efficiency. Blades 31 may have a shorter span than blades 21 , as shown in FIG. 1 , for example, 50% of the span of blades 21 , or may have longer span or the same span as blades 21 as desired. Vanes 31 may be attached to an aircraft structure associated with the propulsion system, as shown in FIG. 1 , or another aircraft structure such as a wing, pylon, or fuselage. Vanes 31 of the stationary element may be fewer or greater in number than, or the same in number as, the number of blades 21 of the rotating element and typically greater than two, or greater than four, in number.
[0032] In the embodiment shown in FIG. 1 , an annular 360 degree inlet 70 is located between the fan blade assembly 20 and the fixed or stationary blade assembly 30 , and provides a path for incoming atmospheric air to enter the gas generator 40 radially inwardly of the stationary element 30 . Such a location may be advantageous for a variety of reasons, including management of icing performance as well as protecting the inlet 70 from various objects and materials as may be encountered in operation.
[0033] FIG. 5 illustrates another exemplary embodiment of a gas turbine engine 10 , differing from the embodiment of FIG. 1 in the location of the inlet 71 forward of both the rotating element 20 and the stationary element 30 and radially inwardly of the rotating element 20 .
[0034] FIGS. 1 and 5 both illustrate what may be termed a “puller” configuration where the thrust-generating rotating element 20 is located forward of the gas generator 40 . FIG. 6 on the other hand illustrates what may be termed a “pusher” configuration embodiment where the gas generator 40 is located forward of the rotating element 20 . As with the embodiment of FIG. 5 , the inlet 71 is located forward of both the rotating element 20 and the stationary element 30 and radially inwardly of the rotating element 20 . The exhaust 80 is located inwardly of and aft of both the rotating element 20 and the stationary element 30 . The system depicted in FIG. 6 also illustrates a configuration in which the stationary element 30 is located forward of the rotating element 20 .
[0035] The selection of “puller” or “pusher” configurations may be made in concert with the selection of mounting orientations with respect to the airframe of the intended aircraft application, and some may be structurally or operationally advantageous depending upon whether the mounting location and orientation are wing-mounted, fuselage-mounted, or tail-mounted configurations.
[0036] FIGS. 7 and 8 illustrate “pusher” embodiments similar to FIG. 6 but wherein the exhaust 80 is located between the stationary element 30 and the rotating element 20 . While in both of these embodiments the rotating element 20 is located aft of the stationary element 30 , FIGS. 7 and 8 differ from one another in that the rotating element 20 of FIG. 7 incorporates comparatively longer blades than the embodiment of FIG. 8 , such that the root 23 of the blades of FIG. 7 is recessed below the airstream trailing aft from the stationary element 30 and the exhaust from the gas generator 40 is directed toward the leading edges of the rotating element 20 . In the embodiment of FIG. 8 , the rotating element 20 is more nearly comparable in length to the stationary element 30 and the exhaust 80 is directed more radially outwardly between the rotating element 20 and the stationary element 30 .
[0037] FIGS. 9 , 10 , and 11 depict other exemplary “pusher” configuration embodiments wherein the rotating element 20 is located forward of the stationary element 30 , but both elements are aft of the gas generator 40 . In the embodiment of FIG. 9 , the exhaust 80 is located aft of both the rotating element 20 and the stationary element 30 . In the embodiment of FIG. 10 , the exhaust 80 is located forward of both the rotating element 20 and the stationary element 30 . Finally, in the embodiment of FIG. 11 , the exhaust 80 is located between the rotating element 20 and the stationary element 30 .
[0038] FIGS. 12 and 13 show different arrangements of the gas generator 40 , the low pressure turbine 50 and the rotating element 20 . In FIG. 12 , the rotating element 20 and the booster 300 are driven by the low pressure turbine 50 directly coupled with the booster 300 and connected to the rotating element 20 via the speed reduction device 60 . The high pressure compressor 301 is driven directly by the high pressure turbine 302 . In FIG. 13 the rotating element 20 is driven by the low pressure turbine 50 via the speed reduction device 60 , the booster 303 is driven directly by the intermediate pressure turbine 306 , and the high pressure compressor 304 is driven by the high pressure turbine 305 .
[0039] FIG. 15 is a cross-sectional schematic illustration taken along lines 15 - 15 of FIG. 14 illustrating the inlet configuration of the unducted thrust producing system of FIG. 14 as a non-axisymmetric, non-annular inlet. In the configuration shown, the inlet 70 takes the form of a pair of radially-opposed inlets 72 each feeding into the core.
[0040] The gas turbine or internal combustion engine used as a power source may employ an inter-cooling element in the compression process. Similarly, the gas turbine engine may employ a recuperation device downstream of the power turbine.
[0041] In various embodiments, the source of power to drive the rotating element 20 may be a gas turbine engine fuelled by jet fuel or liquid natural gas, an electric motor, an internal combustion engine, or any other suitable source of torque and power and may be located in proximity to the rotating element 20 or may be remotely located with a suitably configured transmission such as a distributed power module system.
[0042] In addition to configurations suited for use with a conventional aircraft platform intended for horizontal flight, the technology described herein could also be employed for helicopter and tilt rotor applications and other lifting devices, as well as hovering devices.
[0043] It may be desirable to utilize the technologies described herein in combination with those described in the co-pending applications listed above.
[0044] The foregoing description of the embodiments of the invention is provided for illustrative purposes only and is not intended to limit the scope of the invention as defined in the appended claims.
[0045] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. | An unducted thrust producing system has a rotating element with an axis of rotation and a stationary element. The rotating element includes a plurality of blades, and the stationary element has a plurality of vanes configured to impart a change in tangential velocity of the working fluid opposite to that imparted by the rotating element acted upon by the rotating element. The system includes an inlet forward of the rotating element and the stationary element. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
Reference is made to and priority claimed from pending Provisional Patent Application Ser. No. 60/085,448 filed May 14, 1998.
FIELD OF THE INVENTION
The present invention relates to a process for the preparation of trifluoromethyl containing derivatives useful in the synthesis of trifluoromethylated organic compounds, particularly CF 3 CCl═CHCH 2 OC(═O)CH 3 and CF 3 CH 2 CH 2 CH 2 OH.
BACKGROUND OF THE INVENTION
Trifluoromethyl group containing derivatives such as CF 3 CCl═CHCH 2 OAc and CF 3 CH 2 CH 2 CH 2 OH are useful in the synthesis of fluorinated organic compounds having utility as pharmaceuticals, agricultural chemicals and materials such as liquid crystals. Traditionally, they have been prepared from 1,3-dichloro-4,4,4-trifluoro-2-butene (CF 3 CCl═CHCH 2 Cl) or HCFC-1343. U.S. Pat. No. 5,654,473, herein incorporated by reference in its entirety, discloses the preparation of a number of trifluoromethylated compounds from HCFC-1343. The synthesis of this starting material by the prior art methods is problematic in that high conversion is obtained at the sacrifice of selectivity. Thus, the drawbacks of the processes by which the intermediate is produced limit the useful yield of trifluoromethyl group containing derivatives.
The objective of the invention is to produce trifluoromethyl group containing derivatives by a process having higher yield and selectivity than the known processes.
DESCRIPTION OF THE INVENTION
The invention relates to a process comprising: reacting a compound of the formula CF 3 CCl 2 CH 2 CH 2 Cl (HCFC-353) with a salt of a carboxylic acid in the presence of a polar aprotic solvent and under conditions sufficient to produce a compound of the formula CF 3 CCl═CHCH 2 OC(═O)R wherein R is unsubstituted or substituted C 1 to C 6 straight chain or branched alkyl, unsubstituted or substituted C 3 to C 7 cycloalkyl, unsubstituted or substituted C 2 to C 12 alkenyl, a benzyl group unsubstituted or substituted with R', or a phenyl group unsubstituted or substituted with R'; wherein R' is an unsubstituted or substituted C 1 to C 6 straight chain or branched alkyl; and wherein when R and/or R' are substituted each is substituted with R'; and recovering a compound of the formula CF 3 CCl═CHCH 2 OC(═O)R.
When a carboxylic acid salt other than a lithium-based salt is used in the invention, CF 3 CCl 2 CH═CH 2 by-product is produced in a 1:2 (CF 3 CCl═CHCH 2 OC(═O)R) ratio. This by-product can be separated (by conventional means such as distillation) and isomerized with LiCl (See, VanDerPuy et al., Journal of Fluorine Chemistry, 76 (1996) 49-54 which is incorporated herein by reference) to HCFC-1343 which readily reacts with the carboxylic acid salt in the presence of a polar aprotic solvent (See, U.S. Pat. No. 5,654,473) under conditions sufficient to produce a compound of the formula CF 3 CCl═CHCH 2 OC(═O)R. See Example 2.
When a lithium-based carboxylic acid salt is used, by-product formation is eliminated by in situ conversion to HCFC-1343 which readily reacts with the carboxylic acid salt in the presence of a polar aprotic solvent under conditions sufficient to produce a compound of the formula CF 3 CCl═CHCH 2 OC(═O)R.
The ability to convert the by-product ultimately to a compound of the formula CF 3 CCl═CHCH 2 OC(═O)R after separation or via in situ conversion defines a great advantage over the prior art processes. With the process of the invention, a product mixture comprising >96% useful materials is obtained.
The HCFC-353 starting material may be produced as described in U.S. Pat. No. 5,532,419, herein incorporated by reference in its entirety by the addition reaction of ethylene and 1,1,1-trichloro-2,2,2-trifluoroethane in the presence of a catalyst and an inert solvent.
The lithium chloride used in the invention should be substantially anhydrous (i.e., it should contain less than about 5 weight percent water). This material is commercially available from most chemical suppliers (e.g., Aldrich). A catalytic amount of LiCl is used in the process. Typically, the LiCl is present in an amount of from about 2 to about 25 mole percent based on HCFC-1343.
Any carboxylic acid salt of the formula R--COO 31 M + can be used in the invention wherein R is unsubstituted or substituted C 1 to C 6 straight chain or branched alkyl, unsubstituted or substituted C 3 to C 7 cycloalkyl, unsubstituted or substituted C 2 to C 12 alkenyl, a benzyl group unsubstituted or substituted with R', or a phenyl group unsubstituted or substituted with R'; wherein R' is an unsubstituted or substituted C 1 to C 6 straight chain or branched alkyl; and wherein when R and/or R' are substituted each is substituted with R'; and M is a Group IA metal. Preferably R is unsubstituted or substituted C 1 to C 6 straight chain or branched alkyl and most preferably R is CH 3 . M is preferably lithium, sodium or potassium.
Any polar, aprotic solvent may be used in the invention provided it is capable of dissolving at least about 10 mole % of the carboxylic acid salt relative to HCFC-353. Suitable solvents include dimethylsulfoxide (DMSO), sulfolane, N-methylpyrrolidinone (NMP) and dimethylformamide (DMF). DMF and DMSO are preferred because the carboxylic acid salts are very soluble in these solvents. When solvents with lower solubility for the acid salts are used, phase transfer catalysis may be employed. This helps the reaction rate by bringing into the solvent phase the inorganic part of the salt which is otherwise too insoluble for a reasonable reaction rate. This might be useful for sulfolane or NMP where the solubility of the salt is generally less than in DMF or DMSO. Typically, the solvents are used in an amount sufficient to form about a 0.5 to about 3.0 M solution of HCFC-353, HCFC-1343 or CF 3 CCl 2 CH═CH 2 .
The pressure at which the process is conducted is not critical. For convenience, the process is preferably conducted at atmospheric pressure in any convenient, suitable reaction vessel.
Generally, the reaction temperature will range from about 50° C. to about the boiling point of the polar aprotic solvent used in the process. With the preferred solvents, reaction temperatures range from about 50° C. to about 150° C. and preferably from about 85° C. to about 150° C. Under these conditions, reaction times vary from about 2 hours to about 48 hours, preferably from about 10 hours to about 24 hours.
The preferred CF 3 CCl═CHCH 2 OC(═O)R compounds are generally liquids that can be purified by distillation. The ratio of the geometrical isomers produced is about 93 to about 97% of the major isomer to about 3 to about 7% of the minor isomer. After the reaction is complete, volatile products may be recovered from the reaction medium either by direct distillation, provided the boiling points of the products and solvent are well separated (e.g. with solvents such as sulfolane or N-methylpyrrolidinone), or the entire mixture may be diluted with water, the organic products extracted, and subsequently purified by distillation (e.g. with solvents such as DMF and dimethylsulfoxide).
The stoichiometry of the reaction requires that about 2 moles of carboxylic acid salt be reacted for every about 1 mole of HCFC-353 or HCFC-1343. Typically from about 2 to about 4 moles of the carboxylic acid salt are used per about 1 mole of HCFC-353 or HCFC-1343.
In another embodiment, the invention relates to a process for the production of a compound of the formula (CF 3 CCl═CHCH 2 OC(═O)CH 3 ) comprising reacting either sodium acetate or potassium acetate with HCFC-353 in DMF at a temperature of from about 50° C. to about 150° C., optimally between about 65° C. to about 85° C. for a time sufficient to produce CF 3 CCl═CHCH 2 OC(═O)CH 3
Several other useful compounds can be prepared from CF 3 CCl═CHCH 2 OC(═O)R. Consequently, this invention provides, by extension, an improved process for their manufacture too. For example, CF 3 CH 2 CH 2 CH 2 OH can be prepared from CF 3 CCl═CHCH 2 OC(═O)R via hydrolysis, followed by reduction. See, U.S. Pat. No. 5,654,473. Thus, in yet another embodiment, the invention relates to a process comprising (1) hydrolyzing CF 3 CCl═CHCH 2 OC(═O)R with a base in the presence of a solvent to produce CF 3 CCl═CHCH 2 OH; (2) reducing CF 3 CCl═CHCH 2 OH with hydrogen in the presence of a hydrogenation catalyst and a base to produce CF 3 CH 2 CH 2 CH 2 OH; and recovering CF 3 CH 2 CH 2 CH 2 OH.
The first process step is exothermic and proceeds quickly, thus, cooling may be necessary to control the reaction. Reaction times for the first step are typically less than or equal to about one hour at a temperature of about 35° C. Any solvent in which the base is soluble may be used in the first process step. Suitable solvents include lower molecular weight alcohols such as methanol, tetrahydrofuran, water, and mixtures thereof Any base known to be useful in the hydrolysis of halogenated acetates may be used in the first step of the process. Suitable bases include, but are not limited to, potassium or sodium hydroxide.
The second process step proceeds smoothly under mild conditions (i.e., hydrogen pressures of from about 1 to about 10 atmospheres and temperatures in the range of from about 30° C. to about 100° C.). Suitable hydrogenation catalyst include, but are not limited to, Pd, Pt, and Rh supported on carbon or alumina. These catalysts are commercially available, alternately they may be made by methods known in the art. The catalyst is used in an amount of from about 1 to about 10 mg per gram of solvent. The catalyst loadings range from about 1 to about 20%, preferably from about 5 to about 10%.
A base is used (e.g. sodium acetate) in the second process step to prevent the reaction medium from becoming too acidic (i.e., pH<2), since under highly acidic conditions, the hydroxyl group can undergo hydrogenolysis, forming CF 3 CCl═CHCH 3 . The base is generally present in an amount of from about 1 to about 2 equivalents relative to the starting material.
One of ordinary skill in the art will recognize the versatility of the process of the invention to prepare other trifluoromethylated intermediates useful in synthesizing trifluoromethylated organic compounds.
EXAMPLES
Example 1
This example demonstrates the preparation of CF 3 CCl 2 CH═CH 2 and CF 3 CCl═CHCH 2 OAc from HCFC-353. A mixture of sodium acetate (300 g), dimethylformamnide (750 mL), and HCFC-353 (323 g, 1.5 mol) were heated to 70-75° C. with mechanical stirring for 40 hours. The conversion was >99%. The cooled mixture was poured into 2 liters of ice and water. The lower layer was separated, and the aqueous layer extracted with 2×200 mL portions of ether. The combined organic layers were washed with water, brine, dried, and distilled to give 76.6 g (0.43 mol) CF 3 CCl 2 CH═CH 2 and 173.0 g (0.85 mol) of 96% pure CF 3 CCl═CHCH 2 OAc. Prior to distillation, a typical crude product mixture has the following composition: 32.93% CF 3 CCl 2 CH═CH 2 , 1.24% CF 3 CHClCH═CHCl, 0.33% CF 3 CCl═CHCH 2 Cl, 1.62% HCFC-353, and 63.47% CF 3 CCl═CHCH 2 OAc.
Comparative Example 1
Comparative Examples 1-3 demonstrate the importance of using the preferred solvents (i.e., solvents in which the carboxylic acid salt is at least 10% soluble relative to HCFC-353). Sodium acetate (100 g), CF 3 CCl 2 CH 2 CH 2 Cl (100 g), and methanol (600 mL) were mixed and refluxed for 3 hours. Negligible reaction had occurred by GC analysis.
Comparative Example 2
The reaction was conducted and the reaction product was analyzed in the same manner as in Comparative Example 1 except that water was used instead of methanol. The reaction similarly failed to convert any of the starting material.
Comparative Example 3
Sodium acetate (25 g), 75 mL triglyme, and 20 g CF 3 CCl 2 CH 2 CH 2 Cl were heated to 106° C. for 17 hours. The conversion of starting material was only about 3% by GC analysis.
Comparative Example 4
Comparative Example 4 is illustrative of the prior art in which HCFC-353 is converted to HCFC-1343 and by-product, CF 3 CHClCH═CHCl. This by-product which is produced in significant quantity, does not produce CF 3 CCl═CHCH 2 OAc on reaction with sodium acetate, and consequently represents a yield loss. Sodium methoxide (135.0 g, 2495 mol) in 550 ml methanol was added over 100 minutes with mechanical stirring to 411.0 g (1.907 mol) HCFC-353 in 200 ml MeOH at 0-10° C. Stirring was continued for 20 hours and the reaction mixture poured into 3 L water. The lower product layer was washed twice with 100 ml water and dried (Na 2 SO 4 ), providing 308.1 g of crude product. Distillation gave 6.0 g forerun, 133.2 g of CF 3 CCl 2 CH═CH 2 , 94.7 g of a mixture of CF 3 CHClCH═CHCl and CF 3 CCl═CHCH 2 Cl, 20.7 g starting material CF 3 CCl 2 CH 2 CH 2 Cl, 33 g. intermediate cuts and 16.1 g pot residue. Thus, the combined yield of dehydrochlorination products, CF 3 CCl 2 CH═CH 2 , CF 3 CHClCH═CHCl and CF 3 CCl═CHCH 2 Cl, based on unrecovered starting material was 70%. The ratio of CF 3 CCl 2 CH═CH 2 : CF 3 CHClCH═CHCl : CF 3 CCl═CHCH 2 Cl was 59:35:7 as determined by GC and 19 F NMR data.
Example 2--Recycle of CF 3 CCl 2 CR═CH 2 to improve the yield of CF 3 CCl═CHCH 2 OAc.
90.4 g (0.505 mol) of CF 3 CCl 2 CH═CH 2 produced by the reaction reported in Example 1 and 3.0 g LiCl were dissolved in 150 mL DMF and heated to 95-105° C. for 3 hours. The mixture was allowed to cool to 80° C. before adding 45 g sodium acetate, followed by stirring 1 hour at 80° C. The cooled mixture was poured into 400 mL water, and worked up as described in Example 1 (2×150 mL extractions with ether). Distillation gave 86.1 g (0.43 mol) of 97% pure CF 3 CCl═CHCH 2 OAc. Thus with recycle, the overall distilled yield of CF 3 CCl═CHCH 2 OAc from HCFC-353 is 81%.
Example 3--Preparation of CF 3 CH 2 CH 2 CH 2 OH.
A solution of 8.0 grams NaOH in 30 nL water was added, over 1 hour, to 40.6 g of CF 3 CCl═CHCH 2 OC(O)CH 3 in 40 mL methanol, keeping the temperature less than 35° C. with the use of a water bath. After 1 hour, the mixture was diluted with 100 mL water. The lower layer was separated and the aqueous layer extracted with 2×50 mnL ether. The combined organic layers were washed with 25 mnL brine, dried (Na 2 SO 4 ), and distilled to give 26.9 g (84% yield) of 99.7% pure CF 3 CCl═CHCH 2 OH.
A 375 mL glass pressure vessel was charged with 16.1 g (0.10 mole) of 3-chloro-4,4,4-trifluorobut-2-en-1-ol (obtained above), 9.8 g (0.1 mole) potassium acetate, 30 mnL methanol, and 55 mg 5% Pd/C catalyst. Hydrogenation was carried out at 45-50° C. and at an operating hydrogen pressure of 40-60 psi, adding hydrogen as needed until the theoretical quantity had been taken up (about 14 hours). The mixture was cooled and filtered. The filtrate was poured into 150 mL water and extracted 4×50 mL ether. The combined ether layers were washed with 50 mnL bicarbonate solution and dried (MgSO4). Distillation gave 9.4 g (73% yield) of 97% pure 4,4,4-trifluorobutan-1-ol. | The present invention relates to a process for the preparation of trifluoromethylated derivatives of the formula CF 3 CCl═CHCH 2 OC(═O)R, wherein R is unsubstituted or substituted C 1 to C 6 straight chain or branched alkyl, unsubstituted or substituted C 3 to C 7 cycloalkyl, unsubstituted or substituted C 2 to C 12 alkenyl, a benzyl group unsubstituted or substituted with R', a phenyl group unsubstituted or substituted with R'; R' is an unsubstituted or substituted C 1 to C 6 straight chain or branched alkyl; and wherein where R and/or R' are substituted each is substituted with R', by reaction of HCFC-353 with carboxylic acid salts. The trifluoromethylated derivatives, particularly CF 3 CCl═CHCH 2 OC(═O)CH 3 , are versatile intermediates for the synthesis of a wide variety of trifluoromethylated organic compounds, which find utility as pharmaceuticals, agricultural chemicals, and materials such as liquid crystals. | 2 |
BACKGROUND OF INVENTION
The present invention relates generally to waste heat recovery from a power steering system.
An ongoing concern with automotive vehicles is quick warm-up of the passenger cabin on cold winter days. For conventional gasoline powered automotive vehicles, when outside ambient temperatures are low and the vehicle has not been operated for a time, slow engine coolant warm-up results in a slow warm-up of the passenger cabin. In particular, with fuel economy becoming more of a concern, many automotive vehicles are employing smaller engines or diesel engines, which exacerbates the issue. Thus, some have resorted to add-on auxiliary heating systems, such as, for example, electric heaters, fuel fired heaters, engine driven viscous heaters, and hot gas heaters. All of these auxiliary heating systems, however, use extra fuel, or put extra load on the engine in order to produce the heat, which is counter to the original intended purpose of improving vehicle fuel economy.
In addition, for automotive vehicles with automatic transmissions, operation of the transmission when the transmission oil is cold can result in less than optimal transmission operation. Thus, this can lead to a reduction in fuel economy under cold operating conditions.
SUMMARY OF INVENTION
One or more embodiments may contemplate a power steering waste heat recovery system for a vehicle that may comprise a power steering system and a waste heat absorption system. The power steering system may include a power steering pump, a liquid-to-liquid heat exchanger located downstream of the power steering pump and configured to allow power steering fluid flow therethrough, and a steering rack operatively engaging the heat exchanger to receive the power steering fluid therefrom. The waste heat absorption system including an auxiliary heater loop configured to direct a liquid through the heat exchanger; and an automatically controllable heat control valve having an inlet, a first outlet for directing the liquid to bypass the auxiliary heater loop, and a second outlet for directing the liquid through the heat exchanger in the auxiliary heater loop.
An embodiment contemplates a method of warming a liquid using heat from power steering fluid of a power steering system, the method comprising the steps of: pumping the power steering fluid through a liquid-to-liquid heat exchanger, a power steering rack, and a liquid-to-air power steering cooler; determining if an ambient air temperature is below a predetermined ambient air temperature threshold; determining if a liquid temperature of a waste heat absorption system is below a predetermined liquid temperature threshold; and actuating a heat control valve to direct the liquid to bypass an auxiliary heater loop containing the liquid-to-liquid heat exchanger if the ambient air temperature is not below the predetermined ambient air temperature threshold or the liquid temperature is not below the predetermined liquid temperature threshold.
An advantage of an embodiment is the ability to recover the energy supplied to the power steering system that is otherwise rejected as waste heat by selectively transferring the waste heat to coolant passing through an auxiliary coolant heater loop. This enhances the heater performance of a heating, ventilation and air conditioning (HVAC) system, allowing for a faster warm-up of a passenger cabin. The faster warm-up is achieved without the need for the engine to provide extra energy. A restriction introduced by the auxiliary coolant heater loop may also help to reduce noise emanating from the power steering system. Moreover, such an auxiliary coolant heater loop may be employed with minimal packaging and weight impact since the power steering system in typical automotive vehicles is close to the vehicle's instrument panel. Hence, coolant hoses to the heater core can be easily plumbed, and the small sized liquid-to-liquid heat exchanger can be easily packaged in the vehicle. In addition, no new vehicle fluids need to be introduced, since the vehicles already employ coolant and power steering fluid.
An advantage of an embodiment is the ability to recover the energy supplied to the power steering system that is otherwise rejected as waste heat by selectively transferring the waste heat to transmission oil passing through an auxiliary transmission oil heater loop. This may enhance the operation of the automatic transmission (or transaxle) by minimizing the time at which the transmission is operating with cold transmission oil, which has a higher than desired viscosity. The enhanced transmission performance may improve fuel economy under this operating condition.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic diagram of a power steering waste heat recovery system according to a first embodiment.
FIG. 2 is a schematic diagram of a power steering waste heat recovery system according to a second embodiment.
DETAILED DESCRIPTION
Referring to FIG. 1 , a waste heat recovery system 20 for a vehicle is shown. The waste heat recovery system 20 encompasses portions of a power steering system 22 and a heating, ventilation and air conditioning (HVAC) system 24 .
The power steering system 22 includes a hydraulic system 26 having a high pressure line 28 and low pressure line 30 . The arrowheads on the lines between illustrated components in FIGS. 1 and 2 represent fluid lines, with the arrows indicating the direction of fluid flow in the particular line when there is flow in that line. A power steering pump 32 , which may be driven by a pulley (not shown) coupled to the engine, draws power steering fluid 96 from a power steering reservoir 34 and directs it to a power steering control valve 36 . The control valve 36 directs the power steering fluid 96 either through a first outlet 38 back to the intake side of the pump 32 or forwards it through a second outlet 40 into the high pressure line 28 on the high pressure side of the hydraulic system 26 . The power steering fluid 96 is directed through a viscous heater with a liquid-to-liquid heat exchanger 42 before being directed into the steering rack 44 . The fluid pressure applied to the steering rack is used to provide assistance to the steering process, which is accomplished in a conventional manner. The power steering fluid 96 exits the power steering rack 44 into the low pressure line 30 on the low pressure side of the hydraulic system 26 , where it is directed through a power steering cooler 46 in order to allow for air cooling of the fluid 96 . The power steering fluid 96 is then directed back into the power steering reservoir 34 .
The portion of the HVAC system 24 shown is the heating portion of the system, and uses engine coolant 95 as its system fluid. An engine 50 includes a first coolant outlet 52 to a radiator cooling loop 54 , within which is a radiator 56 . A second coolant outlet 58 directs coolant 95 into an engine coolant bypass loop 60 . A third coolant outlet 62 directs coolant 95 into a heater core coolant loop 64 , within which is located a heat control valve 66 and a heater core 68 . Each of the coolant loops 54 , 60 , 64 directs the coolant 95 back to a thermostat and water pump 70 (shown with a single symbol in FIG. 1 ). The thermostat and water pump may operate a conventional manner, as is known to those skilled in the art. While three engine coolant outlets 52 , 58 , 62 are schematically shown and discussed, this may be a single opening from the engine 50 , with hoses that split into the three loops 54 , 60 , 64 .
The heater core 68 , heat control valve 66 and viscous heater 42 also form a portion of an auxiliary coolant heater loop 74 . The heat control valve 66 includes an inlet 76 from the third coolant outlet 62 and two outlets—a heater core outlet 78 directing coolant 95 to the heater core 68 , and a viscous heater outlet 80 directing coolant 95 to the viscous heater 42 . Coolant 95 directed into the heat exchanger 42 is then directed to the heater core 68 to complete the auxiliary coolant heater loop 74 . A controller 82 controls the heat control valve 66 , which controls to which outlet 78 or 80 the coolant 95 is directed. Dashed lines in FIGS. 1 and 2 represent control or communication lines, such as electrical wires. The controller 82 may be a stand alone controller or may be incorporated into another vehicle controller, such as a HVAC controller, if so desired. An ambient air temperature sensor 84 and a coolant temperature sensor 86 may be in communication with the controller 82 . The sensors 84 , 86 may be located as desired on the vehicle in order to get the desired ambient air and coolant temperature readings.
The operation of the waste heat recovery system 20 as it interacts with the power steering system 22 and HVAC system 24 will now be discussed. When the vehicle is operating, the power steering system 22 essentially operates the same as conventional power steering systems with the exception that the power steering fluid 96 now flows through the heat exchanger 42 . The operation of the power steering system 22 causes the power steering fluid 96 to heat up as part of the normal operation of the system. Also, with the heat control valve 66 set to direct the coolant 95 through the heater core outlet 78 to the heater core 68 , the HVAC system and engine cooling essentially operate the same as with a conventional system.
However, when the temperature sensors 84 , 86 detect that the ambient temperature is below a predetermined ambient temperature threshold and the coolant temperature is below a predetermined coolant temperature threshold, and the HVAC system 24 is in a heater mode, then the controller 82 will actuate the heat control valve 66 to cause the coolant 95 to flow through the viscous heater outlet 80 . The coolant 95 , then, flows through the heat exchanger 42 where it absorbs heat from the power steering fluid 96 . Thus, waste heat from the power steering system 22 is transferred to the HVAC system 24 . This warmed coolant 95 then flows through the auxiliary coolant heater loop 74 to the heater core 68 and back to the engine 50 . The extra heat absorption by the coolant 95 in the heat exchanger 42 will provide additional heat sooner to the heater core 68 . Thus, the time to heat the vehicle passenger cabin on cold days when the coolant 95 starts out near ambient temperature is reduced. Once the coolant 95 warms up due to engine operation, the controller 82 will then actuate the heat control valve 66 to direct the coolant 95 through the heater core outlet 78 .
FIG. 2 illustrates a second embodiment. Since this embodiment is similar to the first, similar element numbers will be used for similar elements, but employing 100-series numbers. The power steering system 122 , including the hydraulic system 126 , power steering pump 132 , power steering reservoir 134 , power steering control valve 136 , the viscous heater with liquid-to-liquid heat exchanger 142 , power steering rack 144 and power steering cooler 146 , may remain essentially unchanged from the first embodiment.
In this embodiment, the heat exchanger 142 is coupled to an auxiliary transmission oil heater loop 174 of a transmission oil cooling system 190 , which incorporates part of the wasted heat recovery system 120 . The auxiliary transmission oil heater loop 174 includes a heat control valve 166 that has an inlet 176 from an oil outlet 162 of a transmission (or transaxle) 150 , a transmission oil cooler outlet 178 and a viscous heater outlet 180 . The viscous heater outlet 180 directs transmission oil 197 to the heat exchanger 142 , which then directs the transmission oil 197 back to the transmission 150 to complete the auxiliary transmission oil heater loop 174 . The transmission oil cooler outlet 178 directs the transmission oil 197 to a transmission oil cooler 168 , which then directs the transmission oil 197 back to the transmission 150 to complete a transmission oil cooling loop 154 .
A controller 182 controls the heat control valve 166 , which controls to which outlet 178 or 180 the transmission oil 197 is directed. The controller 182 may be a stand alone controller or may be incorporated into another vehicle controller, such as a transmission (or transaxle) controller, if so desired. An ambient air temperature sensor 184 , a coolant temperature sensor 186 and transmission oil temperature sensor 192 may be in communication with the controller 182 . The sensors 184 , 186 , 192 may be located as desired on the vehicle in order to get the desired temperature readings.
The operation of the waste heat recovery system 120 as it interacts with the power steering system 122 and transmission oil cooling system 124 will now be discussed. When the vehicle is operating, the power steering system 122 essentially operates the same as convention power steering systems with the exception that the power steering fluid 196 now flows through the heat exchanger 142 . The operation of the power steering system 122 causes the power steering fluid 196 to heat up as part of the normal operation of the system. Also, with the heat control valve 166 set to direct the transmission oil 197 through the transmission oil cooler outlet 178 to the transmission oil cooler 168 , the transmission oil cooling system 124 essentially operates the same as with a conventional system.
However, when the temperature sensors 184 , 186 , 192 detect that the ambient temperature is below a predetermined ambient temperature threshold, the coolant temperature is below a predetermined coolant temperature threshold, and the transmission oil temperature is below a predetermined transmission oil temperature threshold, then the controller 182 will actuate the heat control valve 166 to cause the transmission oil 197 to flow through the viscous heater outlet 180 . The transmission oil 197 , then, flows through the heat exchanger 142 where it absorbs heat from the power steering fluid 196 . This warmed transmission oil 197 then flows through the auxiliary transmission oil heater loop 174 and back to the transmission 150 . One will note that, in this mode, the transmission oil 197 does not flow through the transmission oil cooler 168 . The extra heat absorption by the transmission oil 197 in the heat exchanger 142 will provide additional heat sooner, thus reducing the time to optimal transmission operation on cold days when the transmission oil 197 starts out near ambient temperature. Once the transmission oil 197 warms up due to vehicle operation, the controller 182 will then actuate the heat control valve 166 to direct the transmission oil 197 through the transmission oil cooler outlet 178 .
While certain embodiments of the present invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims. | A power steering waste heat recovery system for a vehicle and method of operating is disclosed. The system may include a power steering system and a waste heat absorption system. The power steering system may include a power steering pump, a liquid-to-liquid heat exchanger located downstream of the power steering pump and configured to allow power steering fluid flow therethrough, and a steering rack operatively engaging the heat exchanger to receive the power steering fluid therefrom. The waste heat absorption system may include an auxiliary heater loop configured to direct a liquid through the heat exchanger; and an automatically controllable heat control valve having an inlet, a first outlet for directing the liquid to bypass the auxiliary heater loop, and a second outlet for directing the liquid through the heat exchanger in the auxiliary heater loop. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates generally to the field of signal telemetry for equipment used in drilling wellbores through the Earth. More particularly, the invention relates to methods and apparatus for locating faults in so-called “wired” drill pipe used for such telemetry.
[0003] 2. Background Art
[0004] Devices are known in the art for making measurements of various drilling parameters and physical properties of Earth formations as a wellbore is drilled through such formations. The devices are known as measurement while drilling (“MWD”) for devices that measure various drilling parameters such as wellbore trajectory, stresses applied to the drill string and motion of the drill string. The devices are also known as logging while drilling (“LWD”) for devices that measure various physical properties of the formations, such as electrical resistivity, natural gamma radiation emission, acoustic velocity, bulk density and others. The various MWD and LWD devices are coupled near the bottom end of a “drill string,” which is an assembly of drill pipe segments and other drilling tools threadedly coupled end to end with a drill bit at the lowest end. During operation of the drill string, the drill string is suspended in the wellbore so that a portion of its weight is transferred to the drill bit, and the drill bit is rotated to drill through the Earth formations. Sensors on the various MWD and LWD devices can make the respective measurements during drilling operations. Wellbore drilling operators generally find that MWD and LWD measurements are particularly valuable when obtained during the actual drilling of the wellbore. For example, resistivity and gamma radiation measurements obtained during drilling may be compared with similar measurements made from a nearby wellbore so as to determine which Earth formations are believed to be penetrated by the wellbore at any moment in time. The wellbore operator may use such measurements to determine that the wellbore has been drilled to a particular depth necessary to conduct additional operations, such as running a casing or increasing the density of drilling fluid used in drilling operations. In general, MWD and LWD measurements may be communicated to the surface through telemetry between the bottom hole assembly and the surface. A telemetry device or tool in the bottom hole assembly with encode and transmit the data to the surface. It is often the case that the telemetry bandwidth cannot accommodate all of the MWD and LWD data that is collected. Thus, typically only a selected portion of the data is communicated to the surface, while all of the MWD and LWD data may be stored in one of the downhole components.
[0005] The signal telemetry that is most often used with MWD and LWD devices is so-called “mud pulse” telemetry. Mud pulse telemetry is generated by modulating the flow of the drilling fluid proximate the MWD or LWD devices in a manner to cause detectable changes in pressure and/or flow rate of the drilling fluid at the Earth's surface. The modulation is typically performed to represent binary digital words, using techniques such as Manchester code or phase shift keying. It is well known in the art that drilling fluid flow modulation is capable of transmitting at a rate of only a few bits per second. Thus, for most MWD and LWD applications, only a selected portion of the total amount of data being acquired is transmitted to the surface, while the data collected is stored in a recording device disposed in one or more of the MWD and LWD devices or in a another device for storing data.
[0006] Considerable effort has been made to provide a higher speed telemetry system for MWD and LWD devices. Such effort has been undertaken for a considerable time, and has resulted in a number of different approaches to high rate telemetry. For example, U.S. Pat. No. 4,126,848 issued to Denison discloses a drill string telemetry system, wherein an armored electrical cable (“wireline”) is used to transmit data from near the bottom of the wellbore to an intermediate position in the drill string, and a special drill string, having an insulated electrical conductor, is used to transmit the information from the intermediate position to the Earth's surface. Similarly, U.S. Pat. No. 3,957,118 issued to Barry, et al., discloses a cable system for wellbore telemetry. U.S. Pat. No. 3,807,502 issued to Heilhecker, et al., discloses methods for installing an electrical conductor in a drill string.
[0007] More recently, alternative forms of “wired” drill pipe have been described in U.S. Pat. No. 6,670,880 issued to Hall, et al. The system disclosed in the '880 patent is for transmitting data through a string of components disposed in a wellbore. In one aspect, the system includes first and second magnetically conductive, electrically insulating elements at both ends of each drill string component. Each element includes a first U-shaped trough with a bottom, first and second sides and an opening between the two sides. Electrically conducting coils are located in each trough. An electrical conductor connects the coils in each component. In operation, a time-varying current applied to a first coil in one component generates a time-varying magnetic field in the first magnetically conductive, electrically insulating element, which time-varying magnetic field is conducted to and thereby produces a time-varying magnetic field in the second magnetically conductive, electrically insulating element of a connected component, which magnetic field thereby generates a time-varying electrical current in the second coil in the connected component.
[0008] Another wired drill pipe telemetry system is disclosed in U.S. Pat. No. 7,096,961 issued to Clark, et al., and assigned to the assignee of the present invention. A wired drill pipe telemetry system disclosed in the '961 patent includes a surface computer; and a drill string telemetry link comprising a plurality of wired drill pipes each having a telemetry section, at least one of the plurality of wired drill pipes having a diagnostic module electrically coupling the telemetry section and wherein the diagnostic module includes a line interface adapted to interface with a wired drill pipe telemetry section; a transceiver adapted to communicate signals between the wired drill pipe telemetry section and the diagnostic module; and a controller operatively connected with the transceiver and adapted to control the transceiver.
[0009] The '961 patent describes a number of issues that must be addressed for the successful implementation of a wired drill pipe (“WDP”) telemetry system. For drilling operations in a typical wellbore, a large number of pipe segments are coupled end to end to form a pipe string extending from a Kelley (or top drive) located on a drilling unit at the Earth's surface and the various drilling, MWD and LWD devices in the wellbore with the drill bit at the end thereof. For example, a 15,000 ft (5472 m) wellbore will typically have about 500 drill pipe segment if each of the drill pipe segments is about 30 ft (9.14 m) long. The sheer number of pipe to pipe connections in such a WDP drill string raises concerns of reliability for the system. A commercially acceptable drilling system is expected to have a mean time between failure (“MTBF)” of about 500 hours or more. If any one of the electrical connections in the WDP drill string fails, then the entire WDP telemetry system fails. Therefore, where there are 500 WDP drill pipe segments in a 15,000 ft (5472 m) well, each WDP would have to have an MTBF of at least about 250,000 hr (28.5 yr) in order for the entire WDP system to have an MTBF of about 500 hr. This means that each WDP segment would have a failure rate of less than 4×10 −6 per hour. Such a requirement is beyond the current state of WDP technology. Therefore, it is necessary that methods are available for testing the reliability of a WDP segment and drill string and for quickly identifying any failure.
[0010] Currently, there are few tests that can be performed to ensure WDP reliability. Before the WDP segments are brought onto the drilling unit, they may be visually inspected and the pin and box connections of the pipes may be tested for electrical continuity using test boxes. It is possible that two WDP sections may pass a continuity test individually, but they might fail when they are connected together. Such failures might, for example result from debris in the connection that damages the inductive coupler. Once the WDP segments are connected (e.g., made up into “stands”), visual inspection of the pin and box connections and testing of electrical continuity using test boxes will be difficult, if not impossible, on the drilling unit. This limits the utility of such methods for WDP inspection.
[0011] In addition, the WDP telemetry link may suffer from intermittent failures that would be difficult to identify. For example, if the failure is due to shock, downhole pressure, or downhole temperature, then the faulty WDP section might recover when conditions change as drilling is stopped, or as the drill string is tripped out of the hole. This would make it extremely difficult, if not impossible, to locate the faulty WDP section.
[0012] In view of the above problems, there continues to be a need for techniques and devices for performing diagnostics on and/or for monitoring the integrity of a WDP telemetry system.
SUMMARY OF THE INVENTION
[0013] A method for determining electrical condition of a wired drill pipe according to one aspect of the invention includes inducing an electromagnetic field in at least one joint of wired drill pipe. Voltages induced by electrical current flowing in at least one electrical conductor in the at least one wired drill pipe joint are detected. The electrical current is induced by the induced electromagnetic field. The electrical condition is determined from the detected voltages.
[0014] A method for determining electrical condition of a wired drill pipe string according to another aspect of the invention includes moving an instrument along a string of wired drill pipe joints connected end to end. Electrical current is passed through a transmitter antenna on the instrument to induce an electromagnetic field in the string. Voltages induced in a receiver antenna on the instrument as a result of electrical current flowing in at least one electrical conductor in the pipe string are detected. The electrical current is induced by the induced electromagnetic field. The electrical condition between the transmitter antenna and the receiver antenna is determined from the detected voltages. The passing electrical current, detecting voltages and determining condition are then repeated at a plurality of positions along the pipe string.
[0015] A method for drilling a wellbore according to another aspect of the invention includes suspending a string of wired drill pipe joints coupled end to end in a wellbore. The pipe string has a drill bit at a distal end thereof. The drill bit is rotated while releasing the drill string from the surface to maintain a selected amount of weight on the drill bit. An electromagnetic field is induced in the pipe string at a first selected position outside the pipe string. Voltages are detected at a second selected position outside the pipe string and spaced apart from the first selected position. The voltages result from electrical current flowing in at least one electrical conductor in the pipe string. The flowing current results from the induced electromagnetic field. Electrical condition of the pipe string is determined from the detected voltages. Releasing the pipe string continues while rotating the drill bit. The inducing, detecting and determining are repeated as the pipe string is moved.
[0016] Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 shows an example of a WDP testing device as it would be used in evaluating one or more segments of WDP.
[0018] FIG. 2 shows a cross sectional view of one example of a WDP testing device.
[0019] FIGS. 3 and 4 show additional examples of a WDP testing device having selectable span between transmitter and receiver.
[0020] FIG. 5 shows another example of a WDP testing device that operates outside the WDP.
[0021] FIG. 6 shows the example device shown in FIG. 5 as it may be used with a drilling rig.
[0022] FIG. 7 shows another example fault locating device including an external transmitter coil and a movable receiver coil insertable inside the WDP.
[0023] FIG. 8 shows an example record with respect to depth in a wellbore of signals measured using the example shown in FIG. 7 .
DETAILED DESCRIPTION
[0024] One example of a device and method for locating an electrical fault in a wired drill pipe (“WDP”) telemetry system will be explained with reference to FIG. 1 . Two threadedly coupled segments or “joints” of WDP are shown generally at 10 . Each WDP joint 10 includes a pipe mandrel 12 having a male threaded connection (“pin”) 18 at one end and a female threaded connection (“box”) 16 at the other end. A shoulder 20 A on each of the pin 18 and box 16 may include a groove or channel 20 in which may be disposed a toroidal transformer coil 22 . Structure of and operation of such toroidal transformer coils to transfer signals from one joint to another are explained in U.S. Pat. No. 7,096,961 issued to Clark, et al., assigned to the assignee of the present invention and incorporated herein by reference. Electrical conductors 24 are disposed in a suitable place within the joint 10 , such as in a longitudinally formed bore or tube (not shown) so as to protect the conductors 24 from drilling fluid that is typically pumped through a central bore or passage 14 in the center of the WDP joint 10 . Such passage 14 is similar to those found in conventional (not wired) joints of drill pipe known in the art. When the pin 18 and box 16 of two WDP joints 10 are threadedly coupled, corresponding ones of the toroidal transformer coils 22 are placed proximate each other so that signals may be communicated from on joint 10 to the next joint.
[0025] In the present embodiment, a fault locating device 26 may in inserted into the passage 14 and disposed in one of the joints 10 for inspection thereof. The example fault locating device 26 is shown in FIG. 1 as being suspended inside the joint 10 by an armored electrical cable 32 . The armored electrical cable may be extended from and retracted onto a winch (not shown) or similar device known in the art for spooling armored electrical cable. As will be readily appreciated by those skilled in the art, by suspending the fault locating device 26 from such a cable 32 , it is possible to use the fault locating device 26 while an entire string of WDP joints 10 is deployed in a wellbore being drilled through Earth formations. Thus the entire string of WDP may be evaluated by moving the fault locating device 26 along the inside of the pipe string by operating the winch (not shown).
[0026] It should be understood that conveyance by a cable, such as shown in FIG. 1 , is not the only manner in which the fault locating device 26 may be moved through WDP joints. Other conveyance means known in the art include, for example, coupling the fault locating device 26 to the end of a coiled tubing, coupling the device to the end of a string of threadedly coupled rods or production tubing, or any other manner of conveyance known in the art for deploying a measuring instrument into a wellbore.
[0027] The functional components of the fault locating device 26 shown in FIG. 1 include an electromagnetic transmitter antenna 28 and an electromagnetic receiver antenna 30 . The antennas 28 , 30 may be in the form of longitudinally wound wire coils, or may be any other antenna structure capable of inducing an electromagnetic field in the WDP joint 10 when electrical power is passed through the transmitter antenna 28 and capable of producing a detectable voltage in the receiver antenna 30 as a result of electromagnetic fields induced in the WDP joint 10 by the current passing through transmitter antenna 28 . In the example shown in FIG. 1 , circuitry (as will be explained in more detail with reference to FIG. 2 ) coupled to the transmitter antenna 28 causes an electromagnetic field to be induced in the WDP joint 10 . The electromagnetic field induces an electric current in the circuit loop created by the electrical conductors 24 and the toroidal transformer coils 22 at each end of the WDP joint 10 . Electromagnetic fields generated by such current in the circuit loop may be detected by measuring a voltage induced in the receiver antenna 30 . Based on properties of the detected voltage, the electrical integrity of the WDP joint 10 may thus be determined.
[0028] One example of a fault locating device 26 will now be explained in more detail with reference to FIG. 2 . The fault locating device 26 may include a pressure resistant housing 34 configured to traverse the interior of the WDP ( 10 in FIG. 1 ). The housing 34 A may define a sealable interior chamber 34 in which electronic components of the fault locating device 26 may be disposed. The antennas 28 , 30 , which as previously explained may be longitudinally wound wire coils, may each be disposed in a respective groove or recess 28 A, 30 A formed in the exterior surface of the housing 34 . The wire of each antenna coil 28 , 30 may enter the chamber 34 A by a pressure sealing, electrical feedthrough bulkhead 46 . The electronic components in the present embodiment may include an electrical power conditioning circuit 48 that may accept electrical power transmitted from the Earth's surface along the cable 32 along one or more insulated electrical conductors (not shown separately). The one or more electrical conductors (not shown separately) may also be used to communicate signals produced in the fault locating device 26 to the Earth's surface. A controller 36 , which may be a microprocessor-based system controller, may provide operating command signals to drive the other principal components of the device 26 . For example, an analog receiver amplifier 40 may be electrically coupled to the receiver antenna 30 to detect and amplify voltages induced in the receiver antenna 30 . The detected and amplified voltages may be digitized in an analog to digital converter (“ADC”) 38 , so that the magnitude of the voltage with respect to time will be in the form of digital words each representing the voltage magnitude. The output of the ADC 38 may be conducted to the controller 36 for storage and/or further processing. The controller 36 may store one or more current waveforms in the form of digital words. The current waveforms are those for alternating electrical current to be passed through the transmitter antenna 28 . In the present embodiment, the current waveform words may be conducted through a digital to analog converter (“DAC”) 42 to generate the analog current waveform. The analog current waveform may be conducted to a transmitter power amplifier 44 for driving the transmitter antenna 28 .
[0029] It will be appreciated by those skilled in the art that the implementation of current generation and signal detection shown in FIG. 2 , which includes digital signal processing circuitry, is only one possible implementation of a fault locating device according to the invention. It is also within the scope of this invention to use analog circuitry to generate the current and to detect the induced voltages.
[0030] In the present example, the current passing through the transmitter antenna 28 causes electromagnetic fields to be induced in the WDP joint, and specifically in the current loop created by the toroidal coils ( 22 in FIG. 1 ) and the electrical conductors ( 24 in FIG. 1 ). In an electrically sound WDP joint, a voltage will be induced in the receiver antenna 30 that corresponds to the entire current loop being properly interconnected and insulated from grounding to the metal pipe mandrel ( 12 in FIG. 1 ). The detected voltages are then digitized in the ADC 38 , and are then communicated to the controller 36 , where the digitized detected voltages may be imparted to any known telemetry for communication to the Earth's surface.
[0031] The example shown in FIG. 2 may have a longitudinal span 50 between the transmitter antenna 28 and the receiver antenna 30 such that antennas 28 , 30 may be spaced proximate respective ones of the toroidal coils ( 22 in FIG. 2 ) in each WDP joint ( 10 in FIG. 1 ) during inspection. As the fault locating device is moved through each WDP pipe joint ( 10 in FIG. 1 ), a record is made of the voltages detected by the receiver antenna 30 . If any WDP joint has an open circuit, such that the current loop described above is not complete, then the magnitude of the detected voltage will be relatively small or zero. If a WDP joint has a short circuit, the detected voltage will be small or zero when the respective antennas 28 , 30 are disposed proximate the ends of the WDP joint. It will be appreciated that under such conditions it could be difficult to distinguish between an open circuit and a short circuit in the WDP joint. Therefore, other examples of a fault locating device according to the invention may have different and/or selectable span between the transmitter antenna and the receiver antenna.
[0032] Alternatively, if there is an open circuit, the detected signal would be approximately zero for the entire pipe segment being investigated. If there were a short between the conductors, however, the current would be induced in the upper part of the segment, and there would be a non-zero signal until the receiver moved past the position of the short circuit. In this respect, the detected signal could be used to identify the type of fault (short or open) and the location of the fault with in the pipe segment in the case of a short circuit.
[0033] FIG. 3 shows another possible example of a fault locating device 26 A having a selectable longitudinal span between the transmitter antenna 28 and the receiver antenna 30 . In the example of FIG. 3 , the housing consists of two slidably engaged housing segments 34 A, 34 B. The transmitter antenna 28 may be formed on or affixed to one segment 34 A while the receiver antenna 30 may be formed on or affixed to the other segment 30 B. By sliding one segment 34 B with respect to the other 34 A, it is possible to change the longitudinal span between the transmitter antenna 28 and the receiver antenna 30 .
[0034] Another example of a fault locating device 26 B having a selectable span between the transmitter antenna and the receiver antenna is shown in FIG. 4 . In the embodiment of FIG. 4 , the housing 34 may be similar to that explained with reference to FIG. 2 . However, the fault locating device 26 B may include a plurality of receiver antennas shown at 30 A, 30 B, 30 C, 30 D disposed on or affixed to the housing 34 at longitudinally spaced apart positions. The receiver amplifier ( 40 in FIG. 2 ) may be preceded by a multiplexer (not shown) or similar switch to select the one of the receiver antennas 30 A- 30 D to be interrogated at any point in time. One or more of the receiver antennas 30 A- 30 B may be used at the same time to interrogate a section of WDP. In one particular example, the transmitter to receiver span is initially set to match the span between the toroidal coils ( 22 in FIG. 1 ) in the typical WDP joint. When inspection of any one or more joints indicates low or no detected receiver voltage, then the span between the transmitter antenna 28 and the receiver antenna may be selected, as in FIG. 3 by sliding the housing segment 34 B to shorten the span until a detectable voltage is found, or as shown in FIG. 4 , by selecting successively shorter spaced receiver antennas 30 D, 30 C, 30 B, 30 A until a detectable voltage is found. The position of a short circuit in a WDP joint my thus be determined.
[0035] It will be appreciated by those skilled in the art that the longitudinal span ( 50 in FIG. 2 ) of the fault locating device 26 is not limited to only the span between the ends of one WDP joint as shown in FIG. 1 . It is clearly within the scope of the present invention to provide a fault locating device having a span of the lengths of two or more WDP joints ( 10 in FIG. 1 ). For example, a fault locating device may have a span that is about equal to the length of three segments of WDP joints. In this manner, a fault locating device may be used to narrow the location of the fault in the WDP system. It is noted that a fault locating device with a span of two, or four or more segments is also possible.
[0036] It is also within the scope of the present invention to determine faults in a WDP joint or joints by using a device that operates on the outside of the WDP. FIG. 5 shows another example of such a fault locating device 26 C. A mandrel 34 B, which in the present embodiment may be made from electrically non-conductive, non magnetic material such as glass fiber reinforced plastic, may include a transmitter antenna 28 A and receiver antenna 30 B which may be longitudinally wound wire coils substantially as explained with reference to FIG. 2 . Not shown in FIG. 5 is the circuitry to actuate the transmitter antenna 28 B and receiver antenna 30 B, which also may be substantially as explained with reference to FIG. 2 . The embodiment shown in FIG. 5 may have particular application on or near the floor of a drilling unit, such that as the WDP string is assembled or “made up” and is lowered into the wellbore, the individual joints of WDP will pass through the device shown in FIG. 5 for inspection during the “trip” into the wellbore. The WDP joints may be inspected again as the WDP string is withdrawn from the wellbore. Variations on the device shown in FIG. 5 that include features for changing the longitudinal span ( 50 in FIG. 2 ) between the transmitter antenna 28 B and the receiver antenna 30 B may be also used with the example fault locating device 26 C shown in FIG. 5 .
[0037] Referring to FIG. 6 , the manner in which the embodiment shown in FIG. 5 may be used as explained above will be explained in more detail. A string of WDP joints 10 coupled end to end is shown suspended by a top drive 52 (or kelly on drilling units so equipped). The top drive 52 may be raised and lowered by a hook 48 coupled to a hoisting system consisting of drawworks 50 , drill line 55 , upper sheave 51 and lower sheave 53 of types well known in the art. All the foregoing components are associated with a drilling unit 46 . A fault locating device 26 substantially as explained with reference to FIG. 5 may be disposed in a convenient location with respect to the drilling unit 46 , such that as the pipe string is moved upwardly or downwardly, the various WDP joints 10 may move through the device 26 for evaluation.
[0038] A drill bit 40 is disposed at the lower end of the string of WDP joints 10 and drills a wellbore 42 through subterranean Earth formations 41 . The drill bit 40 is rotated by operating the top drive 52 to turn the pipe string, or alternatively by pumping fluid through a drilling motor (not shown) typically located in the pipe string near the drill bit 40 . As the drill bit 40 drills formations 41 the pipe string is continuously lowered by operating the drawworks 50 to release the drill line 55 . Such operation maintains a selected portion of the weight of the pipe string on the drill bit 40 . As the pipe string moves correspondingly, successive ones of the WDP joints 10 move through the interior of the fault locating device 26 C. Once inside, the transmitter and receiver antenna may be activated to interrogate the WDP section that is disposed within the fault locating device 26 C.
[0039] The evaluation may continue as the pipe string is withdrawn from the wellbore 42 . Circuitry such as explained with reference to FIG. 2 may be disposed in a recording unit 54 , which may include other systems (not shown) for recording an interpretation of measurements made by the fault locating device 26 .
[0040] During drilling operations as shown in FIG. 6 , if the WDP telemetry fails, in one example, a device such as shown in FIG. 2 may be lowered inside the pipe string at the end of an electrical cable, substantially as explained with reference to FIGS. 1 and 2 . By using a device as shown in FIG. 2 and as explained above inside the pipe string while it is suspended in the wellbore 42 , it may be possible to locate the particular WDP joint 10 where the fault is located. Such location may eliminate the need to remove the entire pipe string from the wellbore 42 and test each WDP joint 10 individually. Alternatively, the fault locating device 26 shown in FIG. 6 may be used while withdrawing the pipe string from the wellbore 42 until the failed WDP joint 10 is located.
[0041] Another example fault locating device is shown in FIG. 7 . The example device shown in FIG. 7 includes a transmitter 26 A similar to the example shown in and explained with reference to FIG. 6 . Such transmitter 26 A may be disposed below the drill floor of the drilling unit (or any other convenience location) and may be disposed outside the WDP joints 10 . A receiver 26 B may include one or more receiver coils 26 C disposed on a sonde mandrel. The receiver 26 B may be moved along the interior of the WDP joints 10 by an armored electrical cable 27 coupled to one end of the receiver 26 B. During operation of the device shown in FIG. 7 , the transmitter may be energized as explained above with reference to other example devices, and a record with respect to depth of voltage induced in the one or more receiver coils 26 C may be made. The position of a fault such as an open or short circuit may be inferred from the record of voltage measurements.
[0042] A possible interpretation of signals measured by the example shown in FIG. 7 will now be explained with reference to FIG. 8 . FIG. 8 is a graph (or “log”) at 80 of detected voltage with respect to depth in the wellbore of the receiver ( 26 B in FIG. 7 ). The detected voltage amplitude 80 exhibits peaks 82 , 84 , 86 , 88 , 90 of decreasing amplitude that correspond to the location along the WDP of connections between successive WDP joints ( 10 in FIG. 7 ). It can also be observed in FIG. 8 that the amplitude of the signal decreases with depth, and correspondingly, as the transmitter ( 26 A in FIG. 7 ) and receiver ( 26 B in FIG. 7 ) become more spaced apart. In one example, a log may be made of the receiver signal when drilling the wellbore begins. A log may be made of the receiver signal at selected times during drilling operations. Changes in the signal amplitude between successive logs above a selected threshold may indicate an impending fault in the WDP that requires intervention.
[0043] Any of the foregoing examples intended to be moved through the interior of a string of WDP may have electrical power supplied thereto by an armored electrical cable, or may include internal electrical power such as may be supplied by batteries. Alternatively, such devices may be powered by a fluid operated turbine/generator combination as will be familiar to those skilled in he art as being used with MWD and/or LWD instrumentation. Such examples may include internal data storage that can be interrogated when he device is withdrawn from the interior of the WDP, or signals generated by the device may be communicated over the armored electrical cable where such cable is used.
[0044] It will also be appreciated by those skilled in the art that multiple receiver antenna example such as shown in FIG. 4 may be substituted by multiple transmitter antennas each or selectively coupled to the source of alternating current. The example explained with reference to FIG. 7 may also be substituted by a receiver in the position where the transmitter is shown below the rig floor, and the receiver inside the WDP may be substituted by one or more transmitters. Such possibility will occur to those of ordinary skill in the art by reason of the principle of reciprocity. Therefore, reference to “transmitter”, “transmitting” or “transmitter antenna” in the description and claims that follow may be substituted by “receiver”, “receiving” or “receiver antenna” where such reference defines location of a particular antenna or act performed through an antenna. The opposite substitution may be made with reference herein to “receiver”, “receiving” or “receiver antenna.”
[0045] While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims. | A method for determining electrical condition of a wired drill pipe includes inducing an electromagnetic field in at least one joint of wired drill pipe. Voltages induced by electrical current flowing in at least one electrical conductor in the at least one wired drill pipe joint are detected. The electrical current is induced by the induced electromagnetic field. The electrical condition is determined from the detected voltages. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to PCT Application No. GB98/03007 filed Oct. 7, 1998 which claims priority to GB Application No. 9721400.1 filed Oct. 9, 1997.
BACKGROUND OF THE INVENTION
This application relates to the construction of underground structures in tunnel excavations without causing surface disruption. This type of excavation technique has been developed in the last 30 years and there is a growing need to install structures such as, for example, traffic underpasses, below an existing rail track or highway without stopping the use and operation of the same. Another example is the creation of a metro station below a busy street or property.
The problem with traditional tunnelling techniques is that for safety reasons there is required to be a depth of soil of approximately 2 to 3 times the diameter of the tunnel which is to be excavated, above the said tunnel. This renders the traditional techniques impractical and so a number of conventional methods have been developed and are now used which reduce the requirement for such a great depth of soil to be provided above the tunnel. These methods are based on the principle of jacking pre-cast structure units into the excavated area, as the same is excavated to form a structure as the tunnel is formed. The formation of the structure allows the support of the tunnel as it is formed without the need to cause disruption to services or property on the surface.
A known approach is to prepare the structure to be installed at the side of the excavation and then jack it horizontally into position in the excavation. This has the disadvantage of requiring large constructions to be formed at the side and an extended area to be prepared for carrying out the work, usually of at least the same dimensions as the installation. It is also a process that is time consuming as a great deal of preparatory work has to be done in forming the working areas and casting the structure units.
A second known approach is a modular approach where a series of pre-cast units are jacked, one on top of another, to form piers and abutments. This is a system which has found extensive use but has the disadvantage of not providing a complete solution to the problem as, although the majority of the excavation work can be completed without disruption it is necessary at some stage to complete the work by taking possession of the excavation so as to allow installation of the spanning beams.
A third known approach is to create a structure of arch shaped cross section which is formed by a series of relatively small section tubes which run along the length of the structure. This provides a canopy which allows excavation to take place safely underneath. The disadvantages with this is that it is difficult and expensive to place all the tubes in position and, normally it is necessary to provide props for the arch across the base of the same and put in temporary support beams to support the tube arch and these procedures are required to be undertaken as work progresses.
SUMMARY OF THE INVENTION
Documents DE3609791 and U.S. Pat. No. 3,916,630 both disclose methods of formation of support structures with DE3609791 disclaiming the formation of a pipe structure and U.S. Pat. No. 3,916,630 the formation of a structure cast in situ; however neither discloses the formation of an arch structure from units pushed or jacked into the excavation.
The aim of the present invention is to provide an improved process of supporting material excavations by utilising a modular pre-cast unit based on the principle of using units formed of an arch shape such that a series of said units allow an arch structure to be formed, said arch being an efficient form of carrying live and dead loads and therefore well suited to creating an underground structure. The approach is to pre-cast arch panels, erect them in the excavated area and jack the assembled elements forward to form the structure.
In a first aspect of the invention there is provided a support structure which can be used to support excavated areas during and/or following excavation, said support structure including a series of upstanding arch shaped sections, positioned along the length of the excavated area, one after the other, and characterised in that said arch sections are pushed or jacked in an upstanding position into the excavated area.
In a preferred embodiment the support structure is formed with arch section ends being located in and along a series of supporting units. In one preferred embodiment the units have recessed sections, which, when the units are laid end to end, form a track along which the arch sections can slide when jacked. Typically, two linear tracks are formed, said tracks spaced apart by a distance determined by the space between the ends of said arch sections.
Typically, the arch sections and/or supporting units are pre-cast. Yet further, each of the arch sections are formed from a series of panels, constructed on site and prior to insertion into the tunnel.
In a further aspect of the invention, there is provided a method for forming a support structure for an excavated area during and/or after excavation of the same, said method comprising, as the tunnel is excavated, pushing or jacking a series of sections in an upstanding position one after another into said excavated area, characterised in that the sections are arch sections in order to form an arch shaped support structure.
Typically the excavated area is a tunnel and the method comprises the steps of jacking a series of arch sections at intervals to increase the length of the support structure into the tunnel as the tunnel is excavated. The activity of the tunnel excavation takes place to the front of the first of the arch sections introduced.
In one embodiment, supporting units are first positioned in the excavation to act as bases and guides along which the arch structures are introduced.
In one embodiment, the supporting units extend upwardly to form the side walls of the arch shaped structure and it is the curved arch sections which are introduced to form the arch shaped structure. Alternatively the arch sections include both the roof and side walls when jacked into the excavation.
The method of the invention has a number of technical and economic advantages. Arch sections can be formed from a number of panels by factory fabrication, delivered to site and connected together to form the arch.
In one embodiment a temporary shield can be fitted at the leading face, i.e. in front of the first arch section, which allows excavation work to be undertaken safely. This shield is recovered at the end of the excavation and can be re-used for excavations thereafter.
Similarly, a shield can be provided at the front of each supporting unit to allow excavation to proceed safely.
The use of arch panels reduces the temporary working areas required at the excavation site and requires less heavy handling equipment, than with conventional techniques.
Typically, the ends of the panel sections are located in tracks formed by a series of supporting units which are jacked into the tunnel and the method further includes the step of jacking said supporting units into the tunnel to provide tracks of a sufficient length to receive the arch sections to form the support structure and therefore may be advanced to a further position into the excavation than the arch sections. Typically, the units are required to be manipulated after jacking to expose recessed portions to allow the formation of the tracks.
To further improve the structure, hydrophilic gaskets or groutable injection hoses can be introduced, between panels as they are installed in the working pit which serve to waterproof the joints and it should be appreciated that there are many possible variations of details in the design of the foundations and the arch configuration and span.
In one embodiment double, side by side arched structures can be created, for example, for a tunnel for the two carriageways of a divided highway. In one embodiment three or four sets of in line supporting units are provided, said supporting units comprising two lines of outer supporting units and a centre line of double units and/or single units having two guide tracks formed therein, thus allowing the introduction of two sets of side by side sections along said supporting units.
As an alternative embodiment to the use of supporting units in block form there is provided the method of forming tunnels, typically of circular cross section, along the line of the support structure to be formed and said tunnels spaced apart by the spacing required for the arch sections. The tunnels are driven by jacking or by segment construction. In each tunnel there is formed a track for the reception of the ends of the arch sections which again pass along the length of the tracks as with the supporting units and therefore act in a similar manner to support the arch sections.
BRIEF DESCRIPTION OF THE DRAWINGS
Specific embodiments of the invention will now be described with reference to the accompanying drawings, wherein:
FIG. 1 illustrates a perspective view of the working area and the installation of the supporting units prior to main tunnel excavation;
FIGS. 2A-2C illustrate cross sections of the supporting unit before and after jacking into the excavation;
FIG. 3A illustrates a side elevation of an excavation with a support structure according to the invention;
FIG. 3B illustrates a sectional elevation of the apparatus of FIG. 3B showing the structure of one of the arch sections;
FIG. 3C illustrates a perspective view of a partially completed structure of the type shown in FIGS. 3A and 3B;
FIG. 4 illustrates the use of the embodiment of using tunnel supports for the arch sections; and
FIG. 5 illustrates a perspective view of a support structure formed according to FIG. 4 on the right hand side of the tunnel and an alternative method on the left hand side for the purpose of illustration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
After preparing the working area 2 adjacent to where the structure is to be installed, a series of supporting or foundation units 4 are driven into the excavation material to form the base 6 , 6 ′ and base reaction (horizontal and vertical load components) for the arch sections. These supporting units are designed to be of the correct dimensions for the loads and are installed by driving them into the tunnel excavation by pipe jacking methods. For convenience and economy the units can be pre-cast off site in suitable handlable lengths and then brought to site as required. The units are designed so that after being installed they can be modified by undertaking work from inside the units by workers to provide a finished foundation structure for the structure and form tracks 10 , 10 ′, at the correct level as shown in FIGS. 2A-2C whereby the supporting units 4 are shown in FIG. 2A in the form in which they are jacked. FIG. 2B shows the supporting units after manipulation when positioned in the excavation and FIG. 2C shows the track 10 with an end of an arch section 12 located therein. The units 4 have removable covers 14 which are removed progressively during the excavation of the soil from within the shield 16 to expose the guide tracks 10 , 10 ′. The units form a track guide and seating during installation of the arch sections and the permanent foundation, thereafter.
With the supporting units installed to a sufficient length the guide channels on the same are levelled so that the tracks formed on the same are level and the units are then pumped with concrete to form a solid foundation. The next stage in the method is to erect the temporary cutting shield 20 of FIG. 3A which is fabricated in steel with the same outside dimensions, plus a small overcut, as the outside dimension of the arch sections. Some overcut in the excavation allows a reduction in soil friction and allows the introduction of measures to improve jacking of the sections such as lubrication or drag sheets The shield, depending on the geotechnical conditions, can be fitted with shelves, compartments, doors, advance spiles and other devices used in tunnelling excavation as required. These devices assist in controlling the face stability and allow excavation machinery to be operated and excavation to proceed at the various levels of the tunnel.
In practise, the shield is introduced into the soil through the head wall and along the tracks 10 , 10 ′ of the supporting units and excavation at the face commences, typically by face miners with the aid of mechanical equipment. As the shield advances, arch sections 12 , art jacked into the excavation behind the shield and along the tracks 10 , 10 ′ as shown in FIGS. 3A and 3B. A steel jacking ring 28 can be used to distribute the jacking loads uniformly onto the arch sections and in one embodiment shown in FIG. 3A spacers 30 are used to allow the jacking reaction from the jacking rig 31 to be transferred onto the reaction wall 32 . Alternatively, it is possible to have telescopic jacks mounted on the reaction wall with a stroke equivalent to the width of the section which would eliminate the need for the spacers to be used. Individual arch sections can be of any suitable dimension, but typically 2 to 3 meters in length. The ends of the sections 12 are located at the end foots in the tracks 10 , 10 ′ of the supporting units 4 so they cannot spread apart during the jacking operation or thereafter. Typically, the staggering of the joints of the supporting units 4 is possible to allow use of the previously placed arch section to provide support for the next one.
It is preferred to have the supporting units extending outwith the excavated area into the working or reception area so as to allow the shield 20 and arch sections 12 to be provided in the correct configuration prior to jacking and, as they are then held in the tracks 10 , 10 ′ they can not deviate from line or level.
It is possible to jack both two pinned arch sections and three pinned arch sections into the excavation. The latter being preferable in that the two panels 36 , 38 of a three pinned arch as shown in FIG. 3B are envisaged to be more easily handleable than the single unit of a two pinned arch. Furthermore a three pinned arch is more structurally efficient and can be provided with a suitably designed crown connection 34 .
The arch sections are introduced and hence pushed forward as excavation advances by jacks mounted in a suitable frame and having a reaction against a suitable structure. Such arrangements are well known and widely used. When the end of the excavation is reached and the reception shaft of the excavation is reached, the shield is removed.
FIG. 3C illustrates a partially formed support structure 31 formed of a series of arch structures 12 and supporting units 4 with part of the arch sections 12 ′, 12 ″ removed in the drawing for ease of reference only. In this case the support structure is being formed under a railway line embankment 33 as shown.
As an alternative embodiment to the use of supporting units in block form, there is provided the method of forming tunnels as shown in FIG. 4 which illustrates a cross section of one tunnel, said tunnel 40 typically of circular cross section, and provided along the line of the support structure to be formed. Typically two or three tunnels, as required, are formed, said tunnels spaced apart by the spacing required for the location of the ends 36 , 38 of the arch sections. The tunnels are driven by jacking or by segment construction. In each tunnel there is formed a track 42 which can be exposed for the reception of the end 44 of the arch sections 12 which again pass along the length of the tracks as with the supporting units and therefore are introduced and act in a similar manner. The tunnels are typically filled with concrete so as to act as foundations for the structure when formed. The advantage of this embodiment is particularly for use in unstable soil conditions, perhaps below the water table level. The circular tunnels can use conventional pressure balance shields to undertake the work remotely under pressure and without inflow or loss of soil. There is also a further advantage in that they can be used as access tunnels from where it is possible to undertake, for example, a program of drilling and injection to stabilize the soil in the area where the arched support structure is to be installed.
FIG. 5 illustrates on the on the right hand side of the tunnel a support structure formed using the tunnels 40 as shown in FIG. 4 . Prior to installing the guide track along the tunnels, the tunnels remains enclosed and allows access to construct. This construction could be by methods such as diaphragm walling, contiguous piling to form a piling wall 52 , for example.
On the left hand side of the tunnel an alternative arrangement is shown whereby the arch structure is formed by arch sections 50 which connect, with the tracks of the supporting units 4 , acting as side wall panels and it is the end of the side wall which locates with the foundations. In this embodiment therefore the support structure is formed of arch sections, side wall supporting units and foundation units, introduced in the same manner as previously described.
The operation according to the invention comprises excavating, jacking and adding new arch sections until the structure is in its final position and excavation is completed.
Furthermore, as the arch sections are moved into place it is possible to structurally link all the sections to provide additional strength such as by using Macalloy HT (Registered Trade Mark) bars placed in ducts provided in the concrete sections and stressed.
It should be noted that any of the embodiments shown can be used to advantage in conditions and requirements to which one, or a combination of the embodiments, is or are suited.
Thus it will be appreciated that there is provided a method for forming a structure in an excavation without the need to disturb the surface above the excavation and also provides for the utilisation of the relevant strength of arch shaped sections. Furthermore, the provision of the tracks, and use of supporting units which can be set to the required line and level before the jacking of the sections, ensures that once set, the line and level no longer needs to be checked and the arched sections can be relatively easily jacked into position along the tracks.
While the invention has been described with a certain degree of particularly, it is manifest that many changes may be made in the details of construction and the arrangement of components without departing from the spirit and scope of this disclosure. It is understood that the invention is not limited to the embodiments set forth herein for purposes of exemplification, but is to be limited only by the scope of the attached claim or claims, including the full range of equivalency to which each element. | A support structure and method for forming same for use in excavations such as underpasses, tunnels and the like for roads, rail or rivers. The support structure allows the utilization of the strength provided by using arch shaped sections and also minimizes the disruption caused to the soil surrounding the excavation thereby allowing existing road, rail or river services to continue to be used during excavation. | 4 |
RELATED APPLICATIONS
This application is based on, and claims priority under 35 U.S.C. §120 to U.S. Provisional Application No. 61/328,395, filed on Apr. 27, 2010, and which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to chemical compounds as receptor modulators with therapeutic utility. These compounds may be used as modulators of sphingosine-1-phosphate receptors. The invention relates specifically to the use of these compounds and pharmaceutical compositions to treat disorders associated with sphingosine-1-phosphate (S1P) receptor modulation.
BACKGROUND OF THE INVENTION
Sphingosine is a compound having the chemical structure shown in the structure below. It is known that various sphingolipids, having sphingosine as a constituent, are widely distributed in the living body including on the surface of cell membranes of cells in the nervous system.
A sphingolipid is one of the lipids having important roles in the living body. A disease called lipidosis is caused by accumulation of a specified sphingolipid in the body. Sphingolipids present on cell membranes function to regulate cell growth; participate in the development and differentiation of cells; function in nerves; are involved in the infection and malignancy of cells; etc. Many of the physiological roles of sphingolipids remain to be solved. Recently the possibility that ceramide, a derivative of sphingosine, has an important role in the mechanism of cell signal transduction has been indicated, and studies about its effect on apoptosis and cell cycle have been reported.
Sphingosine-1-phosphate is an important cellular metabolite, derived from ceramide that is synthesized de novo or as part of the sphingomyeline cycle (in animal's cells). It has also been found in insects, yeasts and plants.
The enzyme, ceramidase, acts upon ceramides to release sphingosine, which is phosphorylated by sphingosine kinase, a ubiquitous enzyme in the cytosol and endoplasmic reticulum, to form sphingosine-1-phosphate. The reverse reaction can occur also by the action of sphingosine phosphatases, and the enzymes act in concert to control the cellular concentrations of the metabolite, which concentrations are always low. In plasma, such concentration can reach 0.2 to 0.9 μM, and the metabolite is found in association with the lipoproteins, especially the HDL. It should also be noted that sphingosine-1-phosphate formation is an essential step in the catabolism of sphingoid bases.
Like its precursors, sphingosine-1-phosphate is a potent messenger molecule that perhaps uniquely operates both intra- and inter-cellularly, but with very different functions from ceramides and sphingosine. The balance between these various sphingolipid metabolites may be important for health. For example, within the cell, sphingosine-1-phosphate promotes cellular division (mitosis) as opposed to cell death (apoptosis), which it inhibits. Intracellularly, it also functions to regulate calcium mobilization and cell growth in response to a variety of extracellular stimuli. Current opinion appears to suggest that the balance between sphingosine-1-phosphate and ceramide and/or sphingosine levels in cells is critical for their viability. In common with the lysophospholipids, especially lysophosphatidic acid, with which it has some structural similarities, sphingosine-1-phosphate exerts many of its extra-cellular effects through interaction with five specific G protein-coupled receptors on cell surfaces. These are important for the growth of new blood vessels, vascular maturation, cardiac development and immunity, and for directed cell movement.
Sphingosine-1 phosphate is stored in relatively high concentrations in human platelets, which lack the enzymes responsible for its catabolism, and it is released into the blood stream upon activation of physiological stimuli, such as growth factors, cytokines, and receptor agonists and antigens. It may also have a critical role in platelet aggregation and thrombosis and could aggravate cardiovascular disease. On the other hand the relatively high concentration of the metabolite in high-density lipoproteins (HDL) may have beneficial implications for atherogenesis. For example, there are recent suggestions that sphingosine-1-phosphate, together with other lysolipids such as sphingosylphosphorylcholine and lysosulfatide, are responsible for the beneficial clinical effects of HDL by stimulating the production of the potent antiatherogenic signaling molecule nitric oxide by the vascular endothelium. In addition, like lysophosphatidic acid, it is a marker for certain types of cancer, and there is evidence that its role in cell division or proliferation may have an influence on the development of cancers. These are currently topics that are attracting great interest amongst medical researchers, and the potential for therapeutic intervention in sphingosine-1-phosphate metabolism is under active investigation.
Fungi and plants have sphingolipids and the major sphingosine contained in these organisms has the formula described below. It is known that these lipids have important roles in the cell growth of fungi and plants, but details of the roles remain to be solved.
Recently it has been known that derivatives of sphingolipids and their related compounds exhibit a variety of biological activities through inhibition or stimulation of the metabolism pathways. These compounds include inhibitors of protein kinase C, inducers of apoptosis, immuno-suppressive compounds, antifungal compounds, and the like. Substances having these biological activities are expected to be useful compounds for various diseases.
Published International Patent Application No. WO 2008037476 describes generically oxadiazoles derivatives with anti-inflammatory and immunosuppressive properties.
Published International Patent Application No. WO 2006131336 describes generically polycyclic oxadiazoles or isoxazoles as S1P receptor ligands.
Published International Patent Application No. WO 2009151621 describes substituted (1,2,4-oxadiazol-3-yl) indolin-1-yl carboxylic acid derivatives useful as S1P1 agonists.
The synthesis of new 1,2,4- and 1,3,4-oxadiazole derivatives structurally related to non-peptide angiotensin II (AII) receptor antagonists is described in Synthesis (2003) Issue 6, pages 899-905.
SUMMARY OF THE INVENTION
The invention provides certain well-defined compounds that are useful as sphingosine-1-phosphate modulators. As such, the compounds described herein are useful in treating a wide variety of disorders associated with modulation of sphingosine-1-phosphate receptors. The compounds of the present invention are novel compounds which are potent and selective sphingosine-1-phosphate modulators. The term “modulator” as used herein, includes but is not limited to: receptor agonist, antagonist, inverse agonist, inverse antagonist, partial agonist, partial antagonist.
The present invention describes novel substituted 3-(4-((1H-imidazol-1-yl)methyl)phenyl)-5-phenyl-1,2,4-oxadiazole derivatives as S1P receptors modulators.
In one aspect, the invention provides a compound having Formula I or a pharmaceutically acceptable salt thereof or stereoisomeric forms thereof, or the geometrical isomers, enantiomers, diastereoisomers, tautomers, zwitterions and pharmaceutically acceptable salts thereof:
wherein:
R is H, C 1-10 alkyl, C 3-10 cycloalkyl, —OR 6 , NR 7 R 8 , halogen, nitrile, nitrogen dioxide, C(O)R 9 , aryl or heterocycle;
R 1 is H, C 1-10 alkyl, C 3-10 cycloalkyl, —OR 10 , NR 11 R 12 , halogen, nitrile, nitrogen dioxide, C(O)R 13 , aryl or heterocycle;
R 2 is H, C 1-10 alkyl, halogen, aryl or heterocycle;
R 3 is C 1-10 alkyl, C 3-10 cycloalkyl, —OR 14 , NR 15 R 16 , halogen, nitrile, nitrogen dioxide, C(O)R 17 , aryl or heterocycle;
R 4 is C 1-10 alkyl, C 3-10 cycloalkyl, —OR 18 , NR 19 R 20 , halogen, nitrile, nitrogen dioxide, C(O)R 21 , aryl or heterocycle;
R 5 is C 1-10 alkyl, C 3-10 cycloalkyl, —OR 22 , NR 23 R 24 , halogen, nitrile, nitrogen dioxide, C(O)R 25 , aryl or heterocycle;
a is 0, 1, 2 or 3;
b is 0, 1, 2 or 3;
c is 0, 1, 2 or 3;
R 6 is H, C 3-10 cycloalkyl or C 1-10 alkyl;
R 7 is H or C 1-10 alkyl;
R 8 is H or C 1-10 alkyl;
R 9 is H, C 3-10 cycloalkyl, —OH, —OC 3-10 cycloalkyl, —OC 1-10 alkyl or C 1-10 alkyl;
R 10 is H, C 3-10 cycloalkyl or C 1-10 alkyl;
R 11 is H or C 1-10 alkyl;
R 12 is H or C 1-10 alkyl;
R 13 is H, C 3-10 cycloalkyl, —OH, —OC 3-10 cycloalkyl, —OC 1-10 alkyl or C 1-10 alkyl;
R 14 is H, C 3-10 cycloalkyl or C 1-10 alkyl;
R 15 is H or C 1-10 alkyl;
R 16 is H or C 1-10 alkyl;
R 17 is H, C 3-10 cycloalkyl, —OH, —OC 3-10 cycloalkyl, —OC 1-10 alkyl or C 1-10 alkyl;
R 18 is H, C 3-10 cycloalkyl or C 1-10 alkyl;
R 19 is H or C 1-10 alkyl;
R 20 is H or C 1-10 alkyl;
R 21 is H, C 3-10 cycloalkyl, —OH, —OC 3-10 cycloalkyl, —OC 1-10 alkyl or C 1-10 alkyl;
R 22 is H, C 3-10 cycloalkyl or C 1-10 alkyl;
R 23 is H or C 1-10 alkyl;
R 24 is H or C 1-10 alkyl; and
R 25 is H, C 3-10 cycloalkyl, —OH, —OC 3-10 cycloalkyl, —OC 1-10 alkyl or C 1-10 alkyl.
The term “alkyl”, as used herein, refers to saturated, monovalent or divalent hydrocarbon moieties having linear or branched moieties or combinations thereof and containing 1 to 10 carbon atoms. One methylene (—CH 2 —) group, of the alkyl can be replaced by oxygen, sulfur, sulfoxide, nitrogen, carbonyl, carboxyl, sulfonyl, or by a divalent C 3-10 cycloalkyl. Alkyl groups can be substituted by halogen, hydroxyl, cycloalkyl, amino, heterocycles, carboxylic acid, phosphonic acid groups, sulphonic acid groups, phosphoric acid. Usually, in the present case, alkyl groups are methyl, isopropyl, isobutyl, trifluoromethyl.
The term “cycloalkyl”, as used herein, refers to a monovalent or divalent group of 3 to 10 carbon atoms, preferably 3 to 5 carbon atoms derived from a saturated cyclic hydrocarbon. Cycloalkyl groups can be monocyclic or polycyclic. Cycloalkyl can be substituted by C 1-3 alkyl groups or halogens. Usually, in the present case, cycloalkyl groups are cyclopropyl and cyclohexyl.
The term “halogen”, as used herein, refers to an atom of chlorine, bromine, fluorine, iodine. Usually, in the present case, halogen groups are chlorine, bromine.
The term “heterocycle” as used herein, refers to a 3 to 10 membered ring, which can be aromatic or non-aromatic, saturated or non-saturated, containing at least one heteroatom selected form O or N or S or combinations of at least two thereof, interrupting the carbocyclic ring structure. The heterocyclic ring can be saturated or non-saturated. The heterocyclic ring can be interrupted by a C═O; the S heteroatom can be oxidized. Heterocycles can be monocyclic or polycyclic. Heterocyclic ring moieties can be substituted by hydroxyl, C 1-3 alkyl or halogens. Usually, in the present case, heterocyclic groups are oxadiazol, imidazol, 2-methylpiperidine.
The term “aryl” as used herein, refers to an organic moiety derived from an aromatic hydrocarbon consisting of a ring containing 6 to 10 carbon atoms by removal of one hydrogen, which can be substituted by halogen atoms, —OC 1-3 alkyl, C 1-3 alkyl, nitrile, C(O)C 1-3 alkyl, amino or hydroxyl groups. Usually, in the present case, aryl is phenyl.
The term “hydroxyl” as used herein, represents a group of formula “—OH”.
The formula “H”, as used herein, represents a hydrogen atom.
The formula “O”, as used herein, represents an oxygen atom.
The formula “N”, as used herein, represents a nitrogen atom.
The formula “S”, as used herein, represents a sulfur atom.
The term “nitrile”, as used herein, represents a group of formula “—CN”.
The term “nitrogen dioxide”, as used herein, represents a group of formula “—NO 2 ”.
The term “sulfoxide” as used herein, represents a group of formula “—S(O)”.
The term “carbonyl” as used herein, represents a group of formula “—C(O)”.
The term “carboxyl” as used herein, represents a group of formula “—(CO)O—”.
The term “sulfonyl” as used herein, represents a group of formula —SO 2 ″.
The term “amino” as used herein, represents a group of formula “—NR 7 R 8 ”.
The term “carboxylic acid” as used herein, represents a group of formula “—COOH”.
The term “phosphonic acid” as used herein, represents a group of formula “—P(O)(OH) 2 ”.
The term “sulphonic acid” as used herein, represents a group of formula “—SO 2 (OH)”.
The term “phosphoric acid” as used herein, represents a group of formula “—OP(O)(OH) 2 ”.
Generally, R is selected from H, C 1-10 alkyl, C 3-10 cycloalkyl, —OR 6 , NR 7 R 8 , halogen, nitrile, nitrogen dioxide, C(O)R 9 , aryl or heterocycle. Usually R is H, nitrile, C 1-10 alkyl, halogen or nitrogen dioxide. Preferably R is H, nitrile, bromine, trifluoromethyl, nitrogen dioxide, methyl or chlorine.
Generally R 1 is selected from H, C 1-10 alkyl, C 3-10 cycloalkyl, —OR 10 , NR 11 R 12 , halogen, nitrile, nitrogen dioxide, C(O)R 13 , aryl or heterocycle. Usually R 1 is C 1-10 alkyl, OR 10 , or heterocycle. Preferably R 1 is isopropoxy, cyclopropoxy, isobutoxy or 2-methylpiperdin-1-yl.
Generally R 2 is selected from H, C 1-10 alkyl, halogen, aryl or heterocycle. Usually R 2 is H, halogen, C 1-10 alkyl. Preferably R 2 is H, methyl, trifluoromethyl or chlorine.
Generally R 3 is selected from C 1-10 alkyl, C 3-10 cycloalkyl, —OR 14 , NR 15 R 16 , halogen, nitrile, nitrogen dioxide, C(O)R 17 , aryl or heterocycle.
Generally R 4 is selected from C 1-10 alkyl, C 3-10 cycloalkyl, —OR 18 , NR 19 R 20 , halogen, nitrile, nitrogen dioxide, C(O)R 21 , aryl or heterocycle.
Generally R 5 is selected from C 1-10 alkyl, C 3-10 cycloalkyl, —OR 22 , NR 23 R 24 , halogen, nitrile, nitrogen dioxide, C(O)R 25 , aryl or heterocycle.
Generally R 6 is selected from H, C 3-10 cycloalkyl or C 1-10 alkyl.
Generally R 7 is selected from H or C 1-10 alkyl.
Generally R 8 is selected from H or C 1-10 alkyl.
Generally R 9 is selected from H, C 3-10 cycloalkyl, —OH, —OC 3-10 cycloalkyl, —OC 1-10 alkyl or C 1-10 alkyl.
Generally R 10 is H, C 3-10 cycloalkyl or C 1-10 alkyl. Usually R 10 is C 1-10 alkyl or C 3-10 cycloalkyl. Preferred R 10 is isopropyl, isobutyl, cyclohexyl or cyclopropyl.
Generally R 11 is H or C 1-10 alkyl.
Generally R 12 is H or C 1-10 alkyl.
Generally R 13 is H, C 3-10 cycloalkyl, —OH, —OC 3-10 cycloalkyl, —OC 1-10 alkyl or C 1-10 alkyl.
Generally R 14 is H, C 3-10 cycloalkyl or C 1-10 alkyl.
Generally R 15 is H or C 1-10 alkyl.
Generally R 16 is H or C 1-10 alkyl.
Generally R 17 is H, C 3-10 cycloalkyl, —OH, —OC 3-10 cycloalkyl, —OC 1-10 alkyl or C 1-10 alkyl.
Generally R 18 is H, C 3-10 cycloalkyl or C 1-10 alkyl.
Generally R 19 is H or C 1-10 alkyl.
Generally R 20 is H or C 1-10 alkyl.
Generally R 21 is H, C 3-10 cycloalkyl, —OH, —OC 3-10 cycloalkyl, —OC 1-10 alkyl or C 1-10 alkyl.
Generally R 22 is H, C 3-10 cycloalkyl or C 1-10 alkyl.
Generally R 23 is H or C 1-10 alkyl.
Generally R 24 is H or C 1-10 alkyl.
Generally R 25 is H, C 3-10 cycloalkyl, —OH, —OC 3-10 cycloalkyl, —OC 1-10 alkyl or C 1-10 alkyl.
Generally a is 0, 1, 2 or 3. Usually a is 0.
Generally b is 0, 1, 2 or 3. Usually b is 0.
Generally c is 0, 1, 2 or 3. Usually c is 0.
In a preferred embodiment of the invention
R is H, nitrile, C 1-10 alkyl, halogen or nitrogen dioxide; and R 1 is C 1-10 alkyl, OR 10 , or heterocycle; and R 2 is H, halogen or C 1-10 alkyl; and a is 0; and b is 0; and c is 0; and R 10 is isopropyl, isobutyl, cyclohexyl or cyclopropyl.
In a more preferred embodiment of the invention
R is H, nitrile, bromine, trifluoromethyl, nitrogen dioxide, methyl or chlorine; and R 1 is isopropoxy, cyclopropoxy, isobutoxy or 2-methylpiperdin-1-yl; and R 2 is H, methyl, trifluoromethyl or chlorine; and a is 0; and b is 0; and c is 0; and R 10 is isopropyl or cyclopropyl.
Compounds of the invention are:
3-(4-Imidazol-1-ylmethyl-phenyl)-5-(4-isobutyl-phenyl)-[1,2,4]oxadiazole; 5-[3-(4-Imidazol-1-ylmethyl-phenyl)-[1,2,4]oxadiazol-5-yl]-2-isopropoxy-benzonitrile; 3-(4-Imidazol-1-ylmethyl-phenyl)-5-(4-isobutoxy-3-trifluoromethyl-phenyl)-[1,2,4]oxadiazole; 5-(4-Cyclohexyloxy-3-trifluoromethyl-phenyl)-3-(4-imidazol-1-ylmethyl-phenyl)-[1,2,4]oxadiazole; 3-(4-Imidazol-1-ylmethyl-phenyl)-5-(4-isopropoxy-3-trifluoromethyl-phenyl)-[1,2,4]oxadiazole; 5-(3-Chloro-4isopropoxy-phenyl)-3-(4-imidazol-1-ylmethyl-phenyl)-[1,2,4]oxadiazole; 5-(3-Bromo-4-isopropoxy-phenyl)-3-(4-imidazol-1-ylmethyl-phenyl)-[1,2,4]oxadiazole; 5-[3-(4-Imidazol-1-ylmethyl-phenyl)-[1,2,4]oxadiazol-5-yl]-2-isobutoxy-benzonitrile; 3-(4-Imidazol-1-ylmethyl-phenyl)-5-(4-isopropoxy-phenyl)-[1,2,4]oxadiazole; 3-(4-Imidazol-1-ylmethyl-phenyl)-5-(4-isopropoxy-3-methyl-phenyl)-[1,2,4]oxadiazole; 3-(4-Imidazol-1-ylmethyl-phenyl)-5-(4-isopropoxy-3-nitro-phenyl)-[1,2,4]oxadiazole; 5-(3-Bromo-4-isobutoxy-phenyl)-3-(4-imidazol-1-ylmethyl-phenyl)-[1,2,4]oxadiazole; 5-[3-(4-Imidazol-1-ylmethyl-2-methyl-phenyl)-[1,2,4]oxadiazol-5-yl]-2-isopropoxy-benzonitrile; 3-(4-Imidazol-1-ylmethyl-2-methyl-phenyl)-5-(4-isopropoxy-3-nitro-phenyl)-[1,2,4]oxadiazole; 5-(3-Bromo-4-isopropoxy-phenyl)-3-(4-imidazol-1-ylmethyl-2-methyl-phenyl)-[1,2,4]oxadiazole; 5-(3-Bromo-4-cyclopropoxy-phenyl)-3-(4-imidazol-1-ylmethyl-phenyl)-[1,2,4]oxadiazole; 5-(3-Bromo-4-cyclopropoxy-phenyl)-3-(4-imidazol-1-ylmethyl-2-methyl-phenyl)-[1,2,4]oxadiazole; 3-(4-Imidazol-1-ylmethyl-2-methyl-phenyl)-5-(4-isopropoxy-3-trifluoromethyl-phenyl)-[1,2,4]oxadiazole; 3-(4-Imidazol-1-ylmethyl-2-methyl-phenyl)-5-(4-isopropoxy-3-methyl-phenyl)-[1,2,4]oxadiazole; 5-[3-(4-Imidazol-1-ylmethyl-2-trifluoromethyl-phenyl)-[1,2,4]oxadiazol-5-yl]-2-isopropoxy-benzonitrile; 5-(3-Bromo-4-isopropoxy-phenyl)-3-(4-imidazol-1-ylmethyl-2-trifluoromethyl-phenyl)-[1,2,4]oxadiazole; 3-[4-(1 H-imidazol-1-ylmethyl)-2-(trifluoromethyl)phenyl]-5-(4-isopropoxy-3-methylphenyl)-1,2,4-oxadiazole; 3-[4-(1H-imidazol-1-ylmethyl)-2-(trifluoromethyl)phenyl]-5-[4-isopropoxy-3-(trifluoromethyl)phenyl]-1,2,4-oxadiazole; 3-[4-(1H-imidazol-1-ylmethyl)-2-(trifluoromethyl)phenyl]-5-(4-isopropoxy-3-nitrophenyl)-1,2,4-oxadiazole; 5-[3-bromo-4-(cyclopropyloxy)phenyl]-3-[4-(1H-imidazol-1-ylmethyl)-2-(trifluoromethyl)phenyl]-1,2,4-oxadiazole; 5-(3-bromo-4-isobutoxyphenyl)-3-[4-(1H-imidazol-1-ylmethyl)-2-(trifluoromethyl)phenyl]-1,2,4-oxadiazole; 5-{3-[2-chloro-4-(1H-imidazol-1-ylmethyl)phenyl]-1,2,4-oxadiazol-5-yl}-2-isopropoxybenzonitrile; 5-(3-bromo-4-isopropoxyphenyl)-3-[2-chloro-4-(1H-imidazol-1-ylmethyl)phenyl]-1,2,4-oxadiazole; 3-[2-chloro-4-(1H-imidazol-1-ylmethyl)phenyl]-5-[4-isopropoxy-3-(trifluoromethyl)phenyl]-1,2,4-oxadiazole; 3-[2-chloro-4-(1 H-imidazol-1-ylmethyl)phenyl]-5-(4-isopropoxy-3-nitrophenyl)-1,2,4-oxadiazole; 5-{3-[4-(1H-imidazol-1-ylmethyl)phenyl]-1,2,4-oxadiazol-5-yl}-2-(2-methylpiperidin-1-yl)benzonitrile.
Preferred compounds of the invention are:
5-[3-(4-Imidazol-1-ylmethyl-phenyl)-[1,2,4]oxadiazol-5-yl]-2-isopropoxy-benzonitrile; 5-(3-Chloro-4-isopropoxy-phenyl)-3-(4-imidazol-1-ylmethyl-phenyl)-[1,2,4]oxadiazole; 5-(3-Bromo-4-isopropoxy-phenyl)-3-(4-imidazol-1-ylmethyl-phenyl)-[1,2,4]oxadiazole; 3-(4-Imidazol-1-ylmethyl-phenyl)-5-(4-isopropoxy-3-methyl-phenyl)-[1,2,4]oxadiazole; 3-(4-Imidazol-1-ylmethyl-phenyl)-5-(4-isopropoxy-3-nitro-phenyl)-[1,2,4]oxadiazole; 5-[3-(4-Imidazol-1-ylmethyl-2-methyl-phenyl)-[1,2,4]oxadiazol-5-yl]-2-isopropoxy-benzonitrile; 3-(4-Imidazol-1-ylmethyl-2-methyl-phenyl)-5-(4-isopropoxy-3-nitro-phenyl)-[1,2,4]oxadiazole; 5-(3-Bromo-4-isopropoxy-phenyl)-3-(4-imidazol-1-ylmethyl-2-methyl-phenyl)-[1,2,4]oxadiazole; 5-(3-Bromo-4-cyclopropoxy-phenyl)-3-(4-imidazol-1-ylmethyl-phenyl)-[1,2,4]oxadiazole; 5-(3-Bromo-4-cyclopropoxy-phenyl)-3-(4-imidazol-1-ylmethyl-2-methyl-phenyl)-[1,2,4]oxadiazole; 3-(4-Imidazol-1-ylmethyl-2-methyl-phenyl)-5-(4-isopropoxy-3-trifluoromethyl-phenyl)-[1,2,4]oxadiazole; 3-(4-Imidazol-1-ylmethyl-2-methyl-phenyl)-5-(4-isopropoxy-3-methyl-phenyl)-[1,2,4]oxadiazole; 5-[3-(4-Imidazol-1-ylmethyl-2-trifluoromethyl-phenyl)-[1,2,4]oxadiazol-5-yl]-2-isopropoxy-benzonitrile; 3-[4-(1H-imidazol-1-ylmethyl)-2-(trifluoromethyl)phenyl]-5-(4-isopropoxy-3-nitrophenyl)-1,2,4-oxadiazole; 5-{3-[2-chloro-4-(1H-imidazol-1-ylmethyl)phenyl]-1,2,4-oxadiazol-5-yl}-2-isopropoxybenzonitrile; 5-(3-bromo-4-isopropoxyphenyl)-3-[2-chloro-4-(1H-imidazol-1-ylmethyl)phenyl]-1,2,4-oxadiazole; 3-[2-chloro-4-(1H-imidazol-1-ylmethyl)phenyl]-5-[4-isopropoxy-3-(trifluoromethyl)phenyl]-1,2,4-oxadiazole; 3-[2-chloro-4-(1H-imidazol-1-ylmethyl)phenyl]-5-(4-isopropoxy-3-nitrophenyl)-1,2,4-oxadiazole.
Some compounds of Formula I and some of their intermediates have at least one stereogenic center in their structure. This stereogenic center may be present in an R or S configuration, said R and S notation is used in correspondence with the rules described in Pure Appli. Chem. (1976), 45, 11-13.
The term “pharmaceutically acceptable salts” refers to salts or complexes that retain the desired biological activity of the above identified compounds and exhibit minimal or no undesired toxicological effects. The “pharmaceutically acceptable salts” according to the invention include therapeutically active, non-toxic base or acid salt forms, which the compounds of Formula I are able to form.
The acid addition salt form of a compound of Formula I that occurs in its free form as a base can be obtained by treating the free base with an appropriate acid such as an inorganic, for example, a hydrohalic such as hydrochloric acid, hydrobromic acid, sulfuric acid, phosphoric acid, nitric acid and the like; or an organic acid such as for example, acetic, hydroxyacetic, propanoic, lactic, pyruvic, malonic, fumaric acid, maleic acid, oxalic acid, tartaric acid, succinic acid, malic acid, ascorbic acid, benzoic acid, tannic acid, pamoic acid, citric, methylsulfonic, ethanesulfonic, benzenesulfonic, formic and the like (Handbook of Pharmaceutical Salts, P. Heinrich Stahal & Camille G. Wermuth (Eds), Verlag Helvetica Chemica Acta-Zürich, 2002, 329-345).
Compounds of Formula I and their salts can be in the form of a solvate, which is included within the scope of the present invention. Such solvates include for example hydrates, alcoholates and the like.
With respect to the present invention reference to a compound or compounds, is intended to encompass that compound in each of its possible isomeric forms and mixtures thereof unless the particular isomeric form is referred to specifically.
Compounds according to the present invention may exist in different polymorphic forms. Although not explicitly indicated in the above formula, such forms are intended to be included within the scope of the present invention.
The compounds of the invention are indicated for use in treating or preventing conditions in which there is likely to be a component involving the sphingosine-1-phosphate receptors.
In another embodiment, there are provided pharmaceutical compositions including at least one compound of the invention in a pharmaceutically acceptable carrier.
In a further embodiment of the invention, there are provided methods for treating disorders associated with modulation of sphingosine-1-phosphate receptors. Such methods can be performed, for example, by administering to a subject in need thereof a pharmaceutical composition containing a therapeutically effective amount of at least one compound of the invention.
These compounds are useful for the treatment of mammals, including humans, with a range of conditions and diseases that are alleviated by S1P modulation: not limited to the treatment of diabetic retinopathy, other retinal degenerative conditions, dry eye, angiogenesis and wounds.
Therapeutic utilities of S1P modulators are ocular diseases, such as but not limited to: wet and dry age-related macular degeneration, diabetic retinopathy, retinopathy of prematurity, retinal edema, geographic atrophy, glaucomatous optic neuropathy, chorioretinopathy, hypertensive retinopathy, ocular ischemic syndrome, prevention of inflammation-induced fibrosis in the back of the eye, various ocular inflammatory diseases including uveitis, scleritis, keratitis, and retinal vasculitis; or systemic vascular barrier related diseases such as but not limited to: various inflammatory diseases, including acute lung injury, its prevention, sepsis, tumor metastasis, atherosclerosis, pulmonary edemas, and ventilation-induced lung injury; or autoimmune diseases and immunosuppression such as but not limited to: rheumatoid arthritis, Crohn's disease, Graves' disease, inflammatory bowel disease, multiple sclerosis, Myasthenia gravis, Psoriasis, ulcerative colitis, antoimmune uveitis, renal ischemia/perfusion injury, contact hypersensitivity, atopic dermititis, and organ transplantation; or allergies and other inflammatory diseases such as but not limited to: urticaria, bronchial asthma, and other airway inflammations including pulmonary emphysema and chronic obstructive pulmonary diseases; or cardiac protection such as but not limited to: ischemia reperfusion injury and atherosclerosis; or wound healing such as but not limited to: scar-free healing of wounds from cosmetic skin surgery, ocular surgery, GI surgery, general surgery, oral injuries, various mechanical, heat and burn injuries, prevention and treatment of photoaging and skin ageing, and prevention of radiation-induced injuries; or bone formation such as but not limited to: treatment of osteoporosis and various bone fractures including hip and ankles; or anti-nociceptive activity such as but not limited to: visceral pain, pain associated with diabetic neuropathy, rheumatoid arthritis, chronic knee and joint pain, tendonitis, osteoarthritis, neuropathic pains; or central nervous system neuronal activity in Alzheimer's disease, age-related neuronal injuries; or in organ transplant such as renal, corneal, cardiac or adipose tissue transplant.
In still another embodiment of the invention, there are provided methods for treating disorders associated with modulation of sphingosine-1-phosphate receptors. Such methods can be performed, for example, by administering to a subject in need thereof a therapeutically effective amount of at least one compound of the invention, or any combination thereof, or pharmaceutically acceptable salts, hydrates, solvates, crystal forms and individual isomers, enantiomers, and diastereomers thereof.
The present invention concerns the use of a compound of Formula I or a pharmaceutically acceptable salt thereof, for the manufacture of a medicament for the treatment of ocular disease, wet and dry age-related macular degeneration, diabetic retinopathy, retinopathy of prematurity, retinal edema, geographic atrophy, glaucomatous optic neuropathy, chorioretinopathy, hypertensive retinopathy, ocular ischemic syndrome, prevention of inflammation-induced fibrosis in the back of the eye, various ocular inflammatory diseases including uveitis, scleritis, keratitis, and retinal vasculitis; or systemic vascular barrier related diseases , various inflammatory diseases, including acute lung injury, its prevention, sepsis, tumor metastasis, atherosclerosis, pulmonary edemas, and ventilation-induced lung injury; or autoimmune diseases and immunosuppression, rheumatoid arthritis, Crohn's disease, Graves' disease, inflammatory bowel disease, multiple sclerosis, Myasthenia gravis, Psoriasis, ulcerative colitis, antoimmune uveitis, renal ischemia/perfusion injury, contact hypersensitivity, atopic dermititis, and organ transplantation; or allergies and other inflammatory diseases, urticaria, bronchial asthma, and other airway inflammations including pulmonary emphysema and chronic obstructive pulmonary diseases; or cardiac protection, ischemia reperfusion injury and atherosclerosis; or wound healing, scar-free healing of wounds from cosmetic skin surgery, ocular surgery, GI surgery, general surgery, oral injuries, various mechanical, heat and burn injuries, prevention and treatment of photoaging and skin ageing, and prevention of radiation-induced injuries; or bone formation, treatment of osteoporosis and various bone fractures including hip and ankles; or anti-nociceptive activity, visceral pain, pain associated with diabetic neuropathy, rheumatoid arthritis, chronic knee and joint pain, tendonitis, osteoarthritis, neuropathic pains; or central nervous system neuronal activity in Alzheimer's disease, age-related neuronal injuries; or in organ transplant such as renal, corneal, cardiac or adipose tissue transplant.
The actual amount of the compound to be administered in any given case will be determined by a physician taking into account the relevant circumstances, such as the severity of the condition, the age and weight of the patient, the patient's general physical condition, the cause of the condition, and the route of administration.
The patient will be administered the compound orally in any acceptable form, such as a tablet, liquid, capsule, powder and the like, or other routes may be desirable or necessary, particularly if the patient suffers from nausea. Such other routes may include, without exception, transdermal, parenteral, subcutaneous, intranasal, via an implant stent, intrathecal, intravitreal, topical to the eye, back to the eye, intramuscular, intravenous, and intrarectal modes of delivery. Additionally, the formulations may be designed to delay release of the active compound over a given period of time, or to carefully control the amount of drug released at a given time during the course of therapy.
In another embodiment of the invention, there are provided pharmaceutical compositions including at least one compound of the invention in a pharmaceutically acceptable carrier therefor. The phrase “pharmaceutically acceptable” means the carrier, diluent or excipient must be compatible with the other ingredients of the formulation and not deleterious to the recipient thereof.
Pharmaceutical compositions of the present invention can be used in the form of a solid, a solution, an emulsion, a dispersion, a micelle, a liposome, and the like, wherein the resulting composition contains one or more compounds of the present invention, as an active ingredient, in admixture with an organic or inorganic carrier or excipient suitable for enteral or parenteral applications. Invention compounds may be combined, for example, with the usual non-toxic, pharmaceutically acceptable carriers for tablets, pellets, capsules, suppositories, solutions, emulsions, suspensions, and any other form suitable for use. The carriers which can be used include glucose, lactose, gum acacia, gelatin, mannitol, starch paste, magnesium trisilicate, talc, corn starch, keratin, colloidal silica, potato starch, urea, medium chain length triglycerides, dextrans, and other carriers suitable for use in manufacturing preparations, in solid, semisolid, or liquid form. In addition auxiliary, stabilizing, thickening and coloring agents and perfumes may be used. Invention compounds are included in the pharmaceutical composition in an amount sufficient to produce the desired effect upon the process or disease condition.
Pharmaceutical compositions containing invention compounds may be in a form suitable for oral use, for example, as tablets, troches, lozenges, aqueous or oily suspensions, dispersible powders or granules, emulsions, hard or soft capsules, or syrups or elixirs. Compositions intended for oral use may be prepared according to any method known to the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents selected from the group consisting of a sweetening agent such as sucrose, lactose, or saccharin, flavoring agents such as peppermint, oil of wintergreen or cherry, coloring agents and preserving agents in order to provide pharmaceutically elegant and palatable preparations. Tablets containing invention compounds in admixture with non-toxic pharmaceutically acceptable excipients may also be manufactured by known methods. The excipients used may be, for example, (1) inert diluents such as calcium carbonate, lactose, calcium phosphate or sodium phosphate; (2) granulating and disintegrating agents such as corn starch, potato starch or alginic acid; (3) binding agents such as gum tragacanth, corn starch, gelatin or acacia, and (4) lubricating agents such as magnesium stearate, stearic acid or talc. The tablets may be uncoated or they may be coated by known techniques to delay disintegration and absorption in the gastrointestinal tract and thereby provide a sustained action over a longer period. For example, a time delay material such as glyceryl monostearate or glyceryl distearate may be employed.
In some cases, formulations for oral use may be in the form of hard gelatin capsules wherein the invention compounds are mixed with an inert solid diluent, for example, calcium carbonate, calcium phosphate or kaolin. They may also be in the form of soft gelatin capsules wherein the invention compounds are mixed with water or an oil medium, for example, peanut oil, liquid paraffin, or olive oil.
The pharmaceutical compositions may be in the form of a sterile injectable suspension. This suspension may be formulated according to known methods using suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil may be employed including synthetic mono- or diglycerides, fatty acids (including oleic acid), naturally occurring vegetable oils like sesame oil, coconut oil, peanut oil, cottonseed oil, etc., or synthetic fatty vehicles like ethyl oleate or the like. Buffers, preservatives, antioxidants, and the like can be incorporated as required.
Invention compounds may also be administered in the form of suppositories for rectal administration of the drug. These compositions may be prepared by mixing the invention compounds with a suitable non-irritating excipient, such as cocoa butter, synthetic glyceride esters of polyethylene glycols, which are solid at ordinary temperatures, but liquify and/or dissolve in the rectal cavity to release the drug.
Since individual subjects may present a wide variation in severity of symptoms and each drug has its unique therapeutic characteristics, the precise mode of administration and dosage employed for each subject is left to the discretion of the practitioner.
The compounds and pharmaceutical compositions described herein are useful as medicaments in mammals, including humans, for treatment of diseases and or alleviations of conditions which are responsive to treatment by agonists or functional antagonists of sphingosine-1-phosphate receptors. Thus, in further embodiments of the invention, there are provided methods for treating a disorder associated with modulation of sphingosine-1-phosphate receptors. Such methods can be performed, for example, by administering to a subject in need thereof a pharmaceutical composition containing a therapeutically effective amount of at least one invention compound. As used herein, the term “therapeutically effective amount” means the amount of the pharmaceutical composition that will elicit the biological or medical response of a subject in need thereof that is being sought by the researcher, veterinarian, medical doctor or other clinician. In some embodiments, the subject in need thereof is a mammal. In some embodiments, the mammal is human.
The present invention concerns also processes for preparing the compounds of Formula I.
The compounds of formula I according to the invention can be prepared analogously to conventional methods as understood by the person skilled in the art of synthetic organic chemistry.
The synthetic scheme set forth below, illustrates how compounds according to the invention can be made. Those skilled in the art will be able to routinely modify and/or adapt the following scheme to synthesize any compounds of the invention covered by Formula I.
To a solution of benzoic acid (a) (1 mmol) in THF (8 mL) was added 1,1′-carbonyldiimidazole (CDI) (1.1 mmol). The mixture was stirred at room temperature for 30 minutes. To the reaction mixture was added imidazole derivative (b) (1.1 mmol) and N,N-dimethylformamide (DMF) (8 mL); the resulting mixture was stirred at 50° C. for 2 hours. The reaction mixture was then transferred to a microwave (MWI) vial and heated at 150° C. for 20 minutes. After cooling to room temperature the mixture was diluted with water and extracted with ethyl acetate. The ethyl acetate phase was washed with water and brine, dried over sodium sulfate and concentrated. Trituration or column chromatography (methanol/ethyl acetate) gave the corresponding compound of Formula I.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the results in a lymphopenia assay in mice using Compound 3.
FIG. 2 shows the results in a lymphopenia assay in mice using Compound 16.
DETAILED DESCRIPTION OF THE INVENTION
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention claimed. As used herein, the use of the singular includes the plural unless specifically stated otherwise.
It will be readily apparent to those skilled in the art that some of the compounds of the invention may contain one or more asymmetric centers, such that the compounds may exist in enantiomeric as well as in diastereomeric forms. Unless it is specifically noted otherwise, the scope of the present invention includes all enantiomers, diastereomers and racemic mixtures. Some of the compounds of the invention may form salts with pharmaceutically acceptable acids or bases, and such pharmaceutically acceptable salts of the compounds described herein are also within the scope of the invention.
The present invention includes all pharmaceutically acceptable isotopically enriched compounds. Any compound of the invention may contain one or more isotopic atoms enriched or different than the natural ratio such as deuterium 2 H (or D) in place of protium 1 H (or H) or use of 13 C enriched material in place of 12 C and the like. Similar substitutions can be employed for N, O and S. The use of isotopes may assist in analytical as well as therapeutic aspects of the invention. For example, use of deuterium may increase the in vivo half-life by altering the metabolism (rate) of the compounds of the invention. These compounds can be prepared in accord with the preparations described by use of isotopically enriched reagents.
The following examples are for illustrative purposes only and are not intended, nor should they be construed as limiting the invention in any manner. Those skilled in the art will appreciate that variations and modifications of the following examples can be made without exceeding the spirit or scope of the invention.
As will be evident to those skilled in the art, individual isomeric forms can be obtained by separation of mixtures thereof in conventional manner. For example, in the case of diasteroisomeric isomers, chromatographic separation may be employed.
The IUPAC names of the compounds mentioned in the examples were generated with ACD version 8.
Unless specified otherwise in the examples, characterization of the compounds is performed according to the following methods:
NMR spectra are recorded on 300 or 600 MHz Varian and acquired at room temperature. Chemical shifts are given in ppm referenced either to internal trimethylsilyl or to the residual solvent signal.
All the reagents, solvents, catalysts for which the synthesis is not described are purchased from chemical vendors such as Sigma Aldrich, Fluka, Bio-Blocks, Ryan Scientific, Syn Chem, Chem-Impex, Aces Pharma, however some known intermediates, for which the CAS registry number [CAS #] are mentioned, were prepared in-house following known procedures.
Usually the compounds of the invention were purified by flash column chromatography using a gradient solvent system of methanol/dichloromethane unless otherwise reported.
The following abbreviations are used in the examples:
DMF N,N-dimethylformamide
NaOH sodium hydroxide
CD 3 OD deuterated methanol
HCl hydrochloric acid
CDCl 3 deuterated chloroform
DMSO-d 6 deuterated dimethyl sulfoxide
CDI 1,1′-carbonyldiimidazole
Et 2 Zn diethylzinc
NH 4 Cl ammonium chloride
CH 2 Cl 2 dichloromethane
K 2 CO 3 potassium carbonate
MPLC medium pressure liquid chromatography
THF tetrahydrofuran
[IrCl(cod)] 2 di-p-chlorobis(1,5-cyclooctadiene)diiridium(I)
ClCH 2 I chloroiodomethane
Those skilled in the art will be able to routinely modify and/or adapt the following schemes to synthesize any compound of the invention covered by Formula I.
Some compounds of this invention can generally be prepared in one step from commercially available literature starting materials.
EXAMPLE 1
Intermediate 1
4-((1H-Imidazol-1-yl)methyl)-2-methylbenzonitrile
To the suspension of potassium carbonate (2.16 g,15.7 mmol) in THF at room temperature was added imidazole (4.27 g, 62.8 mmol). The mixture was stirred at room temperature for 10 minutes then 4-(bromomethyl)-2-methylbenzonitrile (CAS 1001055-64-6) (6.6 g, 31.4 mmol) was added and refluxed for 24 hours. The mixture was then cooled to room temperature. Potassium carbonate was filtered off. The filtrate was concentrated and residue was redissolved in dichloromethane. The dichloromethane phase was washed with water (three times) and then HCl (three times). To the combined HCl phase was added sodium carbonate (solid) and extracted with ethyl acetate. Ethyl acetate phase was washed with water and brine, dried over sodium sulfate and concentrated. Column chromatography (10% methanol/ethyl acetate) gave 4-((1H-imidazol-1-yl)methyl)-2-methylbenzonitrile (3.59 g, 58%) as a white solid.
1 H NMR (300 MHz, CDCl 3 ) δ 2.42(s, 3H), 5.10(s, 2H), 6.84(s, 1H), 6.95-7.02(m, 3H), 7.48(m, 2H).
EXAMPLE 2
Intermediate 2
Ethyl 3-bromo-4-(vinyloxy)benzoate
To a toluene (8 mL) solution of [IrCl(cod)] 2 (54 mg, 0.08 mmol) and sodium carbonate (506 mg, 4.8 mmol) was added ethyl 3-bromo-4-hydroxybenzoate (CAS 37470-58-9) (1.95 g, 7.96 mmol) followed by vinyl acetate (1.5 mL, 15.9 mmol) under argon. The mixture was stirred at 100° C. for 2 hours. The mixture was cooled to room temperature, quenched with wet ether. Solid was filtered off and washed with ether. Column chromatography (3% ethyl acetate/hexane) gave ethyl 3-bromo-4-(vinyloxy)benzoate (1.77 g, 79%) as a yellow oil.
1 H NMR (300 MHz, CDCl 3 ) δ 1.39(t, J=7.2 Hz, 3H), 4.37(t, J=7.2 Hz, 2H), 4.65-4.67(m, 1H), 4.92-4.97(m, 1H), 6.59-6.66(m, 1H), 7.02-7.05(m, 1H), 7.96-7.99 (m, 1H), 8.27(s, 1H).
EXAMPLE 3
Intermediate 3
Ethyl 3-bromo-4-cyclopropoxybenzoate
To a solution of Intermediate 2 (500 mg, 1.76 mmol), ClCH 2 I (0.41 mL, 5.66 mmol) in dichloroethane (6 mL) at −5° C. was added Et 2 Zn (2.3 mL, 1.2M in CH 2 Cl 2 , 2.82 mmol). The mixture was stirred at room temperature for 1 hour. The reaction was quenched with NH 4 Cl(sat.) and extracted with ether. Ether phase was washed with water and brine, dried over sodium sulfate and concentrated to give ethyl 3-bromo-4-cyclopropoxybenzoate (500 mg, 100%) as a yellow solid.
1 H NMR (300 MHz, CDCl 3 ) δ 0.88 (m, 4H), 1.38(t, J=7.2 Hz, 3H), 3.85-3.89(m, 1H), 4.36(t, J=7.2 Hz, 2H), 7.27-7.30(m, 1H), 7.97-8.00 (m, 1H), 8.21(s, 1H).
EXAMPLE 4
Intermediate 4
3-Bromo-4-cyclopropoxybenzoic acid
To a solution of Intermediate 3 (2.2 g, 7.7 mmol) in methanol (20 mL) was added NaOH (2M, 20 mL). The mixture was refluxed for 16 hours. The mixture was cooled room temperature, diluted with water and extracted with ethyl acetate/hexane (1:5). The aqueous phase was added HCl and extracted with ethyl acetate. Ethyl acetate phase was washed with water and brine, dried over sodium sulfate and concentrated to give 3-bromo-4-cyclopropoxybenzoic acid (1.8 g, 90%) as a white solid.
1 H NMR (300 MHz, CDCl 3 ) δ 0.90 (m, 4H), 3.87-3.90(m, 1H), 7.31-7.34(m, 1H), 8.03-8.07 (m, 1H), 8.28(s, 1H).
EXAMPLE 5
Compound 1
5-(3-Bromo-4-cyclopropoxy-phenyl)-3-(4-imidazol-1-ylmethyl-phenyl)-[1,2,4]oxadiazole
To a solution of Intermediate 4 benzoic acid (1 mmol) in THF (8 mL) was added CDI (1.1 mmol). The mixture was stirred at room temperature for 30 minutes. To the reaction mixture was added benzonitrile-4-(1H-imidazol-1-ylmethyl) CAS 112809-54-8 (1.1 mmol) and DMF (8 mL) and resulting mixture was stirred at 50° C. for 2 hours. The reaction mixture was then transferred to a microwave vial and heated at 150° C. for 20 minutes. After cooling to room temperature the mixture was diluted with water and extracted with ethyl acetate. Ethyl acetate phase was washed with water and brine, dried over sodium sulfate and concentrated. Trituration or column chromatography (methanol/ethyl acetate) gave 5-(3-Bromo-4-cyclopropoxy-phenyl)-3-(4-imidazol-1-ylmethyl-phenyl)-[1,2,4]oxadiazole.
1 H NMR (300 MHz, CDCl 3 ) 0.91-0.93(m, 4H), 3.89-3.91(m, 1H), 5.21(s, 2H), 6.94(s, 1H), 7.14(s, 1H), 7.27-7.30(m, 2H), 7.40-7.43(m, 1H), 7.62(s, 1H), 8.12-8.16(m, 3H), 8.39(s, 1H).
Compounds 2-6 were prepared from the corresponding benzoic acids and the corresponding imidazole derivatives, in a similar manner to the method described in Example 5 for Compound 1. The reactants used and the results are described below in Table 1.
TABLE 1
Compound
1 H NMR δ (ppm) for
number
IUPAC name
Reactant(s)
Compound
2
5-(3-Bromo-4-
Intermediate 1
1 H NMR (300 MHz, CDCl 3 ) δ
cyclopropoxy-
Intermediate 4
0.91-0.93(m, 4H), 2.65(s, 3H),
phenyl)-3-(4-imidazol-
3.90(m, 1H), 5.17(s, 2H),
1-ylmethyl-2-methyl-
6.94(s, 1H), 7.11-7.13(m, 3H),
phenyl)-
7.40-7.43(m, 1H), 7.62(s, 1H),
[1,2,4]oxadiazole
8.06-8.14(m, 2H), 8.39(s, 1H)
3
3-(4-Imidazol-1-
Benzonitrile,
1 H NMR (300 MHz, CD 3 OD) δ
ylmethyl-phenyl)-5-
4-(1H-imidazol-1-
1.42-1.44(m, 6H), 4.76-
(4-isopropoxy-3-
ylmethyl)-
4.80(m, 1H), 5.21(s, 2H),
trifluoromethyl-
[CAS 112809-54-8]
6.94(s, 1H), 7.13-7.15(m, 2H),
phenyl)-
Benzoic acid,
7.26-7.29(m, 2H), 7.61(s, 1H),
[1,2,4]oxadiazole
4-(1-methylethoxy)-
8.13-8.16(m, 2H), 8.27-
3-(trifluoromethyl)-
8.30(m, 1H), 8.41(s, 1H)
[CAS 213598-16-4]
4
3-(4-Imidazol-1-
Benzonitrile,
1 H NMR (300 MHz, CD 3 OD) δ
ylmethyl-phenyl)-5-
4-(1H-imidazol-1-
1.07-1.09(m, 6H), 2.10-
(4-isobutoxy-3-
ylmethyl)-
2.17(m, 1H), 3.98--4.00(m,
trifluoromethyl-
[CAS 112809-54-8]
2H), 5.33(s, 2H), 7.03(s, 1H),
phenyl)-
Benzoic acid,
7.17(s, 1H), 7.36-7.42(m, 3H),
[1,2,4]oxadiazole
4-(2-methylpropoxy)-
7.81(s, 1H), 8.11-8.14(m, 2H),
3-(trifluoromethyl)-
8.36-8.38(m, 2H)
[CAS 1008769-62-7]
5
5-(4-Cyclohexyloxy-
Benzonitrile,
1 H NMR (300 MHz, CD 3 OD) δ
3-trifluoromethyl-
4-(1H-imidazol-1-
1.4-1.6(m, 4H), 1.6-2.0(m,
phenyl)-3-(4-imidazol-
ylmethyl)-
6H), 4.5-4.6(m, 1H), 5.21(s,
1-ylmethyl-phenyl)-
[CAS 112809-54-8]
2H), 6.94(s, 1H), 7.14(br, 2H),
[1,2,4]oxadiazole
Benzoic acid,
7.27-7.29(m, 2H), 7.61(s, 1H),
4-(cyclohexyloxy)-
8.14-8.16(m, 2H), 8.26-
3-(trifluoromethyl)-
8.29(m, 1H), 8.42(s, 1H)
[CAS 1008769-64-9]
6
3-(4-Imidazol-1-
Intermediate 1
1 H NMR (300 MHz, CDCl 3 ) δ
ylmethyl-2-methyl-
Benzoic acid,
1.43-1.45(m, 6H), 2.66(s, 3H),
phenyl)-5-(4-
4-(1-methylethoxy)-
4.74-4.82(m, 1H), 5.17(s, 2H),
isopropoxy-3-
3-(trifluoromethyl)-
6.94(s, 1H), 7.12-7.16(m, 4H),
trifluoromethyl-
[CAS 213598-16-4]
7.65(s, 1H), 8.06-8.09(m, 1H),
phenyl)-
8.29-8.32(m, 1H), 8.42(s, 1H)
[1,2,4]oxadiazole
EXAMPLE 6
Compound 7
3-(4-Imidazol-1-ylmethyl-phenyl)-5-(4-isopropoxy-3-nitro-phenyl)-[1,2,4]oxadiazole
The suspension of 4-isopropoxy-3-nitrobenzoic acid CAS 156629-52-6 (1.27 mmol), 4-Benzonitrile, (1H-imidazol-1-ylmethyl) CAS 112809-54-8 (1.41 mmol) and K 2 CO 3 (1.41 mmol) in toluene (2 mL) and DMF(2 mL) in microwave vial was heated at 180° C. for 2-5 hours. The mixture was cooled to room temperature and diluted with water, extracted with dichloromethane. The dichloromethane phase was washed with water and brine, dried over sodium sulfate and concentrated. MPLC (50% MeOH/CH 2 Cl 2 ) followed by recrystalization (ethylacetate/hexane) gave 3-(4-Imidazol-1-ylmethyl-phenyl)-5-(4-isopropoxy-3-nitro-phenyl)-[1,2,4]oxadiazole (60 mg, 12%) as a white solid.
1 H NMR (300 MHz, CD 3 OD) δ 1.41-1.43(d, J=5.86, 6H), 4.85-4.97(m, 1H), 5.33(s, 2H), 7.03(s, 1H), 7.17(s, 1H), 7.39-7.42(m, 2H), 7.50-7.53(m, 1H), 7.81(s, 1H), 8.11-8.14(m, 2H), 8.34-8.37(m, 1H), 8.55(s, 1H).
Compounds 8-17 were prepared from the corresponding benzoic acids and the corresponding imidazole derivatives, in a similar manner to the method described in Example 6 for Compound 7. The reactants used and the results are described below in Table 2.
TABLE 2 Compound Reactant (s) 1 H NMR δ (ppm) for number IUPAC name used Compound 8 5-[3-(4-Imidazol-1- Benzonitrile, 1 H NMR (300 MHz, CD 3 OD) ylmethyl-phenyl)- 4-(1H-imidazol-1- δ 1.10-1.12(d, J = 6.74, 6H), [1,2,4]oxadiazol-5-yl]- ylmethyl)- 2.16-2.21(m, 1H), 4.03- 2-isobutoxy- [CAS 112809-54-8] 4.05(m, 2H), 5.33(s, 2H), benzonitrile Benzoic acid, 7.03(s, 1H), 7.17(s, 1H), 3-cyano-4-(2- 7.38-7.42(m, 3H), 7.80(s, methylpropoxy)- 1H), 8.11-8.14(m, 2H), [CAS 528607-60-5] 8.39-8.44(m, 2H) 9 5-(3-Bromo-4- Benzonitrile, 1 H NMR (300 MHz, CDCl 3 ) isobutoxy-phenyl)-3- 4-(1H-imidazol-1- δ 1.09-1.11(d, J = 6.74, 6H), (4-imidazol-1- ylmethyl)- 2.18-2.23(m, 1H), 3.87- ylmethyl-phenyl)- [CAS 112809-54-8] 3.89(m, 2H), 5.20(s, 2H), [1,2,4]oxadiazole Benzoic acid, 6.94-7.00(m, 2H), 7.13(s, 3-bromo-4-(2- 1H), 7.26-7.28(m, 2H), methylpropoxy)- 7.60(s, 1H), 8.07-8.15(m, [CAS 881583-05-7] 3H), 8.39(s, 1H) 10 3-(4-Imidazol-1- Benzonitrile, 1 H NMR (300 MHz, CD 3 OD) ylmethyl-phenyl)-5-(4- 4-(1H-imidazol-1- δ 0.89-0.91(d, J = 6.45, 6H), isobutyl-phenyl)- ylmethyl)- 1.86-1.91(m, 1H), 2.52- [1,2,4]oxadiazole [CAS 112809-54-8] 2.54(m, 2H), 5.28(s, 2H), Benzoic acid, 7.02(s, 1H), 7.13(s, 1H), 4-(2-methylpropyl)- 7.31-7.36(m, 4H), 7.79(s, [CAS 38861-88-0] 1H), 8.01-8.08(m, 4H) 11 3-(4-Imidazol-1- Benzonitrile, 1 H NMR (300 MHz, CDCl 3 ) ylmethyl-phenyl)-5-(4- 4-(1H-imidazol-1- δ 1.39-1.41(d, J = 5.86, 6H), isopropoxy-phenyl)- ylmethyl)- 4.64-4.72(m, 1H), 5.21(s, [1,2,4]oxadiazole [CAS 112809-54-8] 2H), 6.94(s, 1H), 7.00- Benzoic acid, 7.02(m, 2H), 7.13(s, 1H), 4-(1-methylethoxy)- 7.26-7.29(m, 2H), 7.61(s, [CAS 13205-46-4] 1H), 8.12-8.17(m, 4H) 12 5-[3-(4-Imidazol-1- Benzonitrile, 1 H NMR (300 MHz, DMSO) ylmethyl-phenyl)- 4-(1H-imidazol-1- δ 1.36-1.38(d, J = 5.86, 6H), [1,2,4]oxadiazol-5-yl]- ylmethyl)- 4.94-4.98(m, 1H), 5.31(s, 2-isopropoxy- [CAS 112809-54-8] 2H), 6.93(s, 1H), 7.22(s, benzonitrile Benzoic acid, 1H), 7.41-7.44(m, 2H), 3-cyano-4-(1- 7.52-7.55(m, 1H), 7.78(s, methylethoxy)- 1H), 8.04-8.07(m, 2H), [CAS 258273-31-3] 8.36-8.39(m, 1H), 8.47(s, 1H) 13 5-[3-(4-Imidazol-1- Intremediate 1 1 H NMR (300 MHz, CDCl 3 ) ylmethyl-2-methyl- Benzoic acid, δ 1.47-1.49(d, J = 5.86, 6H), phenyl)- 3-cyano-4-(1- 2.65(s, 3H), 4.73-4.80(m, [1,2,4]oxadiazol-5-yl]- methylethoxy)- 1H), 5.17(s, 2H), 6.94(s, 2-isopropoxy- [CAS 258273-31-3] 1H), 7.11-7.13(m, 4H), benzonitrile 7.61(s, 1H), 8.06-8.08(m, 1H), 8.31-8.34(m, 1H), 8.41(s, 1H) 14 5-(3-Bromo-4- Benzonitrile, 1 H NMR (300 MHz, CDCl 3 ) isopropoxy-phenyl)-3- 4-(1H-imidazol-1- δ 1.44-1.46(d, J = 5.86, 6H), (4-imidazol-1- ylmethyl)- 4.69-4.73(m, 1H), 5.21(s, ylmethyl-phenyl)- [CAS 112809-54-8] 2H), 6.95(s, 1H), 7.00- [1,2,4]oxadiazole Benzoic acid, 7.03(m, 1H), 7.14(s, 1H), 3-bromo-4-(1- 7.27-7.30(m, 2H), 7.65(s, methylethoxy)- 1H), 8.08-8.16(m, 3H), [CAS 213598-20-0] 8.41(s, 1H) 15 5-(3-Bromo-4- Intremediate 1 1 H NMR (300 MHz, CDCl 3 ) isopropoxy-phenyl)-3- Benzoic acid, δ 1.44-1.46(d, J = 5.86, 6H), (4-imidazol-1- 3-bromo-4-(1- 2.65(s, 3H), 4.67-4.75(m, ylmethyl-2-methyl- methylethoxy)- 1H), 5.17(s, 2H), 6.94(s, phenyl)- [CAS 213598-20-0] 1H), 7.00-7.03(m, 1H), [1,2,4]oxadiazole 7.11-7.14(m, 3H), 7.64(s, 1H), 8.05-8.11(m, 2H), 8.41(s, 1H) 16 5-(3-Chloro-4- Benzonitrile, 1 H NMR (300 MHz, CDCl 3 ) isopropoxy-phenyl)-3- 4-(1H-imidazol-1- δ 1.44-1.46(d, J = 5.86, 6H), (4-imidazol-1- ylmethyl)- 4.70-4.73(m, 1H), 5.21(s, ylmethyl-phenyl)- [CAS 112809-54-8] 2H), 6.94(s, 1H), 7.04- [1,2,4]oxadiazole Benzoic acid, 7.07(m, 1H), 7.14(s, 1H), 3-chloro-4-(1- 7.27-7.30(m, 2H), 7.64(s, methylethoxy)- 1H), 8.04-8.07(m, 1H), [CAS 213598-07-3] 8.14-8.16(m, 2H), 8.23(s, 1H) 17 3-(4-Imidazol-1- Benzonitrile, 1 H NMR (300 MHz, CD 3 OD) ylmethyl-phenyl)-5-(4- 4-(1H-imidazol-1- δ 1.37-1.39(d, J = 6.15, 6H), isopropoxy-3-methyl- ylmethyl)- 2.25(s, 3H), 4.73-4.77(m, phenyl)- [CAS 112809-54-8] 1H), 5.32(s, 2H), 7.02(s, [1,2,4]oxadiazole Benzoic acid, 1H), 7.07-7.10(m, 1H), 3-methyl-4-(1- 7.16(s, 1H), 7.38-7.41(m, methylethoxy 2H), 7.80(s, 1H), 7.95- [CAS 856165-81-6] 8.00(m, 2H), 8.09-8.12(m, 2H) 18 3-(4-Imidazol-1- Intermediate 1 1 H NMR (300 MHz, CDCl 3 ) ylmethyl-2-methyl- Benzoic acid, δ 1.40(d, J = 5.86, 6H), phenyl)-5-(4- 3-methyl-4-(1- 2.28(s, 3H), 2.65(s, 3H), isopropoxy-3-methyl- methylethoxy 4.65-4.69(m, 1H), 5.17(s, phenyl)- [CAS 856165-81-6] 2H), 6.93-6.95(m, 2H), [1,2,4]oxadiazole 7.10-7.13(m, 3H), 7.63(s, 1H), 8.01-8.08(m, 3H) 19 3-(4-Imidazol-1- Intermediate 1 1 H NMR (300 MHz, CDCl 3 ) ylmethyl-2-methyl- Benzoic acid, δ 1.46-1.48(d, J = 5.86, 6H), phenyl)-5-(4- 4-(1-methylethoxy)- 2.66(s, 3H), 4.79-4.85(m, isopropoxy-3-nitro- 3-nitro- 1H), 5.18(s, 2H), 6.94(s, phenyl)- [CAS 156629-52-6] 1H), 7.12-7.14(m, 3H), [1,2,4]oxadiazole 7.22-7.25(m, 1H), 7.63(s, 1H), 8.06-8.09(m, 1H), 8.29-8.33(m, 1H), 8.62- 8.64(m, 1H)
Biological Data:
Novel compounds were synthesized and tested for S1P1 activity using the GTP γ 35 S binding assay. These compounds may be assessed for their ability to activate or block activation of the human S1P1 receptor in cells stably expressing the S1P1 receptor. GTP γ 35 S binding was measured in the medium containing (mM) HEPES 25, pH 7.4, MgCl 2 10, NaCl 100, dithitothreitol 0.5, digitonin 0.003%, 0.2 nM GTP γ 35 S, and 5 μg membrane protein in a volume of 150 μl. Test compounds were included in the concentration range from 0.08 to 5,000 nM unless indicated otherwise. Membranes were incubated with 100 μM 5′-adenylylimmidodiphosphate for 30 min, and subsequently with 10 μM GDP for 10 min on ice. Drug solutions and membrane were mixed, and then reactions were initiated by adding GTP γ 35 S and continued for 30 min at 25° C. Reaction mixtures were filtered over Whatman GF/B filters under vacuum, and washed three times with 3 mL of ice-cold buffer (HEPES 25, pH 7.4, MgCl 2 10 and NaCl 100). Filters were dried and mixed with scintillant, and counted for 35 S activity using a β-counter. Agonist-induced GTP γ 35 S binding was obtained by subtracting that in the absence of agonist. Binding data were analyzed using a non-linear regression method. In case of antagonist assay, the reaction mixture contained 10 nM S1P in the presence of test antagonist at concentrations ranging from 0.08 to 5000 nM.
S1P1
% S1P1
Biological Data:
GTPγ 35 S
STIMULATION
Intrinsic Activity
EC50 (nM)
@ 5 μM (%)
3-(4-Imidazol-1-ylmethyl-phenyl)-5-(4-isobutyl-
543
79.8
phenyl)-[1,2,4]oxadiazole
5-[3-(4-Imidazol-1-ylmethyl-phenyl)-
3.31
94.6
[1,2,4]oxadiazol-5-yl]-2-isopropoxy-
benzonitrile
3-(4-Imidazol-1-ylmethyl-phenyl)-5-(4-
998
72.2
isobutoxy-3-trifluoromethyl-phenyl)-
[1,2,4]oxadiazole
5-(4-Cyclohexyloxy-3-trifluoromethyl-phenyl)-
149
91.8
3-(4-imidazol-1-ylmethyl-phenyl)-
[1,2,4]oxadiazole
3-(4-Imidazol-1-ylmethyl-phenyl)-5-(4-
0.51
95.6
isopropoxy-3-trifluoromethyl-phenyl)-
[1,2,4]oxadiazole
5-(3-Chloro-4-isopropoxy-phenyl)-3-(4-
2.79
99.8
imidazol-1-ylmethyl-phenyl)-[1,2,4]oxadiazole
5-(3-Bromo-4-isopropoxy-phenyl)-3-(4-
0.92
93.9
imidazol-1-ylmethyl-phenyl)-[1,2,4]oxadiazole
5-[3-(4-Imidazol-1-ylmethyl-phenyl)-
62
75.9
[1,2,4]oxadiazol-5-yl]-2-isobutoxy-benzonitrile
3-(4-Imidazol-1-ylmethyl-phenyl)-5-(4-
453
92.8
isopropoxy-phenyl)-[1,2,4]oxadiazole
3-(4-Imidazol-1-ylmethyl-phenyl)-5-(4-
10.3
133
isopropoxy-3-methyl-phenyl)-[1,2,4]oxadiazole
3-(4-Imidazol-1-ylmethyl-phenyl)-5-(4-
3.24
118
isopropoxy-3-nitro-phenyl)-[1,2,4]oxadiazole
5-(3-Bromo-4-isobutoxy-phenyl)-3-(4-imidazol-
28.6
86.2
1-ylmethyl-phenyl)-[1,2,4]oxadiazole
5-[3-(4-Imidazol-1-ylmethyl-2-methyl-phenyl)-
4.76
96.4
[1,2,4]oxadiazol-5-yl]-2-isopropoxy-
benzonitrile
3-(4-Imidazol-1-ylmethyl-2-methyl-phenyl)-5-
8.98
102
(4-isopropoxy-3-nitro-phenyl)-
[1,2,4]oxadiazole
5-(3-Bromo-4-isopropoxy-phenyl)-3-(4-
19.6
109
imidazol-1-ylmethyl-2-methyl-phenyl)-
[1,2,4]oxadiazole
5-(3-Bromo-4-cyclopropoxy-phenyl)-3-(4-
14.4
99.9
imidazol-1-ylmethyl-phenyl)-[1,2,4]oxadiazole
5-(3-Bromo-4-cyclopropoxy-phenyl)-3-(4-
32
96
imidazol-1-ylmethyl-2-methyl-phenyl)-
[1,2,4]oxadiazole
3-(4-Imidazol-1-ylmethyl-2-methyl-phenyl)-5-
3.38
95.5
(4-isopropoxy-3-trifluoromethyl-phenyl)-
[1,2,4]oxadiazole
3-(4-Imidazol-1-ylmethyl-2-methyl-phenyl)-5-
19.8
94.6
(4-isopropoxy-3-methyl-phenyl)-
[1,2,4]oxadiazole
5-[3-(4-Imidazol-1-ylmethyl-2-trifluoromethyl-
5.22
97.6
phenyl)-[1,2,4]oxadiazol-5-yl]-2-isopropoxy-
benzonitrile
5-(3-Bromo-4-isopropoxy-phenyl)-3-(4-
102
100
imidazol-1-ylmethyl-2-trifluoromethyl-phenyl)-
[1,2,4]oxadiazole
3-[4-(1H-imidazol-1-ylmethyl)-2-
—
7.4
(trifluoromethyl)phenyl]-5-(4-isopropoxy-3-
methylphenyl)-1,2,4-oxadiazole
3-[4-(1H-imidazol-1-ylmethyl)-2-
62.4
80.9
(trifluoromethyl)phenyl]-5-[4-isopropoxy-3-
(trifluoromethyl)phenyl]-1,2,4-oxadiazole
3-[4-(1H-imidazol-1-ylmethyl)-2-
6.37
79.4
(trifluoromethyl)phenyl]-5-(4-isopropoxy-3-
nitrophenyl)-1,2,4-oxadiazole
5-[3-bromo-4-(cyclopropyloxy)phenyl]-3-[4-
119
89.6
(1H-imidazol-1-ylmethyl)-2-
(trifluoromethyl)phenyl]-1,2,4-oxadiazole
5-(3-bromo-4-isobutoxyphenyl)-3-[4-(1H-
144
98.3
imidazol-1-ylmethyl)-2-(trifluoromethyl)phenyl]-
1,2,4-oxadiazole
5-{3-[2-chloro-4-(1H-imidazol-1-
4.56
94.9
ylmethyl)phenyl]-1,2,4-oxadiazol-5-yl}-2-
isopropoxybenzonitrile
5-(3-bromo-4-isopropoxyphenyl)-3-[2-chloro-4-
29.7
102
(1H-imidazol-1-ylmethyl)phenyl]-1,2,4-
oxadiazole
3-[2-chloro-4-(1H-imidazol-1-ylmethyl)phenyl]-
3.55
79.6
5-[4-isopropoxy-3-(trifluoromethyl)phenyl]-
1,2,4-oxadiazole;
3-[2-chloro-4-(1H-imidazol-1-ylmethyl)phenyl]-
8.79
92.3
5-(4-isopropoxy-3-nitrophenyl)-1,2,4-
oxadiazole
5-{3-[4-(1H-imidazol-1-ylmethyl)phenyl]-1,2,4-
130
99.9
oxadiazol-5-yl}-2-(2-methylpiperidin-1-
yl)benzonitrile
Lymphopenia Assay in Mice
Test drugs are prepared in a solution containing 3% (w/v) 2-hydroxy propyl β-cyclodextrin (HPBCD) and 1% DMSO to a final concentration of 1 mg/ml, and subcutaneously injected to female C57BL6 mice (CHARLES RIVERS) weighing 20-25 g at the dose of 10 mg/Kg. Blood samples are obtained by puncturing the submandibular skin with a Goldenrod animal lancet at 5, 24, 48, 72, and 96 hrs post drug application. Blood is collected into microvettes (SARSTEDT) containing EDTA tripotassium salt. Lymphocytes in blood samples are counted using a HEMAVET Multispecies Hematology System, HEMAVET HV950FS (Drew Scientific Inc.). (Hale, J. et al Bioorg. & Med. Chem. Lett. 14 (2004) 3351).
A lymphopenia assay in mice; as previously described, was employed to measure the in vivo blood lymphocyte depletion after dosing with 3-(4-Imidazol-1-ylmethyl-phenyl)-5-(4-isopropoxy-3-trifluoromethyl-phenyl)-[1,2,4]oxadiazole, Compound 3, ( FIG. 1 ) and 5-(3-Chloro-4-isopropoxy-phenyl)-3-(4-imidazol-1-ylmethyl-phenyl)-[1,2,4]oxadiazole, Compound 16, ( FIG. 2 ). These S1P agonist (or modulator) is useful for S1P-related diseases, and exemplified by the lymphopenia in vivo response. In general, test drugs Compound 3 and 16 were prepared in a solution containing 3% (w/v) 2-hydroxy propyl β-cyclodextrin (HPBCD) and 1% DMSO to a final concentration of 1 mg/ml, and subcutaneously injected to female C57BL6 mice (CHARLES RIVERS) weighing 20-25 g at the dose of 10 mg/Kg. Blood samples were obtained by puncturing the submandibular skin with a Goldenrod animal lancet at 5, 24, 48, and 72 hrs post drug application. Blood was collected into microvettes (SARSTEDT) containing EDTA tripotassium salt. Lymphocytes in blood samples were counted using a HEMAVET Multispecies Hematology System, HEMAVET HV950FS (Drew Scientific Inc.). Results are shown in the following figures below that depict lowered lymphocyte count after 5 hours (<1 number of lymphocytes 10 3 /μL blood). | Substituted 3-(4-((1H-imidazol-1-yl)methyl)phenyl)-5-phenyl-1,2,4-oxadiazole derivatives which are useful as sphingosine-1-phosphate modulators and useful for treating a wide variety of disorders associated with modulation of sphingosine-1-phosphate receptors. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates generally to the field of oilfield exploration, production, and testing), and more specifically to protection of polymeric components used in such ventures.
[0003] 2. Related Art
[0004] Electrical submersible pumps (ESPs) are used for artificial lifting of fluid from a well or reservoir. An ESP typically comprises an electrical submersible motor, a seal section (sometimes referred to in the art as a protector) which functions to equalize the pressure between the inside of the system and the outside of the system and also acts as a reservoir for compensating the internal oil expansion from the motor; and a pump having one or more pump stages inside a housing. The protector may be formed of metal, as in a bellows device, or an elastomer, in which case the protector is sometimes referred to as a protector bag. Elastomers may also be used in packer elements, blow out preventer elements, O-rings, gaskets, electrical insulators and pressure sealing elements for fluids.
[0005] Common to all of these uses of elastomers is exposure to hostile chemical and mechanical subterranean environments that tend to unacceptably decrease the life and reliability of the elastomers.
[0006] Three basic approaches have been taken in addressing the pump protector problem. Replacing the elastomer with a thin metal membrane or bellows may be an expensive alternative that requires extensive redesign of the parts together with their mechanical attachment and interfaces. Improving the bulk properties of the elastomer material using additives is another alternative; however, that may require conflicting compromises in the mechanical, chemical, or reliability performance of the finished part. Typically, it is not feasible to find a combination of additives that satisfy all the requirements, or it is prohibitively expensive to either procure the additive materials or to manufacture the part. Applying some type of protective coating to elastomer seals has been tried in the medical, computer and electronics, defense, automotive, food processing and aerospace industries. Focus has been on various types and methods of applying either a metal or a polymer coating to protect elastomeric seals for either low friction, abrasion resistance or for chemically enhancing the wear resistance and environmental resistance of the part without changing the physical properties of the base elastomer. For example, U.S. Pat. No. 5,075,174 discusses Parylene-coated silicone elastomeric gaskets for use in the computer and electronics industry. There are two principal coating methods: Physical Vapor Deposition (PVD) and Chemical Vapor Decomposition (CVD). PVD coatings are typically made either by thermal evaporation or sputtering. Unfortunately, PVD is a line-of-sight coating process; therefore, coverage of the substrate is poor when a part is odd shaped or has cavities. In contrast, CVD is not restricted to line-of-sight; therefore it can coat all surfaces of the substrate. Examples of film coatings on elastomers include a silane polymer that was applied by plasma deposition in a radio frequency/microwave dual power source reactor (see U.S. Pat. No. 6,488,992), and a blend of elastomer and polyethylene co-extruded onto rubber weather stripping material (U.S. Pat. No. 5,110,685).
[0007] There remains a need in the natural resources exploration and production field for improving reliability and life of elastomeric and other polymeric components used in oilfield environments, such as protector bags, packer elements, pressure seals, valves, blow out preventer components, and the like.
SUMMARY OF THE INVENTION
[0008] In accordance with the present invention, apparatus and methods of making and using same are described that reduce or overcome problems in previously known apparatus and methods. By combining the properties of polymeric substrates with the properties of thin polymer coatings, the materials act together to increase reliability and life of oilfield elements that include the materials or are made from the materials.
[0009] A first aspect of the invention are apparatus comprising:
(a) a polymeric substrate formed into an oilfield element; (b) a polymeric coating, which may be a conformal coating, adhered to at least a portion of the polymeric substrate.
[0012] The polymeric coating is a condensed phase formed by any one or more processes. The coating may be conformal (i.e., the coating conforms to the surfaces of the polymeric substrate), although this may not be necessary in all oilfield applications or all oilfield elements, or on all surfaces of the polymeric substrates. The coating may be formed from a vaporizable or depositable and polymerizable monomer, as well as particulate polymeric materials. The polymer in the coating is also generally responsible for adhering the coating to the polymeric substrate, although the invention does not rule out adhesion aids, which are further discussed herein. A major portion of the polymeric coating may comprise a carbon or heterochain chain polymer. Useful carbon chain polymers may be selected from polymers within formula —[R(R 1 x )(R 2 y )] n —, wherein R is the repeating unit and may be selected from C, aryl, or —C(R 3 p )(R 4 q )-aryl-C(R 5 r )(R 6 s )—. If R═C, then R 1 and R 2 may be the same or different halogen atoms, x and y are integers each ranging from 0 to 4, x+y=4, and n ranges from 10 to 10,000. Examples include polytetrafluoroethylene and polychlorotrifluoroethylene. If R is aryl, the aryl is fused to at least one other aryl sharing two carbon atoms, R 1 and R 2 may be the same or different and may be on the same or different aryl moieties, R 1 and R 2 may be independently selected from any organic or inorganic group which can normally be substituted on aryl moieties, including, but not limited to alkyl, alkenyl, amino, cyano, carboxyl, alkoxy, hydroxy alkyl, carbalkoxy, hydroxyl, nitro, acyl, acylamino, or a halogen atom, x and y range from 0 up to the total number of available aryl substitution positions, and n is as defined above. Examples are polycyclic aromatic hydrocarbons such as polynaphthalene, polyanthracene, and polyphenanthrene. If R is —C(R 3 p )(R 4 q )-aryl-C(R 5 r )(R 6 s )—, R 1 and R 2 may be independently selected from any organic or inorganic group which can normally be substituted on aromatic nuclei, including, but not limited to alkyl, aryl, alkenyl, amino, cyano, carboxyl, alkoxy, hydroxy alkyl, carbalkoxy, hydroxyl, nitro or a halogen atom, x and y may be a number from 0 to 3 as long as x+y=3, n is a number from 10 to 10,000 or higher, R 3 , R 4 , R 5 , and R 6 are independently selected from halogen atoms and hydrogen atoms, and p, q, r, and s may be 0, 1, or 2, with p+q=2 and r+s=2. Examples are Parylene N, wherein x=0, y=0, R 3 , R 4 , R 5 , and R 6 are all hydrogen atoms, and p, q, r, and s are all equal to 1; Parylene C, wherein R 1 is a chlorine atom, x=1, y=0, R 3 , R 4 , R 5 , and R 6 are all hydrogen atoms, and p, q, r, and s are all equal to 1; Parylene D, wherein R 1 is a chlorine atom, x=2, y=0, or R 1 and R 2 are both chlorine atoms and x=1 and y=1, R 3 , R 4 , R 5 , and R 6 are all hydrogen atoms, and p, q, r, and s are all equal to 1; and Parylene Nova HT, wherein x=0, y=0, R 3 , R 4 , R 5 , and R 6 are all fluorine atoms, and p, q, r, and s are all equal to 1.
[0013] One method of forming a polymeric coating on a polymeric substrate is by vaporizing or subliming a monomer or dimer into a pyrolysis chamber under mild vacuum, pyrolyzing the monomer or dimer under mild vacuum, and condensing the monomer or dimer onto the substrate where polymerization takes place. This is commonly referred to as vapor deposition polymerization (VDP). Depending on the polymeric coating composition, the polymeric coating may alternatively be formed by spraying monomers, oligomers, or pre-polymer solutions or small particles of the polymer onto the substrate. Fluidized bed coating may be used if the substrate is able to be heated to a high enough temperature to melt the fluidized polymer to be coated thereon without melting the polymeric substrate. In each deposition process, mechanical, chemical, or a combination of mechanical and chemical priming, for example using adhesion promoters and/or chemical coupling agents, may enhance adhesion of the polymer coating to the polymeric substrate formed into an oilfield element. The particular deposition methods are not considered a part of the present invention, but are presented for complete disclosure.
[0014] Apparatus of the invention may comprise polymeric substrates selected from natural and synthetic polymers, blends of natural and synthetic polymers, and layered versions of polymers, wherein individual layers may be the same or different in composition and thickness. The term “polymeric substrate” includes composite polymeric materials, such as, but not limited to, polymeric materials having fillers, plasticizers, and fibers therein. The polymeric substrate may comprise one or more thermoplastic polymers, one or more thermoset polymers, one or more elastomers, and combinations thereof.
[0015] Apparatus within the invention include those wherein the oilfield element may be selected from packer elements, submersible pump motor protector bags, sensor protectors, blow out preventer elements, sucker rods, O-rings, T-rings, gaskets, pump shaft seals, tube seals, valve seals, seals and insulators used in electrical components, such as power cable coverings, seals used in fiber optic connections, and pressure sealing elements for fluids (gas, liquid, or combinations thereof). Apparatus of the invention include apparatus wherein the oilfield element is a submersible pump motor protector, which may or may not be integral with the motor, and may include integral instrumentation adapted to measure one or more downhole parameters.
[0016] Another aspect of the invention are oilfield assemblies for exploring for, drilling for, or producing hydrocarbons, one oilfield assembly comprising:
(a) one or more oilfield elements; and (b) one or more of the oilfield elements comprising a polymeric substrate having a polymeric coating thereon as in the first aspect of the invention.
[0019] Yet another aspect of the invention are methods of exploring for, drilling for, or producing hydrocarbons, one method comprising:
(a) selecting one or more oilfield elements having a component comprising a polymeric substrate having a polymeric coating thereon, the coating comprising a major portion of a polymer as described in the first aspect of the invention; and (b) using the oilfield element in an oilfield operation, thus exposing the oilfield element to an oilfield environment.
[0022] Methods of the invention may include, but are not limited to, running one or more oilfield elements into a wellbore using one or more surface oilfield elements, and/or retrieving the oilfield element from the wellbore. The oilfield environment during running and retrieving may be the same or different from the oilfield environment during use in the wellbore or at the surface.
[0023] The various aspects of the invention will become more apparent upon review of the brief description of the drawings, the detailed description of the invention, and the claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The manner in which the objectives of the invention and other desirable characteristics can be obtained is explained in the following description and attached drawings in which:
[0025] FIG. 1 is a front elevation view of an exemplary electrical submersible pump disposed within a wellbore;
[0026] FIG. 2 is a diagrammatical cross-section of the pump of FIG. 1 having a polymer-coated elastomer protector bag in accordance with the invention to separate well fluid from motor fluid, which is positively pressurized within the motor housing;
[0027] FIG. 3 is a schematic side elevation view, partially in cross-section, of a packer having polymer-coated elastomer packer elements in accordance with the invention;
[0028] FIGS. 4A and 4B are schematic cross-sectional views of two reversing tools utilizing polymer-coated elastomeric components in accordance with the invention;
[0029] FIGS. 5A and 5B are schematic side elevation views of two bottom hole assemblies which may utilize polymer-coated elastomer components in accordance with the invention;
[0030] FIGS. 6-8 show example test results of H 2 S gas permeability resistance tests of one elastomer in non-coated state, coated state, and coated and fatigued state, respectively;
[0031] FIGS. 9 and 10 show scanning electron microscopic (SEM) inspections of one elastomer as purchased, and as fatigued;
[0032] FIGS. 11A and 11B show SEM inspections of one coated elastomer in accordance with the invention;
[0033] FIGS. 12A and 12B show SEM inspections of the coated elastomer of FIGS. 11A and 11B after fatigue; and
[0034] FIGS. 13A and 13B are schematic cross-sectional views of a flow control valve that may be utilized to control the flow of petroleum production or well fluids out of specific zones in a well or reservoir, or injection of fluid into specific zones, the valve utilizing polymer-coated elastomeric components in accordance with the invention.
[0035] It is to be noted, however, that the appended drawings are not to scale and illustrate only typical embodiments of this invention, and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION
[0036] In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
[0037] All phrases, derivations, collocations and multiword expressions used herein, in particular in the claims that follow, are expressly not limited to nouns and verbs. It is apparent that meanings are not just expressed by nouns and verbs or single words. Languages use a variety of ways to express content. The existence of inventive concepts and the ways in which these are expressed varies in language-cultures. For example, many lexicalized compounds in Germanic languages are often expressed as adjective-noun combinations, noun-preposition-noun combinations or derivations in Romanic languages. The possibility to include phrases, derivations and collocations in the claims is essential for high-quality patents, making it possible to reduce expressions to their conceptual content, and all possible conceptual combinations of words that are compatible with such content (either within a language or across languages) are intended to be included in the used phrases.
[0038] The invention describes coated polymeric components useful in oilfield applications, including exploration, drilling, and production activities. As used herein the term “oilfield” includes land based (surface and sub-surface) and sub-seabed applications, and in certain instances seawater applications, such as when exploration, drilling, or production equipment is deployed through seawater. The term “oilfield” as used herein includes oil and gas reservoirs, and formations or portions of formations where oil and gas are expected but may ultimately only contain water, brine, or some other composition. A typical use of the coated polymeric components will be in downhole applications, such as pumping fluids from or into wellbores.
[0039] Polymeric Substrate Materials
[0040] Polymeric substrate materials useful in the invention may be selected from natural and synthetic polymers, blends of natural and synthetic polymers, and layered versions of polymers, wherein individual layers may be the same or different in composition and thickness. The term “polymeric substrate” includes composite polymeric materials, such as, but not limited to, polymeric materials having fillers, plasticizers, and fibers therein. The polymeric substrate may comprise one or more thermoplastic polymers, one or more thermoset and/or thermally cured polymers, one or more elastomers, composite materials, and combinations thereof.
[0041] One class of useful polymeric substrates are the elastomers. “Elastomer” as used herein is a generic term for substances emulating natural rubber in that they stretch under tension, have a high tensile strength, retract rapidly, and substantially recover their original dimensions. The term includes natural and man-made elastomers, and the elastomer may be a thermoplastic elastomer or a non-thermoplastic elastomer. The term includes blends (physical mixtures) of elastomers, as well as copolymers, terpolymers, and multi-polymers. Useful elastomers may also include one or more additives, fillers, plasticizers, and the like.
[0042] Suitable examples of useable fluoroelastomers are copolymers of vinylidene fluoride and hexafluoropropylene and terpolymers of vinylidene fluoride, hexafluoropropylene and tetrafluoroethylene. The fluoroelastomers suitable for use in the disclosed invention are elastomers that comprise one or more vinylidene fluoride units (VF 2 or VdF), one or more hexafluoropropylene units (HFP), one or more tetrafluoroethylene units (TFE), one or more chlorotrifluoroethylene (CTFE) units, and/or one or more perfluoro(alkyl vinyl ether) units (PAVE) such as perfluoro(methyl vinyl ether)(PMVE), perfluoro(ethyl vinyl ether)(PEVE), and perfluoro(propyl vinyl ether)(PPVE). These elastomers can be homopolymers or copolymers. Particularly suitable are fluoroelastomers containing vinylidene fluoride units, hexafluoropropylene units, and, optionally, tetrafluoroethylene units and fluoroelastomers containing vinylidene fluoride units, perfluoroalkyl perfluorovinyl ether units, and tetrafluoroethylene units, such as the vinylidene fluoride type fluoroelastomer known under the trade designation Aflas@, available from Asahi Glass Co., Ltd. Especially suitable are copolymers of vinylidene fluoride and hexafluoropropylene units. If the fluoropolymers contain vinylidene fluoride units, preferably the polymers contain up to 40 mole % VF 2 units, e.g., 30-40 mole %. If the fluoropolymers contain hexafluoropropylene units, preferably the polymers contain up to 70 mole % HFP units. If the fluoropolymers contain tetrafluoroethylene units, preferably the polymers contain up to 10 mole % TFE units. When the fluoropolymers contain chlorotrifluoroethylene preferably the polymers contain up to 10 mole % CTFE units. When the fluoropolymers contain perfluoro(methyl vinyl ether) units, preferably the polymers contain up to 5 mole % PMVE units. When the fluoropolymers contain perfluoro(ethyl vinyl ether) units, preferably the polymers contain up to 5 mole % PEVE units. When the fluoropolymers contain perfluoro(propyl vinyl ether) units, preferably the polymers contain up to 5 mole % PPVE units. The fluoropolymers preferably contain 66%-70% fluorine. One suitable commercially available fluoroelastomer is that known under the trade designation Technoflon FOR HS® sold by Ausimont USA. This material contains Bisphenol AF, manufactured by Halocarbon Products Corp. Another commercially available fluoroelastomer is known under the trade designation Viton® AL 200, by DuPont Dow, which is a terpolymer of VF 2 , HFP, and TFE monomers containing 67% fluorine. Another suitable commercially available fluoroelastomer is Viton® AL 300, by DuPont Dow. A blend of the terpolymers known under the trade designations Viton® AL 300 and Viton® AL 600 can also be used (e.g., one-third AL-600 and two-thirds AL-300). Other useful elastomers include products known under the trade designations 7182B and 7182D from Seals Eastern, Red Bank, N.J.; the product known under the trade designation FL80-4 available from Oil States Industries, Inc., Arlington, Tex.; and the product known under the trade designation DMS005 available from Duromould, Ltd., Londonderry, Northern Ireland.
[0043] Thermoplastic elastomers are generally the reaction product of a low equivalent molecular weight polyfunctional monomer and a high equivalent molecular weight polyfunctional monomer, wherein the low equivalent weight polyfunctional monomer is capable, on polymerization, of forming a hard segment (and, in conjunction with other hard segments, crystalline hard regions or domains) and the high equivalent weight polyfunctional monomer is capable, on polymerization, of producing soft, flexible chains connecting the hard regions or domains.
[0044] “Thermoplastic elastomers” differ from “thermoplastics” and “elastomers” in that thermoplastic elastomers, upon heating above the melting temperature of the hard regions, form a homogeneous melt which can be processed by thermoplastic techniques (unlike elastomers), such as injection molding, extrusion, blow molding, and the like. Subsequent cooling leads again to segregation of hard and soft regions resulting in a material having elastomeric properties, however, which does not occur with thermoplastics. Commercially available thermoplastic elastomers include segmented polyester thermoplastic elastomers, segmented polyurethane thermoplastic elastomers, segmented polyamide thermoplastic elastomers, blends of thermoplastic elastomers and thermoplastic polymers, and ionomeric thermoplastic elastomers.
[0045] “Segmented thermoplastic elastomer”, as used herein, refers to the sub-class of thermoplastic elastomers which are based on polymers which are the reaction product of a high equivalent weight polyfunctional monomer and a low equivalent weight polyfunctional monomer.
[0046] “Ionomeric thermoplastic elastomers” refers to a sub-class of thermoplastic elastomers based on ionic polymers (ionomers). Ionomeric thermoplastic elastomers are composed of two or more flexible polymeric chains bound together at a plurality of positions by ionic associations or clusters. The ionomers are typically prepared by copolymerization of a functionalized monomer with an olefinic unsaturated monomer, or direct functionalization of a preformed polymer. Carboxyl-functionalized ionomers are obtained by direct copolymerization of acrylic or methacrylic acid with ethylene, styrene and similar comonomers by free-radical copolymerization. The resulting copolymer is generally available as the free acid, which can be neutralized to the degree desired with metal hydroxides, metal acetates, and similar salts.
[0047] Another useful class of polymeric substrate materials are thermoplastic materials. A thermoplastic material is defined as a polymeric material (preferably, an organic polymeric material) that softens and melts when exposed to elevated temperatures and generally returns to its original condition, i.e., its original physical state, when cooled to ambient temperatures. During the manufacturing process of an oilfield element, the thermoplastic material may be heated above its softening temperature, and preferably above its melting temperature, to cause it to flow and form the desired shape of the oilfield element. After the desired shape is formed, the thermoplastic substrate is cooled and solidified. In this way, thermoplastic materials (including thermoplastic elastomers) can be molded into various shapes and sizes.
[0048] Thermoplastic materials may be preferred over other types of polymeric materials at least because the product has advantageous properties, and the manufacturing process for the preparation of oilfield elements may be more efficient. For example, an oilfield element formed from a thermoplastic material is generally less brittle and less hygroscopic than an element formed from a thermosetting material. Furthermore, as compared to a process that would use a thermosetting resin, a process that uses a thermoplastic material may require fewer processing steps, fewer organic solvents, and fewer materials, e.g., catalysts. Also, with a thermoplastic material, standard molding techniques such as injection molding can be used. This can reduce the amount of materials wasted in construction.
[0049] Moldable thermoplastic materials that may be used are those having a high melting temperature, good heat resistant properties, and good toughness properties such that the oilfield element or assemblies containing these materials operably withstand oilfield conditions without substantially deforming or disintegrating. The toughness of the thermoplastic material can be measured by impact strength, such as Gardner Impact value.
[0050] Thermoplastic polymeric substrates useful in the invention are those able to withstand expected temperatures, temperature changes, and temperature differentials (for example a temperature differential from one surface of a gasket to the other surface material to the other surface) during use, as well as expected pressures, pressure changes, and pressure differentials during use, with a safety margin on temperature and pressure appropriate for each application. Additionally, the melting temperature of the thermoplastic material should be sufficiently lower, i.e., at least about 25° C. lower, than the melting temperature of any fibrous reinforcing material, and sufficiently higher than the melting temperature of any thermoplastic coating materials to be applied by fluidized bed dip coating. In this way, reinforcing material (if used) is not adversely affected during the molding of the thermoplastic substrate, and the substrate will not melt if a thermoplastic coating is applied by dip coating. Furthermore, the thermoplastic substrate material, if used, should be sufficiently compatible with the material used in the polymeric coating such that the substrate does not deteriorate, and such that there is effective adherence of the coating to the substrate.
[0051] Examples of thermoplastic materials suitable for substrates in oilfield elements according to the present invention include polycarbonates, polyetherimides, polyesters, polysulfones, polystyrenes, acrylonitrile-butadiene-styrene block copolymers, acetal polymers, polyamides, or combinations thereof. Of this list, polyamides and polyesters may provide better performance. Polyamide materials are useful at least because they are inherently tough and heat resistant, typically provide good adhesion to coatings without priming, and are relatively inexpensive. Polyamide resin materials may be characterized by having an amide group, i.e., —C(O)NH—. Various types of polyamide resin materials, i.e., nylons, can be used, such as nylon 6/6 or nylon 6. Of these, nylon 6 may be used if a phenolic-based coating is used because of the excellent adhesion between nylon 6 and phenolic-based coatings. Nylon 6/6 is a condensation product of adipic acid and hexamethylenediamine. Nylon 6/6 has a melting point of about 264° C. and a tensile strength of about 770 kg/cm 2 . Nylon 6 is a polymer of c-caprolactam. Nylon 6 has a melting point of about 223° C. and a tensile strength of about 700 kg/cm 2 . Examples of commercially available nylon resins useable as substrates in oilfield elements according to the present invention include those known under the trade designations “Vydyne” from Solutia, St. Louis, Mo.; “Zytel” and “Minlon” both from DuPont, Wilmington, Del.; “Trogamid T” from Degussa Corporation, Parsippany, N.J.; “Capron” from BASF, Florham Park, N.J.; “Nydur”from Mobay, Inc., Pittsburgh, Pa.; and “Ultramid” from BASF Corp., Parsippany, N.J. Mineral-filled thermoplastic materials can be used, such as the mineral-filled nylon 6 resin “Minlon”, from DuPont.
[0052] Suitable thermoset (thermally cured) polymers for use as polymeric substrates in the present invention include those discussed in relation to polymeric coatings, which discussion follows, although the precursor solutions need not be coatable, and may therefore omit certain ingredients, such as diluents. Thermoset molding compositions known in the art are generally thermosetting resins containing inorganic fillers and/or fibers. Upon heating, thermoset monomers initially exhibit viscosities low enough to allow for melt processing and molding of an article from the filled monomer composition. Upon further heating, the thermosetting monomers react and cure to form hard resins with high stiffness. Thermoset polymeric substrates useful in the invention may be manufactured by any method known in the art. These methods include, but are not limited to, reaction injection molding, resin transfer molding, and other processes wherein dry fiber reinforcement plys (preforms) are loaded in a mold cavity whose surfaces define the ultimate configuration of the article to be fabricated, whereupon a flowable resin is injected, or vacuumed, under pressure into the mold cavity (mold plenum) thereby to produce the article, or to saturate/wet the fiber reinforcement preforms, where provided. After the resinated preforms are cured in the mold plenum, the finished article is removed from the mold. As one non-limiting example of a useable thermosettable polymer precursor composition, U.S. Pat. No. 6,878,782 discloses a curable composition including a functionalized poly(arylene ether); an alkenyl aromatic monomer; an acryloyl monomer; and a polymeric additive having a glass transition temperature less than or equal to 100° C., and a Young's modulus less than or equal to 1000 megapascals at 25° C. The polymeric additive is soluble in the combined functionalized poly(arylene ether), alkenyl aromatic monomer, and acryloyl monomer at a temperature less than or equal to 50° C. The composition exhibits low shrinkage on curing and improved surface smoothness. It is useful, for example, in the manufacture of sucker rods.
[0053] Polymeric Coatings
[0054] “Coating” as used herein as a noun, means a condensed phase formed by any one or more processes. The coating may be conformal (i.e., the coating conforms to the surfaces of the polymeric substrate), although this may not be necessary in all oilfield applications or all oilfield elements, or on all surfaces of the polymeric substrates. Conformal coatings based on urethane, acrylic, silicone, and epoxy chemistries are known, primarily in the electronics and computer industries (printed circuit boards, for example). Another useful conformal coating includes those formed by vaporization or sublimation of, and subsequent pyrolization and condensation of monomers or dimers and polymerized to form a continuous polymer film, such as the class of polymeric coatings based on poly (p-xylylene), commonly known as Parylene. For example, Parylene N coatings may be formed by vaporization or sublimation of a dimer within formula (I), and subsequent pyrolization and condensation of the divalent radicals within formula (II) to form a polymer within formula (III), although the vaporization is not strictly necessary. In formulas (I), (II), and (III), x and y are both equal to 0 to for a Parylene N coating. Other Parylene coatings may be formed in similar fashion.
[0055] Another class of useful polymeric coatings are thermally curable coatings derived from coatable, thermally curable coating precursor solutions, such a those described in U.S. Pat. No. 5,178,646, incorporated by reference herein. Coatable, thermally curable coating precursor solutions may comprise a 30-95% solids solution, or 60-80% solids solution of a thermally curable resin having a plurality of pendant methylol groups, the balance of the solution comprising water and a reactive diluent. The term “coatable”, as used herein, means that the solutions of the invention may be coated or sprayed onto polymeric substrates using coating devices which are conventional in the spray coating art, such as knife coaters, roll coaters, flow-bar coaters, electrospray coaters, ultrasonic coaters, gas-atomizing spray coaters, and the like. This characteristic may also be expressed in terms of viscosity of the solutions. The viscosity of the coatable, thermally curable coating precursor solutions generally should not exceed about 2000 centipoise, measured using a Brookfield viscometer,.number 2 spindle, 60 rpm, at 25° C. The term “percent solids” means the weight percent organic material that would remain upon application of curing conditions. Percent solids below about 30% are not practical to use because of VOC emissions, while above about 95% solids the resin solutions are difficult to render coatable, even when heated.
[0056] The term “diluent” is used in the sense that the reactive diluent dilutes the concentration of thermally curable resin in the solution, and does not mean that the solutions necessarily decrease in viscosity. The thermally curable resin may be the reaction product of a non-aldehyde and an aldehyde, the non-aldehyde selected from ureas and phenolics. The reactive diluent has at least one functional group which is independently reactive with the pendant methylol groups and with the aldehyde, and may be selected from
A) compounds selected from the group consisting of compounds represented by the general formula R 7 R 8 N(C═X)Y and mixtures thereof wherein X═O or S and Y═—NR 9 R 10 or —OR 11 , such that when X═S, Y═NR 9 R 10 , each of R 7 , R 8 , R 9 , R 10 and R 11 is a monovalent radical selected from hydrogen, alkyl groups having 1 to about 10 carbon atoms, hydroxyalkyl groups having from about 2 to 4 carbon atoms and one or more hydroxyl groups, and hydroxypolyalkyleneoxy groups having one or more hydroxyl groups, and which may include the provisos that:
(i) the compound contains at least one —NH and one —OH group or at least two —OH groups or at least two —NH groups; (ii) R 7 and R 8 or R 7 and R 9 can be linked to form a ring structure; and (iii) R 7 , R 8 , R 9 , R 10 and R 11 are never all hydrogen at the same time;
B) compounds having molecular weight less than about 300 and selected from the group consisting of alkylsubstituted 2-aminoalcohols, β-ketoalkylamides, and nitro alkanes; C) poly(oxyalkylene) amines having molecular weight ranging from about 90 to about 1000; and D) poly(oxyalkylene) ureido compounds having molecular weight ranging from about 90 to about 1000.
[0064] Reactive diluents useful in the compositions include those wherein X is O, Y═NR 9 R 10 , R 7 is 2-hydroxyethyl, R 8 and R 9 are linked to form an ethylene bridge, and R 10 is hydrogen.
[0065] One alkylsubstituted 2-aminoalcohol useful as a reactive diluent is 2-amino-2-methyl-1-propanol, while the β-ketoalkylamide may be β-ketobutyramide. Additionally, nitroalkanes with at least 1 active hydrogen atom attached to the alpha carbon atom will scavenge formaldehyde in coatable thermally curable polymer precursor solutions useful in the invention. Representative poly(oxyalkylene) amines include poly(oxyethylene-co-oxypropylene) amine, poly(oxypropylene) amine, and poly(oxypropylene) diamine, whereas representative poly(oxyalkylene) ureido compounds are the reaction product of urea and the poly(oxyalkylene) amines previously enumerated. Optionally, useful coatable, thermally curable polymeric coating precursor solutions may include up to about 50 weight percent (of the total weight of thermally curable resin) of ethylenically unsaturated monomers. These monomers, such as tri- and tetra-ethylene glycol diacrylate, are radiation curable and can reduce the overall cure time of the thermally curable resins by providing a mechanism for pre-cure gelation of the thermally curable resin.
[0066] Two other classes of useful coatings are condensation curable and addition polymerizable resins, wherein the addition polymerizable resins are derived from a polymer precursor which polymerizes upon exposure to a non-thermal energy source which aids in the initiation of the polymerization or curing process. Examples of non-thermal energy sources include electron beam, ultraviolet light, visible light, and other non-thermal radiation. During this polymerization process, the resin is polymerized and the polymer precursor is converted into a solidified polymeric coating. Upon solidification of the polymer precursor, the coating is formed. The polymer in the coating is also generally responsible for adhering the coating to the polymeric substrate, however the invention is not so limited. Addition polymerizable resins are readily cured by exposure to radiation energy. Addition polymerizable resins can polymerize through a cationic mechanism or a free radical mechanism. Depending upon the energy source that is utilized and the polymer precursor chemistry, a curing agent, initiator, or catalyst may be used to help initiate the polymerization.
[0067] Examples of useful organic resins to form these classes of polymeric coating include the before-mentioned methylol-containing resins such as phenolic resins, urea-formaldehyde resins, and melamine formaldehyde resins; acrylated urethanes; acrylated epoxies; ethylenically unsaturated compounds; aminoplast derivatives having pendant unsaturated carbonyl groups; isocyanurate derivatives having at least one pendant acrylate group; isocyanate derivatives having at least one pendant acrylate group; vinyl ethers; epoxy resins; and mixtures and combinations thereof. The term “acrylate” encompasses acrylates and methacrylates.
[0068] Phenolic resins are widely used in industry because of their thermal properties, availability, and cost. There are two types of phenolic resins, resole and novolac. Resole phenolic resins have a molar ratio of formaldehyde to phenol of greater than or equal to one to one, typically between 1.5:1.0 to 3.0:1.0. Novolac resins have a molar ratio of formaldehyde to phenol of less than one to one. Examples of commercially available phenolic resins include those known by the tradenames. “Durez” and “Varcum” from Durez Corporation, a subsidiary of Sumitomo Bakelite Co., Ltd.; “Resinox” from Monsanto; “Aerofene” from Ashland Chemical Co. and “Aerotap” from Ashland Chemical Co.
[0069] Acrylated urethanes are diacrylate esters of hydroxy-terminated, isocyanate (NCO) extended polyesters or polyethers. Examples of commercially available acrylated urethanes include those known under the trade designations “UVITHANE 782”, available from Morton Thiokol Chemical, and “CMD 6600”, “CMD 8400”, and “CMD 8805”, available from Radcure Specialties.
[0070] Acrylated epoxies are diacrylate esters of epoxy resins, such as the diacrylate esters of Bisphenol A epoxy resin. Examples of commercially available acrylated epoxies include those known under the trade designations “CMD 3500”, “CMD 3600”, and “CMD 3700”, available from Radcure Specialties.
[0071] Ethylenically unsaturated resins include both monomeric and polymeric compounds that contain atoms of carbon, hydrogen, and oxygen, and optionally, nitrogen and the halogens. Oxygen or nitrogen atoms or both are generally present in ether, ester, urethane, amide, and urea groups. Ethylenically unsaturated compounds may have a molecular weight of less than about 4,000 and may be esters made from the reaction of compounds containing aliphatic monohydroxy groups or aliphatic polyhydroxy groups and unsaturated carboxylic acids, such as acrylic acid, methacrylic acid, itaconic acid, crotonic acid, isocrotonic acid, maleic acid, and the like. Representative examples of acrylate resins include methyl methacrylate, ethyl methacrylate styrene, divinylbenzene, vinyl toluene, ethylene glycol diacrylate, ethylene glycol methacrylate, hexanediol diacrylate, triethylene glycol diacrylate, trimethylolpropane triacrylate, glycerol triacrylate, pentaerythritol triacrylate, pentaerythritol methacrylate, pentaerythritol tetraacrylate and pentaerythritol tetraacrylate. Other ethylenically unsaturated resins include monoallyl, polyallyl, and polymethallyl esters and amides of carboxylic acids, such as diallyl phthalate, diallyl adipate, and N,N-diallyladipamide. Still other nitrogen containing compounds include tris(2-acryloyloxyethyl)isocyanurate, 1,3,5-tri(2-methyacryloxyethyl)-triazine, acrylamide, methylacrylamide, N-methylacrylamide, N,N-dimethylacrylamide, N-vinylpyrrolidone, and N-vinylpiperidone.
[0072] The aminoplast resins have at least one pendant a,p-unsaturated carbonyl group per molecule or oligomer. These unsaturated carbonyl groups can be acrylate, methacrylate, or acrylamide type groups. Examples of such materials include N-(hydroxymethyl) acrylamide, N,N′-oxydimethylenebisacrylamide, ortho- and para-acrylamidomethylated phenol, acrylamidomethylated phenolic novolac, and combinations thereof. These materials are further described in U.S. Pat. Nos. 4,903,440 and 5,236,472 both incorporated herein by reference.
[0073] Isocyanurate derivatives having at least one pendant acrylate group and isocyanate derivatives having at least one pendant acrylate group are further described in U.S. Pat. No. 4,652,274 incorporated herein after by reference. The isocyanurate material may be a triacrylate of tris(hydroxy ethyl) isocyanurate.
[0074] Epoxy resins have an oxirane and are polymerized by the ring opening. Such epoxide resins include monomeric epoxy resins and oligomeric epoxy resins. Examples of some useful epoxy resins include 2,2-bis[4-(2,3-epoxypropoxy)-phenyl propane] (diglycidyl ether of Bisphenol) and commercially available materials under the trade designations “Epon 828”, “Epon 1004”, and “Epon 1001F” available from Shell Chemical Co., Houston, Tex., “DER-331”, “DER-332”, and “DER-334” available from Dow Chemical Co., Freeport, Tex. Other suitable epoxy resins include glycidyl ethers of phenol formaldehyde novolac (e.g., “DEN-431” and “DEN-428” available from Dow Chemical Co.).
[0075] Epoxy resins useful in the invention can polymerize via a cationic mechanism with the addition of an appropriate cationic curing agent. Cationic curing agents generate an acid source to initiate the polymerization of an epoxy resin. These cationic curing agents can include a salt having an onium cation and a halogen containing a complex anion of a metal or metalloid. Other cationic curing agents include a salt having an organometallic complex cation and a halogen containing complex anion of a metal or metalloid which are further described in U.S. Pat. No. 4,751,138 incorporated here in after by reference (column 6, line 65 to column 9, line 45). Another example is an organometallic salt and an onium salt is described in U.S. Pat. No. 4,985,340 (column 4, line 65 to column 14, line 50); and European Patent Application Nos. 306,161 and 306,162, both published Mar. 8, 1989, all incorporated by reference. Still other cationic curing agents include an ionic salt of an organometallic complex in which the metal is selected from the elements of Periodic Group IVB, VB, VIB, VIIB and VIIIB which is described in European Patent Application No. 109,581, published Nov. 21, 1983, incorporated by reference.
[0076] Regarding free radical curable resins, in some embodiments the polymeric precursor solution may further comprise a free radical curing agent. However in the case of an electron beam energy source, the curing agent is not always required because the electron beam itself generates free radicals. Examples of free radical thermal initiators include peroxides, e.g., benzoyl peroxide, azo compounds, benzophenones, and quinones. For either ultraviolet or visible light energy source, this curing agent is sometimes referred to as a photoinitiator. Examples of initiators, that when exposed to ultraviolet light generate a free radical source, include but are not limited to those selected from organic peroxides, azo compounds, quinones, benzophenones, nitroso compounds, acryl halides, hydrozones, mercapto compounds, pyrylium compounds, triacrylimdazoles, bisimidazoles, chloroalkytriazines, benzoin ethers, benzil ketals, thioxanthones, and acetophenone derivatives, and mixtures thereof. Examples of initiators that when exposed to visible radiation generate a free radical source can be found in U.S. Pat. No. 4,735,632, incorporated herein by reference. The initiator for use with visible light may be that known under the trade designation “Irgacure 369” commercially available from Ciba Specialty Chemicals, Tarrytown, N.Y.
[0077] Adhesion Promoters, Coupling Agents and Other Optional Ingredients
[0078] For embodiments wherein a better bond between the polymeric coating and the polymeric substrate is desired, mechanical and/or chemical adhesion promotion (priming) techniques may used. For example, if the polymeric substrate is a thermoplastic polycarbonate, polyetherimide, polyester, polysulfone, or polystyrene material, use of a primer may be preferred to enhance the adhesion between the substrate and the coating. The term “primer” as used in this context is meant to include both mechanical and chemical type primers or priming processes. Examples of mechanical priming processes include, but are not limited to, corona treatment and scuffing, both of which increase the surface area of the backing. An example of a preferred chemical primer is a colloidal dispersion of, for example, polyurethane, acetone, isopropanol, water, and a colloidal oxide of silicon, as taught by U.S. Pat. No. 4,906,523, which is incorporated herein by reference.
[0079] Besides the polymeric material, the substrate of the invention may include an effective amount of a fibrous reinforcing material. Herein, an “effective amount” of a fibrous reinforcing material is a sufficient amount to impart at least improvement in the physical characteristics of the substrate, i.e., heat resistance, toughness, flexibility, stiffness, shape control, adhesion, etc., but not so much fibrous reinforcing material as to give rise to any significant number of voids and detrimentally affect the structural integrity of the substrate. The amount of the fibrous reinforcing material in the substrate may be within a range of about 1-40%, or within a range of about 5-35%, or within a range of about 15-30%, based upon the weight of the backing.
[0080] The fibrous reinforcing material may be in the form of individual fibers or fibrous strands, or in the form of a fiber mat or web. The mat or web can be either in a woven or nonwoven matrix form. Examples of useful reinforcing fibers in applications of the present invention include metallic fibers or nonmetallic fibers. The nonmetallic fibers include glass fibers, carbon fibers, mineral fibers, synthetic or natural fibers formed of heat resistant organic materials, or fibers made from ceramic materials.
[0081] By “heat resistant” organic fibers, it is meant that useable organic fibers must be resistant to melting, or otherwise breaking down, under the conditions of manufacture and use of the coated substrates of the present invention. Examples of useful natural organic fibers include wool, silk, cotton, or cellulose. Examples of useful synthetic organic fibers include polyvinyl alcohol fibers, polyester fibers, rayon fibers, polyamide fibers, acrylic fibers, aramid fibers, or phenolic fibers. Generally, any ceramic fiber is useful in applications of the present invention. An example of a ceramic fiber suitable for the present invention is “Nextel” which is commercially available from 3M Co., St. Paul, Minn. Glass fibers may be used, at least because they impart desirable characteristics to the coated abrasive articles and are relatively inexpensive. Furthermore, suitable interfacial binding agents exist to enhance adhesion of glass fibers to thermoplastic materials. Glass fibers are typically classified using a letter grade. For example, E glass (for electrical) and S glass (for strength). Letter codes also designate diameter ranges, for example, size “D” represents a filament of diameter of about 6 micrometers and size “G” represents a filament of diameter of about 10 micrometers. Useful grades of glass fibers include both E glass and S glass of filament designations D through U. Preferred grades of glass fibers include E glass of filament designation “G” and S glass of filament designation “G.” Commercially available glass fibers are available from Specialty Glass Inc., Oldsmar, Fla.; Owens-Corning Fiberglass Corp., Toledo, Ohio; and Mo-Sci Corporation, Rolla, Mo. If glass fibers are used, the glass fibers may be accompanied by an interfacial binding agent, i.e., a coupling agent, such as a silane coupling agent, to improve the adhesion to the thermoplastic material. Examples of silane coupling agents include “Z-6020” and “Z-6040,” available from Dow Coming Corp., Midland, Mich.
[0082] The substrates of the present invention may further include an effective amount of a toughening agent. This will be preferred for certain applications. A primary purpose of the toughening agent is to increase the impact strength of the substrate. By “an effective amount of a toughening agent” it is meant that the toughening agent is present in an amount to impart at least improvement in the substrate toughness without it becoming too flexible. The substrates of the present invention preferably include sufficient toughening agent to achieve the desirable impact test values listed above. A substrate of the present invention may contain between about 1% and about 30% of the toughening agent, based upon the total weight of the substrate. For example, the less elastomeric characteristics a toughening agent possesses, the larger quantity of the toughening agent may be required to impart desirable properties to the substrates of the present invention. Toughening agents that impart desirable stiffness characteristics to the backing of the present invention include rubber-type polymers and plasticizers. Of these, the rubber toughening agents may be mentioned, and synthetic elastomers. Examples of preferred toughening agents, i.e., rubber tougheners and plasticizers, include: toluenesulfonamide derivatives (such as a mixture of N-butyl- and N-ethyl-p-toluenesulfonamide, commercially available from Akzo Chemicals, Chicago, Ill., under the trade designation “Ketjenflex 8”); styrene butadiene copolymers; polyether backbone polyamides (commercially available from Atochem, Glen Rock, N.J., under the trade designation “Pebax”); rubber-polyamide copolymers (commercially available from DuPont, Wilmington, Del., under the trade designation “Zytel FN”); and functionalized triblock polymers of styrene-(ethylene butylene)-styrene (commercially available from Shell Chemical Co., Houston, Tex., under the trade designation “Kraton FG1901”); and mixtures of these materials. Of this group, rubber-polyamide copolymers and styrene-(ethylene butylene)-styrene triblock polymers may be used, at least because of the beneficial characteristics they impart to substrates. Rubber-polyamide copolymers may also be used, at least because of the beneficial impact characteristics they impart to the substrates of the present invention. If the backing is made by injection molding, typically the toughener is added as a dry blend of toughener pellets with the other components. The process usually involves tumble-blending pellets of toughener with pellets of fiber-containing thermoplastic material. A more preferred method involves compounding the thermoplastic material, reinforcing fibers, and toughener together in a suitable extruder, pelletizing this blend, then feeding these prepared pellets into the injection molding machine. Commercial compositions of toughener and thermoplastic material are available, for example, under the designation “Ultramid” from BASF Corp., Parsippany, N.J. Specifically, “Ultramid B3ZG6” is a nylon resin containing a toughening agent and glass fibers that is useful in the present invention.
[0083] Optional Substrate Additives
[0084] Besides the materials described above, polymeric substrates useful in the invention may include effective amounts of other materials or components depending upon the end properties desired. For example, the substrate may include a shape stabilizer, i.e., a thermoplastic polymer with a melting point higher than that described above for the thermoplastic material. Suitable shape stabilizers include, but are not limited to, poly(phenylene sulfide), polyimides, and polyaramids. An example of a preferred shape stabilizer is polyphenylene oxide nylon blend commercially available from GE Plastics, Pittsfield, Mass., under the trade designation “Noryl GTX 910.” If a phenolic-based coating is employed, however, the polyphenylene oxide nylon blend may not be preferred because of possible nonuniform interaction between the phenolic resin coating and the nylon, resulting in reversal of the shape-stabilizing effect. This nonuniform interaction results from a difficulty in obtaining uniform blends of the polyphenylene oxide and the nylon.
[0085] Other such materials that may be added to the substrate for certain applications of the present invention include inorganic or organic fillers. Inorganic fillers are also known as mineral fillers. A filler is defined as a particulate material, typically having a particle size less than about 100 micrometers, preferably less than about 50 micrometers. Examples of useful fillers for applications of the present invention include carbon black, calcium carbonate, silica, calcium metasilicate, cryolite, phenolic fillers, or polyvinyl alcohol fillers. If a filler is used, it is theorized that the filler fills in between the reinforcing fibers and may prevent crack propagation through the substrate. Typically, a filler would not be used in an amount greater than about 20%, based on the weight of the substrate. Preferably, at least an effective amount of filler is used. Herein, the term “effective amount” in this context refers to an amount sufficient to fill but not significantly reduce the tensile strength of the hardened substrate.
[0086] Other useful materials or components that can be added to the substrate for certain applications of the present invention include, but are not limited to, oils, antistatic agents, flame retardants, heat stabilizers, ultraviolet stabilizers, internal lubricants, antioxidants, and processing aids. One would not typically use more of these components than needed for desired results.
[0087] The apparatus, in particular the polymeric substrates, if filled with fillers, may also contain coupling agents. When an organic polymeric matrix has an inorganic filler, a coupling agent may be desired. Coupling agents may operate through two different reactive functionalities: an organofunctional moiety and an inorganic functional moiety. When a resin/filler mixture is modified with a coupling agent, the organofunctional group of the coupling agent becomes bonded to or otherwise attracted to or associated with the uncured resin. The inorganic functional moiety appears to generate a similar association with the dispersed inorganic filler. Thus, the coupling agent acts as a bridge between the organic resin and the inorganic filler at the resin/filler interface. In various systems this results in:
1. Reduced viscosity of the resin/filler dispersion. Such a dispersion, during a process of preparing a coated substrate, generally facilitates application. 2. Enhanced suspendability of the filler in the resin, i.e., decreasing the likelihood that suspended or dispersed filler will settle out from the resin/filler suspension during storing or processing to manufacture oilfield elements. 3. Improved product performance due to enhanced operation lifetime, for example through increased water resistance or general overall observed increase in strength and integrity of the bonding system.
[0091] Herein, the term “coupling agent” includes mixtures of coupling agents. An example of a coupling agent that may be found suitable for this invention is gamma-methacryloxypropyltrimethoxy silane known under the trade designation “Silquest A-174” from GE Silicones, Wilton, Conn. Other suitable coupling agents are zircoaluminates, and titanates.
[0092] Oilfield Elements, Assemblies, and Wellbores
[0093] An “oilfield assembly”, as used herein, is the complete set or suite of oilfield elements that may be used in a particular job. All oilfield elements in an oilfield assembly may or may not be interconnected, and some may be interchangeable.
[0094] An “oilfield element” includes, but is not limited to one or more items or assemblies selected from tubing, blow out preventers, sucker rods, O-rings, T-rings, jointed pipe, electric submersible pumps, packers, centralizers, hangers, plugs, plug catchers, check valves, universal valves, spotting valves, differential valves, circulation valves, equalizing valves, safety valves, fluid flow control valves, connectors, disconnect tools, downhole filters, motorheads, retrieval and fishing tools, bottom hole assemblies, seal assemblies, snap latch assemblies, anchor latch assemblies, shear-type anchor latch assemblies, no-go locators, and the like.
[0095] A “packer” is a device that can be run into a wellbore with a smaller initial outside diameter that then expands externally to seal the wellbore. Packers employ flexible, elastomeric seal elements that expand. The two most common forms are the production or test packer and the inflatable packer. The expansion of the former may be accomplished by squeezing the elastomeric elements (somewhat doughnut shaped) between two plates or between two conical frusta pointed inward, forcing the elastomeric elements' sides to bulge outward. The expansion of the latter may be accomplished by pumping a fluid into a bladder, in much the same fashion as a balloon, but having more robust construction. Production or test packers may be set in cased holes and inflatable packers may be used in open or cased holes. They may be run down into the well on wireline, pipe or coiled tubing. Some packers are designed to be removable, while others are permanent. Permanent packers are constructed of materials that are easy to drill or mill out. A packer may be used during completion to isolate the annulus from the production conduit, enabling controlled production, injection or treatment. A typical packer assembly incorporates a means of securing the packer against the casing or liner wall, such as a slip arrangement, and a means of creating a reliable hydraulic seal to isolate the annulus, typically by means of an expandable elastomeric element. Packers are classified by application, setting method and possible retrievability. Inflatable packers are capable of relatively large expansion ratios, an important factor in through-tubing work where the tubing size or completion components can impose a significant size restriction on devices designed to set in the casing or liner below the tubing. Seal elements may either be bonded-type, using nitrile rubber seal elements, or chevron-type, available with seal elements comprising one or more proprietary elastomers such as those known under the trade designations Viton®, as mentioned above, available from DuPont Dow Elastomers LLC, and Aflas®, as mentioned above, available from Asahi Glass Co., Ltd. Bonded-type and chevron-type seal elements may both comprise one or more thermoplastic polymers, such as the polytetrafluoroethylene known under the trade designation Teflon@, available from E.I. DuPont de Nemours & Company; the polyphenylene sulfide thermoplastics known under the trade designation Ryton® and polyphenylene sulfide-based alloys known under the trade designation Xtel®, both available from Chevron Phillips Chemical Company LP. Both bond-type and chevron-type seal elements are available from Schlumberger.
[0096] A “wellbore” may be any type of well, including, but not limited to, a producing well, a non-producing well, an injection well, a fluid disposal well, an experimental well, an exploratory well, and the like. Wellbores may be vertical, horizontal, deviated some angle between vertical and horizontal, and combinations thereof, for example a vertical well with a non-vertical component.
[0097] FIGS. 1-5 and 13 illustrate several oilfield assemblies having one or more oilfield elements that may benefit from use of coated polymeric substrates. When an oilfield element is referred to by numeral, if that oilfield element may comprise a coated polymeric susbstrate it will be indicated with an asterisk (*). It will be understood that not all of the described oilfield elements that may comprise coated polymeric substrates need be the same in composition (coating or substrate); indeed, not all of the possible coated polymeric substrate oilfield elements need actually be comprised of coated polymeric substrates. In some embodiments, perhaps only the protector bag may be comprised of a coated polymeric substrate. Further, when an oilfield element is mentioned as being comprised of a coated polymeric substrate, the polymeric substrate may itself be a component of a larger structure, for example coated onto or placed adjacent another material, for example a metallic component.
[0098] FIG. 1 illustrates a first oilfield assembly 10 designed for deployment in a well 18 within a geological formation 20 containing desirable production fluids, such as petroleum. In a typical application, a wellbore 22 is drilled and lined with a wellbore casing 24 . Wellbore casing 24 typically has a plurality of openings 26 , for example perforations, through which production fluids may flow into wellbore 22 .
[0099] Oilfield assembly 10 is deployed in wellbore 22 by a deployment system 28 that may have a variety of forms and configurations. For example, deployment system 28 may comprise tubing 30 connected to pump 12 * by a connector 32 *. Power is provided to a submersible motor 14 * via a power cable 34 *. Motor 14 *, in turn, powers centrifugal pump 12 *, which draws production fluid in through a pump intake 36 * and pumps the production fluid to the surface via tubing 30 .
[0100] It should be noted that the illustrated oilfield assembly 10 is merely an exemplary embodiment. Other oilfield elements may be added to the oilfield assembly, and other deployment systems may be implemented. Additionally, the production fluids may be pumped to the surface through tubing 30 or through the annulus formed between deployment system 28 and wellbore casing 24 . In any of these configurations of oilfield assembly 10 , it may be desirable to be able to use two or more centrifugal pump stages having different operating characteristics. Tubing 30 may be replaced by jointed pipe, which may include flanges and in that case flange gaskets*.
[0101] In certain embodiments, oilfield assembly 10 may have one or more sections of motor protector 16 * disposed about motor 14 *. A schematic cross-sectional view of an exemplary embodiment of oilfield assembly 10 is provided in FIG. 2 . As illustrated, oilfield assembly 10 comprises pump 12 *, motor 14 *, and various motor protection components disposed in a housing 38 . Pump 12 * is rotatably coupled to motor 14 * via a shaft 40 , which extends lengthwise through the housing 38 (for example, one or more housing sections coupled together). Oilfield assembly 10 and shaft 40 may have multiple sections, which can be intercoupled via couplings and flanges. For example, shaft 40 has couplings 42 * and 44 * and an intermediate shaft section 46 disposed between pump 12 * and motor 14 *.
[0102] A variety of seals, filters, absorbent assemblies and other protection elements also may be disposed in housing 38 to protect motor 14 *. A thrust bearing 48 * is disposed about shaft 40 to accommodate and support the thrust load from pump 12 *. A plurality of shaft seals, such as shaft seals 50 * and 52 *, are also disposed about shaft 40 between pump 12 * and motor 14 * to isolate a motor fluid 54 in motor 14 * from external fluids, such as well fluids and particulates. Shaft seals 50 * and 52 * also may include stationary and rotational components, which may be disposed about shaft 40 in a variety of configurations. Oilfield assembly 10 also may include a plurality of moisture absorbent assemblies, such as moisture absorbent assemblies 56 , 58 , and 60 , disposed throughout housing 38 between pump 12 * and motor 14 *. These moisture absorbent assemblies 56 - 60 absorb and isolate undesirable fluids (for example, water, H 2 S, and the like) that have entered or may enter housing 38 through shaft seals 50 * and 52 * or through other locations. For example, moisture absorbent assemblies 56 and 58 may be disposed about shaft 40 at a location between pump 12 * and motor 14 *, while moisture absorbent assembly 60 may be disposed on an opposite side of motor 14 * adjacent a protector bag 64 *. In addition, the actual protector section above the motor may include a hard bearing head with shedder.
[0103] As illustrated in FIG. 2 , motor fluid 54 is in fluid communication with an interior 66 * of protector bag 64 *, while well fluid 68 is in fluid communication with an exterior 70 * of protector bag 64 *. Accordingly, protector bag 64 * seals motor fluid 54 from well fluid 68 , while positively pressurizing motor fluid 54 relative to the well fluid 68 (e.g., a 50 psi pressure differential). The ability of elastomeric protector bag 64 * to stretch and retract ensures that motor fluid 54 maintains a higher pressure than that of well fluid 68 . A separate spring assembly or biasing structure also may be incorporated in protector bag 64 * to add to the resistance, which ensures that motor fluid 54 maintains a higher pressure than that of well fluid 68 .
[0104] Protector bag 64 * may embody a variety of structural features, geometries and materials as known in the art to utilize the pressure of well fluid 68 in combination with the stretch and retraction properties of protector bag 64 * to positively pressurize motor fluid 54 . Initially, motor fluid 54 is injected into motor 14 * and protector bag 64 * is pressurized until a desired positive pressure is obtained within motor 14 *. For example, oilfield assembly 10 may set an initial pressure, such as 25-100 psi, prior to submerging into the well. An exterior chamber 70 adjacent protector bag 64 * also may be filled with fluid prior to submerging the system into the well. Well fluid 68 enters housing 38 through ports 72 and mixes with this fluid in exterior chamber 70 as oilfield assembly 10 is submersed into the well. Protector bag 64 * also may have various protection elements to extend its life and to ensure continuous protection of motor 14 *. For example, a filter 74 may be disposed between ports 72 and exterior chamber 70 of protector bag 64 * to filter out undesirable fluid elements and particulates in well fluid 68 prior to fluid communication with exterior chamber 70 . A filter 76 also may be provided adjacent interior 66 * of protector bag 64 * to filter out motor shavings and particulates. As illustrated, filter 76 is positioned adjacent moisture absorbent assembly 60 between motor cavity 62 and interior 66 * of protector bag 64 *. Accordingly, filter 76 prevents solids from entering or otherwise interfering with protector bag 64 *, thereby ensuring that protector bag 64 * is able to expand and contract along with volume variations in the fluids.
[0105] A plurality of expansion and contraction stops also may be disposed about protector bag 64 * to prevent over and under extension and to prolong the life of protector bag 64 *. For example, a contraction stop 78 * may be disposed within interior 66 * of protector bag 64 * to contact an end section 80 * and limit contraction of protector bag 64 *. An expansion stop 82 * also may be provided at exterior 70 * of protector bag 64 * to contact end section 80 * and limit expansion of the protector bag. These contraction and expansion stops 78 * and 82 * may have various configurations depending on the elastomer utilized for protector bag 64 * and also depending on the pressures of motor fluid 54 and well fluid 68 . A housing 84 * also may be disposed about exterior 70 * to guide protector bag 64 * during contraction and expansion and to provide overall protection about exterior 70 *.
[0106] As oilfield assembly 10 is submersed and activated in the downhole environment, the internal pressure of motor fluid 54 may rise and/or fall due to temperature changes, such as those provided by the activation and deactivation of motor 14 *. A valve 86 * may be provided to release motor fluid 54 when the pressurization exceeds a maximum pressure threshold. In addition, another valve may be provided to input additional motor fluid when the pressurization falls below a minimum pressure threshold. Accordingly, the valves maintain the desired pressurization and undesirable fluid elements are repelled from motor cavity 62 at the shaft seals 50 * and 52 *. Oilfiled assembly 10 also may have a wiring assembly 87 * extending through housing 38 to a component adjacent protector bag 64 *. For example, a variety of monitoring components may be disposed below protector bag 64 * to improve the overall operation of oilfield assembly 10 . Exemplary monitoring components comprise temperature gauges, pressure gauges, and various other instruments, as should be appreciated by those skilled in the art.
[0107] FIG. 3 is a schematic perspective view, partially in cross-section, and not necessarily to scale, of another oilfield assembly 100 in accordance with the invention, in this case a packer. Although oilfield assembly 100 comprises in many instances more than one oilfield element, such as production tubing 104 and packer elements 108 , oilfield assembly 100 is often referred to as a packer, and therefore this oilfield assembly may be considered an oilfield element which is part of a larger oilfield assembly, such as oilfield assembly 10 of FIGS. 1 and 2 . A production liner or casing 102 is shown, partially broken away to reveal production tubing 104 , hold-down slips 106 , set-down slips 110 , and a plurality of packer elements 108 * which, when expanded, produce a hydraulic seal between a lower annulus 109 and an upper annulus 111 .
[0108] FIGS. 4A and 4B illustrate how two actuation arrangements may be used to directly override two flapper-style check valves, allowing uphole flow in a flow reversing oilfield assembly. The flow reversing oilfield assembly 150 illustrated schematically in FIG. 4A may include a motor 152 *, motor shaft 153 , and movable valve gate 156 positioned in a secondary channel 154 , which moves dual flapper actuators 157 and 159 , each having a notch 158 and 160 , respectively. Movement up of shaft 153 , gate 156 , actuators 157 and 159 , and notches 158 and 160 mechanically opens flappers 162 and 164 , allowing reverse flow up tubing primary flow channel 151 . O-ring seals 166 * and 168 * isolate production fluid from motor fluid 172 . The flow reversing oilfield assembly 180 illustrated in FIG. 4B uses dual solenoids 184 and 182 to charge a hydraulic system and release the pressure. When the hydraulic system is charged, the hydraulic pressure in conduits 185 , 185 a, and 185 b shift pistons 191 and 192 , mechanically opening flappers 162 and 164 , while high pressure below flapper 165 opens it, allowing reverse flow up tubing primary channel 151 . When it is desired to stop reverse flow, or power or communication is lost, solenoid 184 is activated, releasing hydraulic pressure in conduits 185 , 185 a, and 185 b, allowing flappers 162 and 164 to close in safe position. Note that an oil compensation system 194 may be used to protect and lubricate the motor, gears, and other mechanical parts, such as ball 193 * and spring 195 * of a check valve. Alternatively, these parts may be comprised of coated polymeric substrates in accordance with the invention. Various O-ring seals, such as seals 196 * and 197 * may be comprised of coated polymeric substrate, such as coated elastomers.
[0109] FIGS. 5A and 5B illustrate two oilfield assemblies 200 and 250 known as bottom hole assemblies, or BHAs. Bottom hole assemblies have many wellbore elements that may benefit from use of coated polymeric substrates in accordance with the teachings of the invention. The lower portion of the drillstring, consisting of (from the bottom up in a vertical well) the bit, bit sub, a mud motor (in certain cases), stabilizers, drill collars, heavy-weight drillpipe, jarring devices (“jars”) and crossovers for various threadforms. The bottomhole assembly must provide force for the bit to break the rock (weight on bit), survive a hostile mechanical environment and provide the driller with directional control of the well. Oftentimes the assembly includes a mud motor, directional drilling and measuring equipment, measurements-while-drilling (MWD) tools, logging-while-drilling (LWD) tools and other specialized devices. A simple BHA may comprise a bit, various crossovers, and drill collars, however they may include many other wellbore elements leading to a relatively complex wellbore assembly.
[0110] Each oilfield assembly 200 and 250 may comprise tubing 202 , a connector 204 *, a check valve assembly 206 *, and a pressure disconnect 208 *. Oilfield assembly 200 is a straight hole BHA, and includes drill collars 210 , a mud pump 216 *, and a drill bit 220 . Oilfield assembly 250 is a BHA for buildup and horizontal bore holes, and includes an orienting tool 212 *, an MWD section in a non-magnetic drill collar 214 , mud pump 216 *, and drill bit 220 , as well as an adjustable bent housing 218 *.
[0111] FIGS. 13A and 13B are schematic cross-sectional views of a flow control valve that may be utilized to control the flow of petroleum production or well fluids out of specific zones in a well or reservoir, or injection of fluid into specific zones, the valve utilizing polymer-coated elastomeric components in accordance with the invention. These flow control valves may be operated by forces produced and controlled hydraulically, electrically or by a hybrid combination of appropriate electric and hydraulic components.
[0112] FIGS. 13A and 13B illustrate one embodiment of a hydraulically actuated valve. An inner tubular member 300 is contained within an actuator housing 301 . A sliding sleeve 302 is equipped with sliding seals 303 *, 304 * and 305 *, thereby defining a confined volume chamber 306 and a controlled volume chamber 307 . If confined volume chamber 306 is pre-charged with a relatively inert gas such as nitrogen at sufficiently high pressure compared to the pressure in controlled volume chamber 307 , then sliding sleeve 302 will be forced to the right, thereby closing fluid flow through an opening 309 in inner tubing 300 and an opening 311 in sliding sleeve 302 . A seal 310 prevents the flow of fluid between tubular member 300 and sliding sleeve 302 . If hydraulic oil is introduced into a tube 308 at a sufficiently high pressure then the force produced within controlled volume chamber 307 will be sufficient to overcome the force due to the pressurized gas in confined volume chamber 306 thereby resulting in sliding sleeve 302 moving to the left as illustrated in FIG. 13B . In FIG. 13B the movement of sliding sleeve 302 is sufficient to position opening 309 of inner tubular member 300 directly in-line with opening 311 in sliding sleeve 302 . In this controlled configuration production fluid 312 can enter into the tubular member and thereby be unimpeded to flow into the tubing and up to the surface, assuming there is a fluid flow path and that the pressure is sufficient to lift the fluid to surface.
[0113] Sliding seals 303 , 304 , and 305 may be comprised of at least one of: O-rings, T-seals, chevron seals, metal spring energized seals, or combination of these to make a seal stack.
[0114] In application, sealing elements tend to adhere to one or both interface metal surfaces of the valve or sealed assembly. This can result in fluid or gas leaking through static or dynamic valve seals. In static, or non-moving seals, destructive mechanical stresses may also result from the difference in coefficient of thermal expansion of the mating parts made of differing materials, for example elastomers, polymers, metals or ceramics, or composites of these materials. Although the sealing element may change very little in size between hot and cold conditions, its expansion or contraction is relatively insignificant compared to the adjacent metal sealing elements of the valve, and since sealing elements are mechanically stressed with every thermal cycle, the sealing element eventually fractures thereby allowing fluid or gas to escape.
[0115] The polymer coatings discussed herein may significantly improve the performance and lifetime of static seals and dynamic (or sliding sleeve) seals in the aforementioned fluid flow control valves by virtue of the coating's lubricant and wear resistance characteristics and its relative impermeability to gases and fluids. For example a 2 μm coating imparts dry lubricant and wear resistance characteristics to the surface of the sliding seals. The lubricity of coating such as Parylene allows the sealing element to slide across the valve surfaces rather than sticking, thereby accommodating expansion and contraction differences that can fracture the seal. Since the sealing elements are not damaged in use, they can serve their intended sealing function and leaks are eliminated during a long functional life.
[0116] As may be seen by the exemplary embodiments illustrated in FIGS. 1-5 and 13 there are many possible uses of coated polymeric substrates formed into oilfield elements and assemblies. Alternatives are numerous. For example, certain electrical submersible pumps, which are modified versions of a pumping system known under the trade designation Axia™, available from Schlumberger Technology Corporation, may feature a simplified two-component pump-motor configuration. Pumps of this nature generally have two stages inside a housing, and a combined motor and protector bag, which may be comprised of a coated polymeric substrate in accordance with the invention. This type of pump may be built with integral intakes and discharge heads. Fewer mechanical connections may contribute to faster installation and higher reliability of this embodiment. The combined motor and protector assembly is known under the trade designation ProMotor™, and may be prefilled in a controlled environment. The pump may include integral instrumentation that measures downhole temperatures and pressures.
[0117] Other alternative electrical submersible pump configurations that may benefit from components comprised of polymer coated polymeric substrates include an ESP deployed on cable, an ESP deployed on coiled tubing with power cable strapped to the outside of the coiled tubing (the tubing acts as the producing medium), and more recently a system known under the trade designation REDACoil™, having a power cable deployed internally in coiled tubing. Certain pumps may have “on top” motors that drive separate pump stages, all pump stages enclosed in a housing. A separate protector bag is provided, as well as an optional pressure/temperature gauge. Also provided in this embodiment may be a sub-surface safety valve (SSSV) and a chemical injection mandrel. A lower connector may be employed, which may be hydraulically releasable with the power cable, and may include a control line and instrument wire feedthrough. A control line set packer completes this embodiment. The technology of bottom intake ESPs (with motor on the top) has been established over a period of years. It is important to securely install pump stages, motors, and protector within coiled tubing, enabling quicker installation and retrieval times plus cable protection and the opportunity to strip in and out of a live well. This may be accomplished using a deployment cable, which may be a cable known under the trade designation REDACoil™, including a power cable and flat pack with instrument wire and one or more, typically three hydraulic control lines, one each for operating the lower connector release, SSSV, and packer setting/chemical injection. Any one or more of the deployment cable, power cable, SSSV, control line set packer, chemical injection mandrel, and the like may comprise polymer coated polymeric substrates, either in their O-ring seals or gaskets, as jackets for cables, as protector bags, and the like.
[0118] Oilfield assemblies of the invention may include many optional items. One optional feature may be one or more sensors located at the protector bag to detect the presence of hydrocarbons (or other chemicals of interest) in the internal motor lubricant fluid. The chemical indicator may communicate its signal to the surface over a fiber optic line, wire line, wireless transmission, and the like. When a certain chemical is detected that would present a safety hazard or possibly damage a motor if allowed to reach the motor, the pump may be shut down long before the chemical creates a problem.
[0119] In summary, generally, this invention pertains primarily to oilfield elements and assemblies comprising a conformal protective coating deposited onto a polymeric substrate, where the substrate may be a thermoplastic, thermoset, elastomeric, or composite material. One coating embodiment is a Parylene coating. Parylene is common name for the family of poly(p-xylylene)s. The Parylene process was commercialized in the mid-1960s by Union Carbide Corporation, who then transferred patent rights to Cookson Electronics. Parylene forms an almost imperceptible plastic conformal coating that protects materials from many types of environmental problems. While the following process description focuses on the Parylene deposition process, which involves no solvent or diluent, and wherein the monomer undergoes no reaction other than with itself, the invention is not so limited. Any process and monomer (or combination of monomers, or pre-polymer or polymer particulate or solution) that forms a conformal polymeric coating may be used. Examples of other methods include spraying processes (e.g. electrospraying of reactive monomers, or non-reactive resins); sublimation and condensation; and fluidized-bed coating, wherein, a single powder or mixture of powders which react when heated may be coated onto a heated substrate, and the powder may be a thermoplastic resin or a thermoset resin.
[0120] Parylene Deposition Process. Parylene is a transparent polymer conformal coating that may be deposited from a gas phase in a medium vacuum. These polymers are polycrystalline and linear in nature, possess superior barrier properties, have extremely good chemical stability, that is, are relatively inert to the hostile well environment and because of the deposition process can be applied uniformly to virtually any surface and shape. A typical Parylene protective coating is about 1,000 times thinner than a plastic sandwich bag. The Parylene deposition process (not a part of the present invention, and publicly available at Cookson Electronics Speciality Coating Systems' website, http://www.scscookson.com.parylene-services/index.cfm) uses a dry, powdered material known as dimer (formula (I) herein) to create a thin, transparent film. There is no intermediate liquid phase and no “cure” cycle. Parylene deposition is via a gas vapor phase deposition; therefore, it is not a line-of-sight coating process. All sides of an object exposed to the vapor phase are uniformly impinged and coated by the gaseous monomer. Multiple parts (ESP Protector bags, 0-rings, and seals for example) may be coated at the same time in an apparatus similar to a clothes washer to make the process very economical to mass-produce finished parts. The process consists of three distinct steps, done in the presence of a medium vacuum.
[0121] 1. Vaporization, where Parylene is vaporized from its solid dimer state. This is accomplished by the application of heat under vacuum.
[0122] 2. Pyrolysis (cleaving) of the gaseous form of the dimer into a monomer may be achieved by using a high temperature tube furnace.
[0123] 3. Polymerization of the gaseous monomer occurs at room temperature as the Parylene deposits as a polymer onto the substrate in the vacuum chamber.
EXAMPLES
[0124] The tests and evaluations described in the following Examples demonstrate that a Parylene coating is highly effective in protecting an elastomer substrate; therefore, it can significantly lengthen the operational life of the protector bag compared to a non-coated bag. The Parylene coating protects the elastomer from chemical attack and decreases its permeability to conductive and corrosive fluids and gases such as salt water and H 2 S. Therefore it lengthens the life of electric submergible electric motors used to operate downhole pumps. However, the process can be applied generally to many elastomers used in the oilfield. The Example test results show the benefits can be significant.
[0125] Objectives of the Examples were to investigate if a Parylene coating could help improve an elastomer's resistance to the following hazards:
[0126] 1. Hydrogen sulfide sour gas permeation through elastomer; and
[0127] 2. Chemical attack from downhole fluids.
[0128] A prerequisite for acceptance of the protective coating was that the improvement in the elastomer must be made without interfering with the basic mechanical behavior, dimensions, and functions (i.e., the form, fit, or function) of the protector bags.
[0129] Materials
[0130] 1. Elastomer
[0131] Protector bag compound: a base elastomer known under the trade designation Aflas®, available from Asahi Glass Co., Ltd., was used to compound the elastomer test slabs (compounded slabs known under the trade designation MS-10-259 were provided by the Schlumberger Lawrence Product Center, Lawrence, Kans.). The base elastomer known under the trade designation Aflas® is a vinylidene fluoride type fluoroelastomer. The compounded slabs differed only slightly from the base elastomer by the addition of additives whose identity and weight percentages were not relevant to the tests conducted or the desired results.
[0132] 2. Parylene Coating
[0133] Samples coated with a fluorinated parylene known under the trade designation Parylene Nova HT were primarily studied herein, due to excellent thermal stability (up to 450° C.) of this type of coating. Table 1 lists the main properties of the Parylene known under the trade designation Parylene Nova HT. The supplier, Cookson Electronics Speciality Coating Systems, provided this information (see their web site at (http://www.scscookson.com/parvlene_services/index.cfm).
TABLE 1 Material property data for Parylene Nova HT* Physical and Parylene Nova Mechanical Unit HT Test Method Tensile Strength PSI 7,500 ASTM D882, 25° C. Modulus PSI 370,000 ASTM 5026 DMA Elongation to break 10% ASTM D882 Hardness Rockwell R122 ASTM D785 Coefficient of Friction Static 0.145 ASTM D1894 Dynamic 0.130 Barrier Water absorption % <0.01 ASTM D570 Gas permeabilities cc * mm/ m2 * day N 2 4.8 Mocon MULTITRAN O 2 23.5 400 CO 2 95.4 *Parylene Nova HT is a trademark and service mark of Specialty Coating Systems.
[0134] Experimental Results
[0135] Parylene coating: Elastomer slabs were coated with Parylene C, N, and Nova HT at Special Coating Systems, Clear Lake, Wis. and Parylene Coating Service, Houston, Tex. Only samples coated with Parylene Nova HT at Special Coating Systems were used for further study listed below.
[0136] Fatigue tests on both non-coated and coated elastomer samples: tensional cycling 1000 times to 20% strain at 1%/second strain rate, at 93° C. (200° F). Testing was conducted at Axel Products, Ann Arbor, Mich.
[0137] H 2 S permeation test
[0138] The following samples were tested with 5% H 2 S, balance N 2 gas, 93° C. (200° F), 14 days, at InterCorr, International, Houston, Tex.
[0139] A. as-received elastomer
[0140] B. fatigued elastomer
[0141] C. elastomer coated with Parylene Nova HT
[0142] D. elastomer coated with Parylene Nova HT and fatigued
[0143] Scanning electronic microscopy (SEM) inspection of samples A-D was conducted at Schlumberger Research Center materials lab.
[0144] Results and Discussion
[0145] H 2 S Permeation Test Results
TABLE 2 Summary of H 2 S permeation test results Permeability, Sample Sample description μmoles/cm 2 /day A compounded Aflas*, as 0.249 received B Fatigued, compounded 0.124 Aflas* C Compounded Aflas*, coated 0.072 with Parylene Nova HT D Compounded Aflas*, coated No permeation detected with Parylene Nova HT, and within testing period fatigued *“Aflas” is a trademark of Asahi Glass Co., Ltd.
[0146] From Table 2 and comparison of FIGS. 6-8 , it can be seen that sample D, which is coated and fatigued, showed the best H 2 S permeation resistance. It is apparent that Parylene Nova HT coating significantly improves H 2 S permeation resistance of the elastomer. Interestingly, it is found that mechanical fatigue of samples also helps improve H 2 S permeation resistance in general.
[0147] SEM Inspection
[0148] Craze-like cracks are observed in both coated samples with and without fatigue cycling ( FIGS. 12 and 13 ). This may indicate debonding between the rubber substrate and the coating. Regardless of the existence of these cracks, H 2 S permeation resistance of the elastomer known under the trade designation Aflas was still improved significantly.
[0149] Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. In the claims, no clauses are intended to be in the means-plus-function format allowed by 35 U.S.C. §112, paragraph 6 unless “means for” is explicitly recited together with an associated function. “Means for” clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. | Oilfield elements and assemblies are described comprising a polymeric substrate and a polymer coating adhered to at least a portion of the substrate. Methods of using the elements and assemblies in oilfield operations are also described. This abstract allows a searcher or other reader to quickly ascertain the subject matter of the disclosure. It will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b). | 4 |
FIELD OF THE INVENTION
This invention pertains to microlithography (projection-transfer of a pattern, defined by a reticle or mask, onto a sensitive substrate such as a semiconductor wafer). Microlithography is a key technology used in the manufacture of semiconductor integrated circuits, displays, and the like. More specifically, the invention pertains to microlithography using a charged particle beam (electron beam or ion beam) as an energy beam. Even more specifically, the invention pertains to methods for making reticles as used in charged-particle-beam (CPB) microlithography, to reticles made using such methods, and to CPB microlithography methods performed using such reticles.
BACKGROUND OF THE INVENTION
In recent years, as semiconductor integrated circuits have become increasingly miniaturized, the resolution limits of optical microlithography (i.e., projection-transfer of a pattern performed using ultraviolet light as an energy beam) have become increasingly apparent. As a result, considerable development effort currently is being expended to develop microlithography methods and apparatus that employ an alternative type of energy beam that offers prospects of better resolution than optical microlithography. For example, considerable effort has been directed to use of X-rays. However, a practical X-ray system has not yet been developed because of many technical problems with that technology. Another candidate microlithography technology utilizes a charged particle beam, such as an electron beam or ion beam, as an energy beam.
A current type of electron-beam pattern-transfer system is an electron-beam system that literally “draws” a pattern on a substrate using an electron beam. In such a system, no reticle is used. Rather, the pattern is drawn line-by-line. These systems can form intricate patterns having features sized at 0.1 μm or less because, inter alia, the electron beam itself can be focused down to a spot diameter of several nanometers. However, with such systems, the more intricate the pattern, the more focused the electron beam must be in order to draw the pattern satisfactorily. Also, drawing a pattern line-by-line requires large amounts of time; consequently, this technology has very little utility in the mass production of semiconductor wafers where “throughput” (number of wafers processed per unit time) is an important consideration.
In view of the shortcomings in electron-beam drawing systems and methods, charged-particle-beam (CPB) projection-microlithography systems have been proposed in which a reticle defining the desired pattern is irradiated with a charged particle beam. The portion of the beam passing through the irradiated region of the reticle is “reduced” (demagnified) as the image carried by the beam is projected onto a corresponding region of a wafer or other suitable substrate using a projection lens.
The reticle is generally of two types. One type is a scattering-membrane reticle 21 as shown in FIG. 15 ( a ), in which pattern features are defined by scattering bodies 24 formed on a membrane 22 that is relatively transmissive to the beam. A second type is a scattering-stencil reticle 31 as shown in FIG. 15 ( b ), in which pattern features are defined by beam-transmissive through-holes 34 in a particle-scattering membrane 32 . The membrane 32 normally is silicon with a thickness of approximately 2 μm.
Because, from a practical standpoint, an entire reticle pattern cannot be projected simultaneously onto a substrate using a charged particle beam, conventional CPB microlithography reticles are divided or segmented into multiple “subfields” 22 a , 32 a each defining a respective portion of the overall pattern. The subfields 22 a , 32 a are separated from one another on the membrane 22 , 32 by boundary regions 25 , 35 , in which no pattern elements are defined. In order to provide the membrane 22 , 32 with sufficient mechanical strength and rigidity, support struts 23 , 33 extend from the boundary regions 25 , 35 .
Each subfield 22 a , 32 a typically measures approximately 1-mm square. The subfields 22 a , 32 a are arrayed in columns and rows across the reticle 21 , 31 . For projection-exposure, the subfields 22 a , 32 a are illuminated in a step-wise or scanning manner by the charged particle beam (serving as an “illumination beam”). As the illumination beam passes through each subfield, the beam becomes “patterned” according to the configuration of pattern elements in the subfield. As depicted in FIG. 15 ( c ), the patterned beam propagates through a projection-optical system (not shown) to the sensitive substrate 27 . (By “sensitive” is meant that the substrate is coated on its upstream-facing surface with a material, termed a “resist,” that is imprintable with an image of the pattern as projected from the reticle.) The images of the subfields have respective locations on the substrate 27 in which the images are “stitched” together (i.e., situated contiguously) in the proper order to form the entire pattern on the substrate.
Conventionally, reticles of the types summarized above are manufactured using semiconductor-fabrication technology. Fabrication begins with a silicon reticle substrate (typically having a thickness of 1 mm or less). The reticle membrane, subfields, and support struts are fabricated from the reticle substrate. The reticle conventionally is attached circumferentially to a peripheral frame typically having a thickness of about 10 mm. The peripheral frame, normally also made of silicon, strengthens the reticle for routine handling and during use of the reticle in the CPB projection-microlithography apparatus.
A conventional scattering-stencil reticle mounted to a peripheral frame is shown in FIGS. 16 ( a )- 16 ( b ). FIG. 16 ( a ) depicts a reticle assembly 39 comprising a stencil-reticle portion 41 that includes a pattern-defining region 45 and a peripheral region 44 . The pattern-defining region 45 includes multiple subfields 42 (each with a respective membrane portion) and support struts 43 . The membrane portions have a thickness of about 2 μm and define respective portions of the reticle pattern, as described above. If the stencil-reticle portion 41 has an outer diameter of about 8 inches, then the thickness of the peripheral region 44 is about 700 μm. The edge region 46 of the stencil-reticle portion 41 is attached to a peripheral frame 40 having a thickness of about 10 mm.
Unfortunately, with reticles made by conventional technology, attachment of the stencil-reticle portion 41 to a peripheral frame 40 generates a stress throughout the stencil-reticle portion 41 that tends to cause warping (deformation) of the pattern-defining region 45 . The warping extends to the subfields 42 and thus to the respective pattern portions defined by the subfields 42 . This warping is especially a problem if the stencil-reticle portion 41 is attached to the peripheral frame 40 after the pattern has been formed on the pattern-defining region 45 . The warping prevents attainment of sufficiently accurate pattern transfer.
Hence, there is a need for a reticle (for CPB microlithography) that is attached to a peripheral frame 40 but that exhibits substantially reduced warp in the pattern-defining region 45 , compared to conventional reticles.
SUMMARY OF THE INVENTION
In view of the shortcomings of the prior art as summarized above, an object of the present invention is to provide reticles in which pattern warp is substantially reduced or reducible.
To such end and according to a first aspect of the invention, reticles are provided, for charged-particle-beam (CPB) microlithography, that comprise a reticle portion. In an embodiment, the reticle portion comprises a pattern-defining region, an inner supporting part, and an outer supporting part. The pattern-defining region comprises multiple subfields separated from one another by support struts. Each subfield defines a respective portion of a pattern defined by the reticle. The inner supporting part is attached peripherally to the pattern-defining region, and is configured to support the pattern-defining region integrally. The outer supporting part surrounds the inner supporting part and is connected to the inner supporting part by multiple connecting structures each having a spring characteristic. The outer supporting part is configured so as to support the inner supporting part and pattern-defining region in a peripheral manner. The reticle can further comprise a peripheral frame peripherally attached to the reticle portion. With such a reticle, stress triggered in the periphery of the reticle as a result, especially, of attaching a peripheral frame to the reticle is absorbed by deformation of the connecting structures rather than warping of the pattern-defining region.
The pattern-defining region can be configured as a stencil reticle in which pattern elements are defined as respective voids in a CPB-scattering reticle membrane. With such a reticle, the temperature of pattern-defining region does not increase excessively during use because the amount of charged-particle absorption by the pattern-defining region is relatively small, even with high illumination-beam currents. Thus, thermally induced warp is reduced. In any event, thermal warp and mechanically engendered warp are dissipated in the connecting structures.
Alternatively, the pattern-defining region can be configured as a scattering-membrane reticle in which pattern elements are defined as respective spaces between CPB-scattering bodies situated on a CPB-transmissive reticle membrane. Even with this type of reticle, temperature increase of the reticle during use is not excessive because the amount of absorption of charged particles by the reticle is small, even at high illumination-beam currents. In any event, thermal warp and mechanically engendered warp are dissipated in the connecting structures.
Each connecting structure can have an H-shaped configuration having two pairs of H-ends. In such a configuration, a first pair of H-ends is connected to the inner supporting part and a second pair of H-ends is connected to the outer supporting part. Alternatively, each connecting structure can have an X-shaped configuration having two pairs of X-ends. In this alternative configuration, a first pair of X-ends is connected to the inner supporting part and a second pair of X-ends is connected to the outer supporting part. With such structures, it is possible to define spring constants by matching the spring constant of connecting structure to a characteristic of mechanical strength (especially an elastic characteristic) of the reticle portion.
The reticle can comprise a number (n) of connecting structures each satisfying a relationship nK f =K s /β, wherein K s is an in-plane elastomeric constant of the reticle portion, β is a connection-relaxation coefficient of the connecting structure, and K f is a spring constant of the connecting structure. With such a configuration, if the number of connecting structures is excessive, then additional mechanical stress is imparted to the reticle portion, which is rendered easily warped. On the other hand, if the number of connecting structures is too low, then proper support of the reticle portion becomes too difficult to achieve. By satisfying this relationship, the reticle portion is supported adequately while inhibiting propagation of warp from the outer supporting part to the inner supporting part (and pattern-defining region).
According to another aspect of the invention, methods are provided for making a reticle for CPB microlithography. Inc an embodiment of such methods, a silicon-on-insulator (SOI) reticle substrate is provided. The reticle substrate comprises a base layer, a silicon oxide layer on an obverse surface of the base layer, and a silicon layer on the silicon oxide layer. An etching mask is applied to a reverse surface of the base layer. The etching mask defines respective openings at anticipated locations of reticle subfields in a patter-defining region. The etching mask also defines respective locations of an inner supporting part surrounding the pattern-defining region, an outer supporting part surrounding the inner supporting part, and multiple connecting structures connecting the inner supporting part to the outer supporting part. The base layer is etched anisotropically at openings in the etching mask. The etching is allowed to proceed depthwise through the base layer to the silicon oxide layer, so as to define the subfields, the inner supporting part, the outer supporting part, and the connecting structures. Afterward, the exposed regions of silicon oxide are removed. Desirably, each connecting structure is composed of silicon and is formed in the anisotropic etching step by selectively etching away complementary regions of the base layer by anisotropic etching. The connecting structures can be formed, in the anisotropic etching step, at the same time as supporting struts separating the subfields from each other in the pattern-defining region. By fabricating the connecting structures at the same time as the support struts, the time (and cost), required to fabricate the reticle is reduced.
The method summarized above can include the step of defining a chip pattern in the pattern-defining region, and/or the step of attaching a peripheral frame to the outer supporting part.
According to another aspect of the invention, CPB microlithography reticles are provided that are formed by any of the methods according to the invention.
According to another embodiment, CPB-microlithography reticles according to the invention comprise a reticle portion that comprises (1) a:pattern-defining region comprising multiple subfields separated from one another by support struts, wherein each subfield defines a respective portion of a pattern defined by the reticle; (2) an inner supporting part peripherally attached to the pattern-defining region and configured so as to integrally support the pattern-defining region; (3) an outer supporting part peripherally surrounding the inner supporting part; and (4) multiple connecting structures connecting the inner supporting part to the outer supporting part. Each connecting structure comprises a first conductive region situated on the outer supporting part and a second conductive region situated on the inner supporting part. At least the first conductive regions are selectively energizable electrically so as to cause, in a selective manner, the respective first and second conductive regions to move relative to each other, thereby displacing the pattern-defining region so as to cancel, at least partially, a warp of the patter-defining region.
In each connecting structure, the first and second conductive regions can exhibit an electrostatic attraction with respect to each other under appropriate conditions of electrical energization of at least the respective first conductive region.
The reticles can further comprise a peripheral frame peripherally attached to the outer supporting part. In such a configuration, the peripheral frame can comprise a conductive pad from which a wiring connection is made to a respective first conductive region.
Each of the first conductive regions can comprise a first flexible membrane member connected to the outer supporting part. Similarly, each of the second conductive regions can comprise a second flexible membrane member connected to the inner supporting part. In such a configuration, each connecting structure desirably further comprises an insulating member situated between the respective first and second flexible membrane members.
According to another aspect of the invention, CPB microlithography apparatus are provided. An embodiment of such an apparatus comprises an illumination-optical system, a projection-optical system, a reticle stage, and a substrate stage. The illumination-optical system is situated and configured to irradiate a charged-particle illumination beam onto a selected region of any of the various embodiments of a reticle, according to the invention, as summarized above. The reticle stage is situated and configured to: (i) hold the reticle as the reticle is being illuminated by the illumination beam, and (ii) selectively energize the conductive regions so as to reduce reticle warp. The projection-optical system is situated and configured to receive a patterned beam, formed by passage of the illumination beam through the reticle and carrying an image of the irradiated region of the reticle, and to focus the image onto a predetermined position on a sensitive substrate. The substrate stage is situated and configured to hold the substrate as the substrate is being exposed by the patterned beam.
According to yet another aspect of the invention, methods are provided for microlithographically exposing a pattern onto a sensitive substrate using a charged particle beam. In an embodiment of such a method, a reticle is provided that comprises: (i) a pattern-defining region comprising multiple subfields each defining a respective portion of a pattern defined by the reticle, (ii) an inner supporting part peripherally attached to the pattern-defining region and configured so as to support the pattern-defining region integrally, (iii) an outer supporting part peripherally surrounding the inner supporting part, and (iv) multiple connecting structures connecting the inner supporting part to the outer supporting part. Each connecting structure comprises a first conductive region situated on the outer supporting part and a second conductive region situated on the inner supporting part. At least one of the conductive regions is energized electrically in a selective manner so as to cause, in a selective manner, the respective first and second conductive regions to move relative to each other, thereby displacing the pattern-defining region so as to cancel, at least:partially, a warp of the pattern-defining region. The charged particle beam is irradiated selectively onto the subfields in an ordered manner to transfer the reticle pattern to the substrate.
The foregoing and additional features and advantages of the invention will be more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 ( a )- 1 ( b ) are an obverse plan view and elevational section (along the line A—A), respectively, of a reticle according to a first representative embodiment of the invention.
FIGS. 2 ( a )- 2 ( j ) are elevational views of the results of certain respective steps of a method, according to the invention, for manufacturing a reticle of the first representative embodiment.
FIG. 3 ( a ) is a reverse plan view of a portion of the reticle of the first representative embodiment, and FIG. 3 ( b ) is a plan view of certain details of a connecting structure in the reticle of FIG. 3 ( a ).
FIG. 4 is a plan view of a reticle according to a second representative embodiment.
FIGS. 5 ( a )- 5 ( b ) are a plan view and elevational section (along the line A-A′), respectively, showing certain features of a reticle according to a third representative embodiment.
FIGS. 6 ( a )- 6 ( b ) depict certain details of a drivable connecting structure in a reticle as shown in FIG. 5 ( a ). FIG. 6 ( a ) includes two sections, one along the line A-A′ and the other along the line B-B′, providing further detail of the connecting structure.
FIG. 7 is a plan view showing the arrangement of the drivable connecting structures of the reticle according to the third representative embodiment.
FIGS. 8 ( a )- 8 ( j ) schematically depict respective modes of motion of the pattern-defining region of a reticle according to the third representative embodiment whenever certain indicated drivable connecting structures are actuated.
FIGS. 9 ( a )- 9 ( b ) depict the results of certain respective steps in the manufacture of a reticle according to the third representative embodiment. FIG. 9 ( a ) shows a plan view and elevational section along the line X-X′, and FIG. 9 ( b ) shows a plan view and elevational section along the line Y-Y′.
FIGS. 10 ( a )- 10 ( b ) depict the results of certain respective steps, continued from FIGS. 9 ( a )- 9 ( b ), in the manufacture of a reticle according to the third representative embodiment. FIG. 10 ( a ) shows an elevational section only, and FIG. 10 ( b ) shows both a plan view and an elevational section along the line Z-Z′.
FIGS. 11 ( a )- 11 ( d ) depict the results of certain steps, continued from FIGS. 10 ( a )- 10 ( b ), in the manufacture of a reticle according to the third representative embodiment. Each of FIGS. 11 ( a )- 11 ( d ) provides a respective elevational section.
FIG. 12 is a schematic elevational diagram of a charged-particle-beam microlithography apparatus according to a fourth representative embodiment of the invention.
FIG. 13 is a process flowchart for manufacturing a semiconductor device, wherein the process includes a microlithography method utilizing a reticle according to the invention.
FIG. 14 is a process flowchart for performing a microlithography method utilizing a reticle according to the invention.
FIG. 15 ( a ) is a schematic elevational view of certain aspects of a conventional scattering-membrane reticle.
FIG. 15 ( b ) is a schematic elevational view of certain aspects of a conventional scattering-stencil reticle.
FIG. 15 ( c ) is a schematic oblique view of certain aspects of conventional microlithographic transfer of a reduced image from a reticle to a substrate using a charged particle beam.
FIGS. 16 ( a )- 16 ( b ) depict certain aspects of a conventional scattering-stencil reticle, for charged-particle-beam microlithography, incorporating a peripheral frame.
DETAILED DESCRIPTION
The following description is directed to scattering-stencil reticles, as exemplary reticles, according to the invention, for charged-particle-beam (CPB) microlithography. It will be understood, however, that embodiments of the invention are not limited to scattering-stencil reticles. The principles described below can be applied with equal facility to other types of reticles for CPB microlithography, such as scattering-membrane reticles.
The invention is described below in the context of representative embodiments. However, it will be understood that the invention is not limited to those embodiments.
FIRST REPRESENTATIVE EMBODIMENT
A reticle 49 according to this embodiment is shown in FIGS. 1 ( a )- 1 ( b ), and comprises a stencil-reticle portion 51 and a peripheral frame 50 . The stencil-reticle portion 51 comprises an outer supporting part 54 , an inner supporting part 57 , a pattern-defining region 55 , and multiple connecting structures 58 for connecting together the outer supporting part 54 and the inner supporting part 57 . The pattern-defining region 55 is divided into multiple subfields 52 a separated from one another by support struts 53 . Each subfield 52 a includes a respective portion of the reticle membrane 52 b . The peripheral frame 50 is attached to the edge region 56 of the stencil-reticle portion 51 .
The reticle 49 can be fabricated using semiconductor-fabrication technology. FIGS. 2 ( a )- 2 ( j ) schematically depict the results of certain respective steps in a fabrication process for making the reticle 49 . In a first step (FIG. 2 ( a )), a silicon.-on-oxide (SOI) reticle substrate 60 is prepared. By way of example, the reticle substrate 60 has an outer diameter of 8 inches and a thickness of 725 μm. The reticle substrate 60 includes a base layer 60 c , a silicon oxide layer 60 b , and a silicon layer 60 a . The silicon layer 60 a has a thickness of approximately 2 μm and normally comprises doped silicon. The silicon oxide layer 60 b has a thickness of approximately 1 μm and serves as an intermediate layer. The base layer, 60 c is made of silicon. A layer 61 of an organic resist is formed on the reverse side of the base, layer 60 c (FIG. 2 ( b )), followed by patterning of the resist 61 (FIG. 2 ( c )). Material of the base layer 60 c is removed selectively by dry etching, in the depthwise direction, from the regions unprotected by the resist 61 (FIG. 2 ( d )). In other words, the patterned resist 61 serves as an etching mask. As shown in FIG. 2 ( d ), depthwise etching stops automatically at the silicon oxide layer 60 b . The dry etching defines subfields 62 , support struts 65 , and the inner supporting part 63 . Next, the remaining resist 61 is removed (FIG. 2 ( e )), and the exposed regions of the silicon oxide 60 b are removed (FIG. 2 ( f )) using hydrogen fluoride or other suitable reagent. Thus, the silicon layer 60 a becomes a reticle membrane. Next, a layer of an organic resist 66 is coated on the upper surface of the SOI substrate 60 (specifically on the upper surface of the silicon layer 60 a , FIG. 2 ( g )), and a desired stencil pattern is imprinted in the resist 66 (FIG. 2 ( h )). Using the remaining resist 66 as an etching mask, a reticle stencil pattern 67 is formed in the silicon layer 60 a , and the remaining resist 66 is removed (FIG. 2 ( i )). Finally, a peripheral frame 68 , made of a material such as silicon, ceramic, or glass, is attached peripherally to the stencil-reticle portion (FIG. 2 ( j )), desirably using an adhesive, or by anodic welding or eutectic welding.
In the method of FIGS. 2 ( a )- 2 ( j ), connecting structures (see item 58 in FIG. 1 ( a )) can be formed at the same time as the support struts 65 . Alternatively, the connecting structures 58 can be formed independently of the struts 65 . Also, the connecting structures 58 can be formed so as to be surrounded by thin membrane regions as shown in FIG. 1 ( b ), or to be surrounded by through-holes (represented by regions 75 a and 75 b in FIG. 3 ( a )).
In a CPB microlithographic reticle fabricated as described above, attachment of the peripheral frame 50 (FIG. 1 ( a )) to the outer supporting part 54 can generate a warp that is transmitted to the inner supporting part 57 and the pattern-defining region 55 . To achieve a substantial reduction (e.g., ten-fold) in warp transmitted to the pattern-defining region 55 each connecting structure 58 desirably is configured to have a spring constant that is approximately one tenth the spring constant of the combined inner supporting part 57 and pattern-defining region 55 .
For example, consider a warp of 100 nm arising by connecting the peripheral frame 50 to the stencil-reticle portion 51 . This warp at the pattern-defining region 55 can be reduced to 10 nm by using a reticle 49 configured according to this embodiment. More specifically, the spring constant of a connecting structure 58 can be defined from the size of the pattern-defining region 55 , the number of support struts 53 , the width of each support strut 53 , and the spacing between the support struts 53 . In general, the stated 10-fold reduction in warp transmission to the pattern-defining region 55 is achieved by employing at least ten to less than 20 connecting structures 58 , each having a spring constant of about 1 N/μm between the inner supporting part 57 and the outer supporting part 54 . More accurately, if the in-plane elastic constant of the stencil-reticle portion 51 is denoted as K s , the connection-relaxation coefficient is denoted as β, and the spring constant of the connecting structure 58 is denoted as K f , then the number “n” of connecting structures 58 and their spring constants can be configured to satisfy the relation: nK f =K s /β.
FIGS. 3 ( a )- 3 ( b ) show a stencil-reticle portion 70 that can be produced using the method described above and shown in FIGS. 2 ( a )- 2 ( j ). The stencil-reticle portion 70 includes an outer supporting part 71 , an inner supporting part 72 , and a pattern-defining region 73 (comprising multiple subfields separated from one another by support struts). The inner supporting part 72 is connected to the outer supporting part via multiple connecting structures 74 (see detail in FIG. 3 ( b )). The pattern-defining region 73 is supported by the struts and by the inner supporting part 72 .
Although the connecting structures 74 of this embodiment have the simple configuration shown in FIG. 3 ( b ), the configuration of the connecting structures 74 is not so limited. In general, to facilitate adjustment of the spring constant, it is desirable that, at the location of each connecting structure, the inner supporting part 72 and the outer supporting part 71 each have two connections. With such a configuration, the connecting structure 74 has an “H” configuration (FIG. 3 ( b )). An alternative configuration providing generally the same effect is a connecting structure having an X-shaped configuration. In any event, the shape and spring constant of the connecting structure 74 can be determined by finite-element analysis using a material constant of the connecting structure 74 such as Young's modulus of elasticity. The edges of the connecting structure 74 are defined by through-holes 75 a , 75 b and edges of adjacent membrane structures.
SECOND REPRESENTATIVE EMBODIMENT
A reticle assembly 80 according to this embodiment is shown in FIG. 4, and is especially suitable in instances in which multiple (two in this embodiment) pattern-defining regions are provided on the same reticle substrate. More specifically, the reticle assembly 80 is a stencil reticle 81 comprising two separate pattern-defining regions 82 a , 82 b . The pattern-defining regions are surrounded by respective inner supporting parts 83 a , 83 b . The inner supporting parts 83 a , 83 b are connected to an outer supporting part 84 by multiple connecting structures 85 . Finally, the stencil reticle 81 is connected to a peripheral frame 86 .
THIRD REPRESENTATIVE EMBODIMENT
A reticle 89 according to this embodiment is shown in FIGS. 5 ( a )- 5 ( b ), and comprises a stencil-reticle portion 91 and a peripheral frame 90 . The stencil-reticle portion 91 comprises an outer supporting part 94 , an inner supporting part 97 (collectively constituting a support part 96 ), a pattern-defining region 95 , and multiple drivable (electrically actuatable) connecting structures 98 ( 1 )- 98 ( 12 ) for connecting together the outer supporting part 94 and the inner supporting part 97 . The pattern-defining region 95 is divided into multiple subfields 92 a separated from one another by support struts 93 . Each subfield 92 a includes a respective portion of the reticle membrane 92 b . An obverse surface of the peripheral frame 90 is attached circumferentially to the stencil-reticle portion 91 .
Each of the drivable connecting structures 98 is electrically actuatable. To such end, pads 99 are provided on the reverse surface of the peripheral frame, wherein wiring 100 connects each pad 99 to a respective connecting structure 90 . In general, and by way of example, the wiring 100 has a diameter of 30 μm, and each pad 99 measures 30 μm square. The wiring 100 is bonded to the pads 99 and connecting structures 98 using conventional semiconductor fabrication techniques. Further details of a drivable connecting structure 98 are shown in FIGS. 6 ( a )- 6 ( b ). Each connecting structure 98 comprises a first flexible membrane member 101 connected to the outer supporting part 94 , a second flexible membrane member 102 connected to the inner supporting part 97 , and an electrically insulating member 103 situated between the first flexible membrane member 101 and the second flexible membrane member 102 . The first and second flexible membrane members 101 , 102 are electrically conductive and can be formed by doping impurities into intrinsic silicon. As noted above, in this embodiment, twelve (by way of example) drivable connecting structures 98 ( 1 )- 98 ( 12 ) are provided. Since each connecting structure 98 has respective first and second flexible membrane members 101 , 102 and a respective insulating member 103 , the respective reference numbers for the first flexible membrane members are 101 ( 1 )- 101 ( 12 ), the respective reference numbers for the second flexible membrane members are 102 ( 1 )- 102 ( 12 ), and the respective reference numbers for the insulating members are 103 ( 1 )- 103 ( 12 ).
The first flexible membrane member 101 ( 1 ) of the first connecting structure 98 ( 1 ), connected to the outer supporting part 94 , is part of a respective conductive region 104 provided in the outer supporting part 94 . The second flexible membrane member 102 ( 1 ) of the first connecting structure 98 ( 1 ), connected to the inner supporting part 97 , is part of a conductive region 105 provided in the inner supporting part 97 . The conductive regions 104 , 105 can be formed by doping impurities into intrinsic silicon. The conductive regions 101 , 104 desirably are made of the same material, and the conductive regions 102 , 105 desirably are made of the same material.
The arrangements of connecting structures 98 ( 1 )- 98 ( 12 ) in this embodiment, and associated conductive regions 104 ( 1 )- 104 ( 12 ), are shown in FIG. 7 . Each of the conductive regions 104 ( 1 )- 104 ( 12 ) is separate from one another. Connected to each of the conductive regions 104 ( 1 )- 104 ( 12 ) is a respective wire 100 ( 1 )- 100 ( 12 ) (not shown, but see FIGS. 6 ( a )- 6 ( b )). The wires 100 ( 1 )- 100 ( 12 ) deliver respective electrical driving signals (from a power source, not shown) to the conductive regions 104 ( a )- 104 ( 12 ). FIG. 7 also shows the conductive region 105 . The conductive region 105 can be the inner support part 97 or a portion of the inner support part 97 .
As shown in FIG. 6 ( b ), upon application of different respective electrical voltages to each conductive region 104 , an electrostatic-charge attraction is generated between the conductive regions 104 , 105 , respectively. Specifically, the conductive region 105 is floated electrically, and the conductive regions 104 receive respective applied voltages. As a result, the conductive regions 104 , 105 move toward each other (arrows 106 ), causing the flexible membrane members 101 , 102 to flex. The attractive force is a function of the applied voltage, the area of the conductive region (relative to the opposing conductive region), and the distance between opposing conductive regions.
For the following discussion, the conductive regions 104 ( 1 )- 104 ( 12 ) are denoted A-L, respectively, as indicated in FIG. 7 . FIGS. 8 ( a )- 8 ( j ) depict respective modes of motion of the inner supporting part (and pattern-defining region 95 ) whenever certain respective groups of conductive regions A-L are energized (arranged as shown: in FIG. 7 ). Selective energization of the conductive regions 104 ( 1 )- 104 ( 12 ) is performed by selectively applying voltages to them. Before applying the voltages, deformation of the reticle is determined. For example, if the adjacent region of the connecting structure A is deformed (i.e., smaller than required), then voltage is applied to the conductive region 104 ( 1 ). From measurements of such deformation and calculations of the relationship, between applied voltage and deformation by attractive force, the required voltage to correct the deformation by attractive force is determined. In general, applied voltages range from 0-140 KV at an accuracy of 140 mV. For example, at 140 KV, 1 μm linear deformation or 3 mdeg rotational deformation can be achieved.
For example, whenever a voltage is applied to each of the conductive regions A,D,G, and J, the inner supporting part 97 (and thus the pattern-defining region 95 ) is rotated to a limited extent in a clockwise direction in the figure (FIG. 8 ( a )). Similarly, whenever a voltage is applied to each of the conductive regions C, F, I, and L, the inner supporting part 97 (and thus the pattern-defining region 95 ) is rotated to a limited extent in a counterclockwise in the figure (FIG. 8 ( b )). If the rotation is symmetrical, then no deformation of the pattern-defining region 95 occurs. However, if this rotation is not symmetrical, then some deformation of the pattern-defining region 95 can occur, which can be corrected by selective energization of other conductive regions as described below. Referring to FIG. 4, if the regions 83 a and 83 b are rotated in opposite directions, then electrically actuated corrective rotations as described above can be used to correct the rotations.
The achievable angle of rotation in each of FIGS. 8 ( a )- 8 ( b ) is approximately 3 μdeg to 3 mdeg. (The rotation of 3 mdeg is achieved at about 140 KV of applied voltage.) The degree of rotation is controllable to with an accuracy of 1 μdeg by appropriately controlling the applied voltage.
To continue, whenever a voltage is applied to each of the conductive regions A, B, and C, the inner supporting part 97 (and thus the pattern-defining region 95 ) moves upward in the figure (FIG. 8 ( c )). Similarly, whenever a voltage is applied to each of the conductive regions G, H, and 1 , the inner supporting part 97 (and thus the pattern-defining region 95 ) moves downward in the figure (FIG. 8 ( d )). Similarly, whenever a voltage is applied to each of the conductive regions I, K, and L, the inner supporting part 97 (and thus the pattern-defining region 95 ) moves to the left in the figure (FIG. 8 ( e )). Similarly, whenever a voltage is applied to each of the conductive regions D, E, and F, the inner supporting part 97 (and thus the pattern-defining region 95 ) to the right in the figure of the drawing (FIG. 8 ( f )). In each of these instances, the displacement distance of the inner supporting part 97 is 1 nm to 1 μm. The accuracy of this movement can be controlled to an accuracy of 1 nm or less. Again, by way of example, the range of applied voltage is 0-140 KV, with an accuracy of 140 mV. At 140 KV, a deformation of about 1.4 μm is obtainable.
To continue, whenever a voltage is applied to each of the conductive regions G, H, I, J, K, and L, the inner supporting part 97 (and thus the pattern-defining region 95 ) moves diagonally downward to the left in the figure (FIG. 8 ( g )). Similarly, whenever a voltage is applied to each of the conductive regions D, E, F, G, H, and I, the inner supporting part 97 (and thus the pattern-defining region 95 ) moves diagonally downward to the right in the figure (FIG. 8 ( h )). Similarly, whenever a voltage is applied to each of the conductive regions A, B, C, D, E, and F, the inner supporting part 97 (and thus the pattern-defining region 95 ) moves diagonally upward to the right in the figure (FIG. 8 ( i )). Similarly, whenever a voltage is applied to each of the conductive regions A, B, C, J, K, and L, the inner supporting part 97 (and thus the pattern-defining region 95 ) moves diagonally upward to the left in the figure (FIG. 8 ( j )). The displacement distance in each instance of the inner supporting part 97 is 1.4 nm to 1.4 μm. The accuracy of motion can be controlled to within 1.4 nm.
Methods for fabricating a reticle according to this embodiment are now described with reference to FIGS. 9 ( a )- 9 ( b ), 10 ( a )- 10 ( b ), and 11 ( a )- 11 ( d ).
An SOI (silicon on insulator) reticle substrate 110 is prepared that comprises a silicon layer 113 , a silicon oxide layer 112 , and a base layer 111 of silicon. The SOI reticle substrate 110 is fabricated by conventional techniques as summarized above (regarding FIG. 2 ( a )). Conductive regions 114 ( 1 )- 114 ( 12 ) and 115 are then formed on (and extending into the thickness dimension of) the silicon base layer 111 (FIG. 9 ( a )).
The conductive regions 114 ( 1 )- 114 ( 12 ) and 115 are formed by doping impurities (e.g., P and/or B) into predetermined regions of the base layer 111 using ion injection or thermal diffusion. The predetermined regions are defined by using a suitable mask (not shown) having openings corresponding to the desired locations.
Next, an etching mask 116 defining a predetermined pattern is applied to the under-surface (in the figure) (FIG. 9 ( b )) using conventional techniques. Using the etching mask 116 as an etching guide, anisotropic etching is performed of the conductive regions 114 ( 1 )- 114 ( 12 ) and 115 to the silicon oxide layer 112 (FIG. 10 ( a )). After etching, the remaining mask 116 is removed. During the anisotropic etching, the base layer 111 is etched to the silicon oxide layer 112 due to substantially different etch rates of silicon versus silicon oxide. The silicon oxide 112 exposed in the trenches formed by etching is removed using hydrofluoric acid, thereby forming the outer supporting part 117 , the drivable connecting structures 118 , the inner supporting part 119 , and support struts 120 (FIG. 10 ( b )). The silicon layer 113 becomes a silicon reticle membrane 113 a in the resulting reticle blank (FIG. 10 ( b )).
A layer of resist 160 is coated on the reticle membrane 113 a (FIG. 11 ( a )). The resist is patterned microlithographically with the desired reticle pattern. The resist is cured and baked to form an etching mask 161 (FIG. 11 ( b )). The reticle blank is etched according to the etching mask 161 to produce a stencil reticle 121 (FIG. 11 ( c )).
The process described above is a so-called “back-etch preceding process” in which the stencil-reticle pattern is formed in the reticle membrane after completing formation of the reticle blank, an alternative process that can be used is the so-called “back-etch successive process” in which the stencil-reticle pattern is formed in the membrane before completing formation of the reticle blank. I.e., in the back-etch successive process, the silicon base layer is etched after the reticle pattern is formed on the silicon layer 113 .
The stencil reticle 121 of FIG. 11 ( c ) is attached to a peripheral frame 162 by eutectic or anodic welding, use of an adhesive, or use of mechanical fasteners. The peripheral frame 162 is attached to the outer supporting part 117 (FIG. 11 ( d )). The peripheral frame 162 desirably is made separately, before attachment to the outer supporting part 117 , from a unit of silicon, glass, or ceramic. The peripheral frame 162 desirably has an inside diameter that is smaller than the outside diameter of the outer supporting part 117 and larger than the inside diameter of the outer supporting part 117 , and an outside diameter that is larger than the outside diameter of the outer supporting part 117 . The peripheral frame 162 has a thickness desirably in the range of 5 to 10 mm (the thickness is a function of the radius of the peripheral frame 162 ). The profile of the inside diameter of the peripheral frame 162 is not limited to circular; for example, it alternatively can be polygonal.
Eutectic bonding of the peripheral frame 162 to the outer supporting part 117 is performed as follows: A gold layer (having a thickness of 200 to 500 nm) is layered in a predetermined region(s) on the peripheral frame 162 that will be bonded to the outer supporting part 117 . The gold layer can be formed by a conventional vacuum evaporation technique. Desirably, the surface of the peripheral frame 162 on which the gold layer is formed is mirror-polished (before applying the gold layer) to achieve maximal adhesion. Gold-silicon eutectic bonds are formed by heating in an electric furnace at a temperature of 400° C. for 5 hours.
The gold-silicon eutectic bond need not be formed entirely around the periphery of the outer supporting part 117 . Alternatively, eutectic “spot welds” can be formed, each having an area of several square millimeters. Spot welds can be formed by forming a ring-shaped gold layer, as described above, and then partially removing portions of the gold layer by etching or the like. Alternatively, the gold can be applied selectively to desired locations using a mask or the like. The number of spot welds and the area of each spot weld are determined by the warp tolerance of the reticle and the desired strength of the welds. After forming the gold spots, the peripheral frame 162 and outer supporting part 17 are brought into contact with each other and heated, such as in an electric furnace at 400° C. for 5 hours.
The reticle pattern can be formed in the reticle membrane after attaching the peripheral frame 162 .
Wire-connecting pads 163 made of an electrically conductive material (e.g., gold) can be applied to the peripheral frame 162 before or after the peripheral frame 162 is bonded to the outer supporting part 117 . The wire-connecting pads 163 are used for connecting respective wires 164 connected to respective conductive regions 114 ( 1 )- 114 ( 12 ) via respective wire-connecting pads 165 . For example, a wire 164 ( 1 ) connects the wire-connecting pad 163 ( 1 ) to a corresponding wire-connecting pad 165 ( 1 ) associated with the conductive region 114 ( 1 ), as shown in FIG. 11 ( d ). Because the conductive regions 114 ( 1 )- 114 ( 12 ) are doped silicon, wire connections as described above facilitate electrical energization of the respective conductive regions.
FOURTH REPRESENTATIVE EMBODIMENT
An electron-beam microlithography apparatus 140 according to this embodiment is shown in FIG. 12 . The apparatus 140 comprises an illumination-optical system 141 that directs an electron beam (“illumination beam” 151 ) from an electron gun (not shown) to a reticle 142 a . The apparatus also comprises a reticle stage 142 for holding the reticle as described above. Downstream of the reticle stage 142 are a projection-optical system 143 and a substrate stage 144 for holding a suitable substrate 144 a (e.g., semiconductor wafer) for exposure with the pattern defined on the reticle 142 a . The projection-optical system 143 receives portions of the illumination beam (i.e., a “patterned beam” 152 ) passing through the illuminated region of the reticle and focuses the beam (beam 153 ) on a corresponding region of the substrate 144 a.
Any warp of the reticle 142 a (i.e., warp of pattern elements defined by the reticle) can be measured at time of using the reticle in the microlithography apparatus 140 . Warp can be measured using, for example, a Nikon optical-wave-coherence-type coordinate-measuring tool.
After measuring reticle warp, the reticle is mounted on the reticle stage 142 . If any warp was detected, selective energization of the conductive regions 114 is made (FIGS. 8 ( a )- 8 ( j )) as required to achieve countervailing motion of the reticle, thereby canceling the warp. The necessary electrical connections to the reticle are made via connectors provided in the reticle stage. The connectors in the reticle stage are connected to a power source (FIG. 12) that is connected to a processor (e.g., the central processor of the microlithography apparatus). The processor supplies appropriate commands to the power source, based on warp-data input to the processor. The processor calculates voltages necessary to cancel the deformation of the reticle. Warp correction can be made in this manner within a tolerance of 5 nm to 20 nm.
After making the warp correction, the illumination beam 151 passing through the illumination-optical system 141 is directed at the reticle mounted on the reticle stage 142 . The resulting patterned beam 152 is directed to the substrate by the projection-optical system 143 .
The substrate can be a silicon wafer, for example, coated with a suitable resist that can be exposed in an image-forming way by the patterned beam 153 . The substrate typically is imaged multiple times with different patterns (with intervening process steps) to form a many-layered semiconductor device on the wafer.
FIFTH REPRESENTATIVE EMBODIMENT
FIG. 13 is a flowchart of an exemplary semiconductor fabrication method to which reticles according to the invention readily can be applied. The fabrication method generally comprises the main steps of wafer production (wafer preparation), reticle production (reticle preparation), wafer processing, device assembly, and inspection. Each step usually comprises several sub-steps.
Among the main steps, wafer processing is key to achieving the smallest feature sizes (critical dimensions) and best inter-layer registration. In the wafer-processing step, multiple circuit patterns are successively layered atop one another on the wafer, wherein the formation of each layer typically involves multiple sub-steps. Usually, many operative semiconductor devices are produced on each wafer.
Typical wafer-processing steps include: (1) thin-film formation involving formation of a dielectric layer for electrical insulation or a metal layer for connecting wires; (2) microlithography to form a resist pattern for selective processing of the thin film or the substrate itself; (3) etching or analogous step to etch the thin film or substrate according to the resist pattern, or doping as required to implant ions or impurities into the thin film or substrate according to the resist pattern; (4) resist stripping to remove the resist from the wafer; and (5) chip inspection. Wafer processing is repeated as required (typically many times) to fabricate the desired semiconductor chips on the wafer.
FIG. 14 provides a flow chart of typical steps performed in microlithography, which is a principal step in wafer processing. The microlithography, step typically includes: (1) resist-coating step, wherein a suitable resist is coated on the wafer substrate (which can include a circuit element formed in a previous wafer-processing step); (2) exposure step, to expose the resist with the desired pattern; (3) resist-developing step, to develop the exposed resist; and (4) optional resist-annealing step, to enhance the durability of the resist pattern.
During microlithography, a charged-particle illumination beam is irradiated onto a reticle made according to the invention. The portion of the illumination beam passing through the irradiated region on the reticle (now termed the “patterned beam”) is projected on the substrate (wafer) by a projection-optical system, thereby exposing a corresponding region on the substrate. As discussed above, the reticle is divided into multiple subfields, and images of the subfields are formed on the substrate in such a way that the images are stitched together. The reticle is divided due to, inter alia, the difficulty of providing a projection-optical system having an optical field sufficiently large to expose an entire reticle pattern in one shot without excessive aberrations. Also as discussed above, the subfields on the reticle are separated from one another by support struts that add rigidity and strength to the reticle. To obtain an image of the entire pattern on the substrate, the reticle and substrate are synchronously moved relative to each other during exposure. Further details of this exposure scheme are set forth in Japanese Kôkai Patent Document No. Hei 9-283405.
Reticles and microlithographic methods according to the invention reduce the effects of reticle warp, thereby reducing semiconductor fabrication costs. Providing a reticle with support structures as described above can be performed at the same time as forming the support struts; hence, reticles according to the invention can be produced with no increase in reticle production time over conventional reticles.
In any event, reducing reticle warp also results in less pattern warp as projected onto the substrate. Certain embodiments within the scope of the invention permit reduction of reticle warp immediately before using the reticle for making a microlithographic exposure, allowing greater accuracy of pattern transfer.
Whereas the invention has been described in connection with multiple representative embodiments, it will be apparent that the invention is not limited to those embodiments. On the contrary, the invention is intended to encompass all modifications, alternatives, and equivalents as may be included within the spirit and scope of the invention, as defined by the appended claims. | Reticles and reticle blanks are disclosed for performing charged-particle-beam (CPB) microlithography. The reticles typically include a rigid peripheral frame attached to a reticle portion. Such attachment can cause warping, and thus deformation, of the reticle portion. To reduce such warp, the reticle portion comprises an inner supporting part (surrounding a pattern-defining region) surrounded by an outer supporting part. Situated between the inner and outer supporting parts are multiple connecting structures. The connecting structures can have spring characteristics that collectively absorb warp. Alternatively, the connecting structures can include respective driving mechanisms. The driving mechanisms are especially adapted to cause, when electrically activated, local electrostatic attraction between a respective first conductive region (located on the outer supporting part) and a respective second conductive region (located on the inner supporting part). Selective energization of the connecting structures causes micro movement of inner supporting part (and thus the pattern-defining region) relative to the outer supporting part, thereby canceling reticle warp. | 7 |
FIELD OF THE INVENTION
This invention relates to a closed loop incineration process which can utilize any type of incineration means for disposing of hazardous, as well as non-hazardous, burnable waste. Such waste include toxic combustible liquids, oil slurries, soils contaminated with dioxin, PCBs, creosote, or any other potentially harmful or toxic combustible material. In particular, the present invention relates to an incineration process which has no continuous stack discharge of pollutants. In this process, a portion of the flue gas stream is enriched with oxygen and recycled to the incineration means. The remaining portion of the flue gas stream is scrubbed to remove acid gases and, if necessary, passed through a purification zone wherein any remaining contaminates ar removed.
BACKGROUND OF THE INVENTION
The disposal of hazardous waste is increasingly becoming a serious problem to industry as governmental regulations become tighter and tighter. Two leading technologies for disposing of hazardous waste are landfills and incineration. While the industry has historically preferred landfills over incineration, primarily because of cost, incineration is becoming more attractive. One reason for this is because governmental regulations regarding landfills are getting tougher. For example, in 1989 a new extended list of chemical streams banned from landfills went into effect. As industry turns toward incineration as the primary means of disposing of hazardous waste, they are also being faced with tougher and tougher incineration restrictions. For example, the destruction and removal efficiency (DRE) ratings for incineration are presently set at 99.99% for most hazardous waste, and 99.9999% for polychlorinated biphenyls (PCBs).
This has created a substantial problem for industry. For example, in the petrochemical and oil producing states, the problem of cleaning up contaminated sites and waste-oil pits are already of paramount importance, and is becoming even more acute. The quantity of waste oil contamination at oil field drilling sites has become a problem of great magnitude. The necessity of hauling the accumulated contaminated material from wide spread areas of contamination to a central decontamination site aggravates the problem considerably. Likewise, the problem of cleaning up abandoned petrochemical sites is even more severe.
The problem is particularly intense in the burning of hazardous waste. This is because not only must the waste be rapidly disposed of before harm is done to the environment, but additionally, the destruction of any potentially toxic chemicals must be sufficiently complete so that the gases which evolve therefrom are non-hazardous. To completely decompose such chemicals, relatively highly efficient and high temperature combustion is needed to lower the cost of incineration, which is typically expensive.
The discharge stack emissions from incineration are typically an important concern for several reasons. One reason is that the public views stack emission plumes with suspicion, and sometimes justifiable fears, that the incinerator operator is discharging hazardous, or toxic, gases into the atmosphere. Another reason is that federal and state authorities have regulations governing stack emissions with regular monitoring, testing, and validation to insure that prescribed emission limits are not being exceeded.
Therefore, there is a substantial need in the art for improved incineration processes which are able to meet the present destruction and removal efficiency requirements, as well as requirements in the foreseen future.
OBJECTIVES
An object of the present invention is to provide an improved incineration process which does not have the conventional discharge stack emissions with the potential for emitting pollutants into the atmosphere.
A specific object of the present invention is to provide an improved incineration process in which all of the flue gases from the incinerator are compressed and a portion is recycled to the combustion zone and another portion is purified and can be used as a substitute for plant air. That is, it can be used for such things as: a carrier, or diluent, to the incineration, or combustion, means; an inert gas for the blanketing of tanks of combustibles; an atomizing gas for any hazardous liquid or liquid fuel burned in the incineration means; an atomizing gas for the water sprays in the scrubbing/cooling zones; process plant air; instrument air; and/or for the manufacture of chemicals, such as fertilizers.
A further object of the present invention is to provide a flue gas purification system in which any trace components of potentially harmful chemical vapors are removed from the flue gases.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided an improved process for combusting waste materials so that substantially no contaminants are released into the environment. The process comprises:
(a) feeding combustible waste material into a first combustion zone where they are combusted at a temperature from about 1400° F. to about 2200° F.;
(b) passing the resulting flue gases from said first combustion zone to a second combustion zone where they are further combusted at a temperature from 1800° F. to about 2500° F.;
(c) passing the resulting flue gases from said second combustion zone to a cooling zone where it is contacted with an aqueous solution or slurry of acid and/or alkaline salts from a downstream scrubbing zone and cooled by at least 1000° F. with the formation of dry acid salts;
(d) passing the flue gases/salts mixture from said cooling zone to a gas/solids separation zone, where the solid salt material is separated and collected from said flue gases;
(e) recycling a portion of the flue gases, and added oxygen, to said first combustion zone and/or second combustion zone; and
(f) passing the remaining portion of said flue gases to a wet gas scrubbing zone, containing an aqueous alkaline solutionry or slurry, wherein acid gases are removed.
In a preferred embodiment of the present invention, the combustible waste material is a hazardous material and the flue gases from the wet scrubbing zone are passed to a purification zone containing a purifier substance selected from the group consisting of an aqueous alkaline solution or slurry, and activated carbon, wherein any remaining acid gases, and any other contaminants, such as hydrocarbon gas and sulfur compounds, are removed.
In another preferred embodiment of the present invention, the flue gases from the first combustion zone are passed to a gas/solids separation zone, preferably a cyclone separator, before entering the second combustion zone.
In yet another preferred embodiment of the present invention, the flue gases which are recycled from step (e) are compressed and oxygen added to bring the oxygen content up to at least 20 vol. %. Any liquid fraction is passed to the wet gas scrubbing zone.
BRIEF DESCRIPTION OF THE FIGURE
The sole FIGURE hereof is a simplified flow diagram of a preferred embodiment of the incineration process of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Any combustible hazardous and non-hazardous material may be incinerated by the practice of the present invention. Non-limiting examples of such materials include toxic combustible liquids, oil slurries, soils contaminated with dioxin, creosote, PCBs, and any other potentially toxic combustible material, preferably those which are potentially hazardous.
The present invention can be best understood by reference to the sole figure hereof. Combustible waste material is fed via 10 into first combustion zone 1. The combustion zone is maintained at a temperature from about 1400° F. to about 2200° F., preferably from about 1700° F. to about 2100° F., more preferably about 1900° F. to about 2100° F. A suitable fuel is also fed to the first combustion zone via line 12. Any suitable fuel can be used which is capable of maintaining said combustion temperatures. Non-limiting examples of such suitable fuels include natural gas, fuel oil, hazardous waste(preferably liquid), and coal. Ash is removed from first combustion zone 1 via line 14. Flue gases from this first combustion zone are passed via line 16 to second combustion zone 2. It is understood that the flue gases from the first combustion zone may be passed through a cyclone separator prior to entering the second combustion zone. The cyclone separator may be any conventional cyclone separator used to separate particulate matter at the temperatures of the flue gases. The cyclone separator can be a single cyclone or a multi-cyclone system. Combustion temperatures of this second combustion zone are maintained at a temperature from about 1800° F. to about 2500° F., preferably from about 1900° F. to about 2300° F., and more preferably at temperatures in excess of 2000° F. It is also preferred that the second combustion zone be operated at a temperature in excess of 100° F., preferably 200° F., and more preferably 300° F. than that of said first combustion zone.
Additional combustible waste material may be introduced into said second combustion zone via line 18, with fuel and/or hazardous waste, being introduced via line 20. The flue gases from said second combustion zone 2 are passed via line 22 to cooling zone 3 and are cooled by at least 1000° F., preferably to a temperature of about 400° F. to 600° F., more preferably to about 450° F. to 550° F. This cooling zone also acts as a drying zone wherein an aqueous solution or slurry of acid and/or alkaline salts from the downstream wet gas scrubbing zone is atomized, or spray dried, into said cooling zone.
The flue gases from cooling zone 3 are passed via line 24 to solids separation zone 4 wherein particulate material is separated from said flue gases and collected via line 25. This separation zone can be a so-called "bag-house" wherein particulate material is separated from the flue gases and collected in drums for disposal. It can also be a series of solids cyclone separators. The remaining flue gases are passed from separation zone 4 via line 26 and split into two portions. One portion is enriched with oxygen and routed via line 28, for recycling to the first and/or second combustion zones and the other portion is sent to further purification which includes first sending it to a wet gas scrubbing zone 6. The flue gases which are recycled to the combustion zones can be further split at the combustion zones to provide a primary oxygen enriched stream and a secondary oxygen enriched stream 29. The secondary oxygen enriched stream will of course be fed downstream in the combustion zone(s) from the primary oxygen enriched stream.
If the solids separation zone 4 was comprised of a series of cyclones instead of a bag-house, then the portion of flue gases being passed to the wet gas scrubbing zone 6 can be passed to a bag-house prior to entering the wet gas scrubbing zone. The portions of the flue gases which are split will depend on such things as water balance in the system. The precise split is within the skill of those in the art and will not be further elaborated on herein. Generally, the portion of the flue gases directed to the wet gas scrubbing zone versus the portion recycled to the combustion zones is about 1 to 1, preferably about 1 to 2, and more preferably about 1 to 3.
It is preferred that before a portion of the flue gases is recycled it first passed through a blower, or compressor 30 to provide enough compressing action to keep the pressure of the stream within an acceptable range. That is, to provide enough pressure for it to return to the combustion zones and to keep the water in vapor form. It is also preferred that it pass through a zone wherein oxygen is added. Such a zone will preferably be a synthetic air generation zone 5 wherein oxygen is added to provide an oxygen level of 20 vol. %, preferably at least 25 vol. %. Higher levels of oxygen, for example up to about 40 vol. %, or more, may also be beneficial for improved burning of certain toxic wastes. While a synthetic air generation means is preferred, it is understood that any suitable means for incorporating oxygen into the flue gas stream can be used. The synthetic air generator may also be of a cyclone design to facilitate mixing and condensate removal. Any liquid fraction separated in the synthetic air generation zone 5 can be passed via line 32 to wet gas scrubbing zone 6. The liquid fraction can also be discarded via line 31. A heat exchanger 33 may also be provided in line 28 after the synthetic air generation zone 5 in order to help insure that any water in the stream is maintained as steam, or vapor, and not as liquid water. This will help prevent corrosion.
It may be desirable to increase the oxygen content of the first combustion zone past the 40 vol. % level. For example from about 40 vol. % to 80 vol. %, preferably from about 60 vol. % to 80 vol. %, when combusting waste having a relatively low heating value, such as contaminated soil. In such a case, a source of oxygen can be provided for the first combustion zone, preferably introduced into the recycle flue gas stream feeding into the combustion zone. The preferred source of oxygen will be a synthetic air generator as previously discussed for adding oxygen into line 28, and which is shown by dashed lines as an optional piece of equipment 8.
The other portion of the flue gases from separation zone 4 is passed to a wet gas scrubbing zone 6 wherein acid gases, and any remaining particulate material, are removed. The wet gas scrubbing zone will typically contain an aqueous alkaline material, such as sodium hydroxide, sodium carbonate, calcium hydroxide, potassium carbonate, and the like. Precipitated acid salts from the wet gas scrubbing zone are sent to the cooling zone 3 via line 27, preferably as an aqueous solution or slurry, and fresh alkaline material is introduced to maintain a steady state. At least a portion of the alkaline material may come from another scrubbing zone, which is downstream of scrubbing zone 6. The scrubbed flue gases can then either be released into the atmosphere if clean via discharge stack 37, or they can be sent for further purification. If sent for further purification, they are first compressed by a compressor (not shown) and cooled via cooler 36, preferably by the use of an oxygen feed to the synthetic air generator(s). Any liquid fraction, usually water, remaining after the compressor following the wet gas scrubbing zone can be discarded, collected, or recycled to the wet gas scrubbing zone via line 34. Any water obtained during the cooling step can be collected or a portion collected and another portion recycled to the wet gas scrubbing zone via line 35.
If contaminants or pollutants are still present, the flue gas stream from the wet gas scrubbing zone is passed to a purification zone 7. Depending on the nature of the pollutants which remain in the flue gases, the purification zone 7 may contain one or more stages. It is preferred for the types of flue gases and pollutants encountered in the incineration of hazardous waste material that the following stages be provided: (a) a stage for removing CO and other light gases, such as hydrocarbon gases, which stage is represented by a vessel comprised of an absorbent material, such as an aqueous cuprous chloride solution, or an organic solvent, preferably a C 1 to C 4 alcohol, preferably ethanol; (b) a stage for removing acid gases and halides such as Cl 2 , F 2 , etc., and any remaining particulate material, which zone is preferably operated by passing the flue gases through an aqueous alkaline solution or slurry; and (c) a stage for removing any residual hydrocarbon gases and sulfur impurities, which zone can be represented by a bed of activated carbon. If necessary, an additional zone may be employed which can be comprised of an organic solvent treatment for removing any residual CO and organic gases. The organic solvent may also be a fuel source for the combustion zones, which fuel is sent to the combustion zones after absorbing the desired level of contaminants. While it is preferred that the sequence of stages be as set forth above, it is to be understood that any appropriate sequence may be used.
The above described stages can be regenerated by any appropriate means, which means are well known in the art. For example, if a stage is used employing an aqueous cuprous chloride solution, it can be regenerated by heating the spent cuprous chloride to release CO. The released CO can be sent to the combustion zones. The alkaline scrubbing zone can be comprised of any appropriate solution or slurry for scrubbing acid gases. Non-limiting examples of suitable solutions or slurries include aqueous alkaline materials as well as alkanolamines, such as monoethanolamine. Preferred aqueous alkaline solutions include sodium hydroxide solutions, sodium carbonate solutions, calcium hydroxide solutions and slurries, and potassium carbonate solutions. Preferred are sodium hydroxide solutions and calcium hydroxide solutions and slurries. Of course, such an alkaline stage is typically operated by removing precipitated salts and maintaining steady state conditions by adding fresh alkaline scrubbing solution or slurry.
Discharge via line 39, from purification zone 7, is a purified gaseous stream which can be used as a substitute for plant air. That is, it can be used for such things as: a carrier, or diluent, to the incineration, or combustion, means; an inert gas for the blanketing of tanks of combustibles; an atomizing gas for any hazardous liquid or liquid fuel burned in the incineration means; an atomizing gas for the water sprays in the scrubbing/cooling zones; process plant air; instrument air; and/or for the manufacture of chemicals, such as fertilizers. | An incineration process which can utilize any type of incineration means for disposing of hazardous, as well as non-hazardous, burnable waste. Such waste include toxic combustible liquids, oil slurries, soils contaminated with dioxin, PCBs, creosote, or any other potentially toxic combustible material. In particular, the present invention relates to an incineration process which has no continuous stack discharge or pollution. In this process, a portion of the flue gas stream is enriched with oxygen and recycled to the incineration means. The remaining portion of the flue gas stream is scrubbed to remove acid gases and passed through a purification zone wherein any remaining contaminates are removed. | 5 |
The present application relates to U.S. Provisional Patent Application Ser. No. 61/517,613 filed on Apr. 21, 2011 and claims priority therefrom.
The present application was not subject to federal research and/or development funding.
TECHNICAL FIELD
Generally, the invention relates to a method and machine for dewatering paper webs. More specifically, the invention is a process and machine which produces paper having more uniform fiber orientation, sheet structure and improved paper strength characteristics. The improved method and machine includes devices that are arranged in the forming or wet section of a Fourdrinier machine, hereinafter referred to as “Fourdrinier.” The devices are adjusted manually or through a computer and associated drive mechanisms.
An improved method of forming paper using a Fourdrinier is composed of a plurality of foil and vacuum assisted drainage elements that are equipped with on-the-run adjustable angle and/or height dewatering foil blades starting from a paper dryness of 0.1% and extending all the way to 5% dryness within the forming section of a Fourdrinier. The foil blade angle, height, and vacuum level are adjusted as applicable along the entire length of the Fourdrinier dewatering table until a paper dryness of 5% is achieved. These adjustments allow for control of the dewatering rate and turbulence (shear) produced from a paper dryness of 0.1% to 5% on the Fourdrinier dewatering table. Controlling drainage and shear along this entire range of dryness has a direct influence on paper fiber orientation. This has a significant influence on paper strength.
The claimed invention works in unison with the paper machine headbox shear forces to promote maximum fiber orientation in either the cross-machine or machine direction orientation of the paper. The headbox controls fiber orientation through a speed difference between its stock jet speed and the dewatering fabric speed. Once the stock jet lands on the dewatering fabric, it is operated at an overspeed compared to the dewatering fabric “rush” or the same speed “square” or an underspeed “drag” to control the orientation of the fibers during the sheet forming process. Operating the headbox in a rush or drag mode will align fibers in the machine direction which is beneficial for machine direction related strength properties in the finished paper product. Operating in a square mode will produce a maximum cross-machine direction fiber orientation of the fibers in the finished paper product which is beneficial for paper strength properties in the cross-machine direction.
The claimed invention provides control of drainage and turbulence anisoptropic shear after the headbox stock jet lands on the dewatering fabric. After the stock lands, the claimed invention is adjusted to preserve or amplify the fiber orientation characteristics produced by the headbox. In this manner, a higher quality of paper is produced with the instant process and machine. Moreover, existing machines may be retrofitted with various devices and operated in the manner disclosed herein to achieve a superior quality of paper stock.
For example, if machine direction fiber orientation is desired, the headbox jet speed is operated in a rush or drag mode to promote an initial strong machine direction alignment of the paper fibers. From here, the foil blade angles and height, along with the vacuum levels on the vacuum assisted dewatering units are adjusted to produce a high early drainage rate in the initial sheet dewatering zone (0.1% to 2% paper dryness) to immediately freeze the machine direction fiber orientation produced by the headbox. In addition to this, the foil blade angles, heights and vacuum levels are also adjusted to produce a high amount of turbulence in this paper dryness zone (0.1% to 2%). This keeps the fibers mobile and prevents entanglement allowing the headbox shear to become more effective in orientating fibers in the machine direction. After 2% paper dryness, the angle and height and vacuum levels are adjusted to gradually achieve a paper dryness of 5%. However, the foil angle and height are adjusted to achieve only moderate turbulence levels to prevent disruption of the machine direction fiber orientation achieved earlier in the sheet dewatering and forming process.
For cross-machine direction fiber alignment, the process is completely reversed. The headbox stock jet is adjusted to produce a speed difference close to zero (square mode) to promote the highest possible cross-machine direction fiber orientation. However, due to contraction created within the headbox nozzle, a certain unavoidable degree of machine direction fiber alignment is still always present in the fiber slurry when it lands on the dewatering fabric that cannot be reversed through normal Fourdrinier dewatering equipment. To break this natural machine direction fiber orientation up and produce the most random fiber orientation and highest amount of cross-machine direction fiber orientation, the claimed invention is operated as follows. First, the foil blade angles and heights along with the vacuum levels of the vacuum assisted dewatering elements are adjusted to significantly retard drainage in the early sheet forming zone (0.1% to 2% dryness). This is completely opposite of the previously described process for machine direction fiber orientation. In addition to this, the angle and height of the foil blades are adjusted to produce a very high degree of turbulence to prevent fiber entanglement and generate the most random fiber orientation possible for the highest level of cross-machine direction fiber alignment. After a dryness of 2% is achieved, the foil angle and height is adjusted to maintain this high level of turbulence all the way until a paper dryness of 5% is achieved. A very gentle early drainage along with high turbulence all the way until a dryness of 5% will create the most random fiber network resulting in the highest amount of cross-machine direction fiber alignment.
The ability of the claimed process and machine improvement to be adjusted in conjunction with shear significantly increases paper sheet strength properties such as Mullen, Burst. Bending Stiffness, or Concora (machine direction strength properties) and Ring Crush, S.T.F.I, SCT (cross machine direction strength properties) and all other strength properties associated with paper manufacturing.
In addition to this, the claimed invention and sheet forming process also improves other paper properties such as formation, smoothness, uniformity, printability, ply bond strength, and the like.
BACKGROUND OF THE INVENTION
The forming or wet section of a Fourdrinier consists mainly of the head box and forming wire. Its main purpose is to generate consistent slurry, or paper pulp, for the forming wire. Several foil, suction boxes, a couch roll, and a breast roll commonly make up the rest of the forming section. The press section and dryer section follow the forming section to further remove water from the stock.
Historically, the main tools used to control paper strength have been fiber species and fiber refining energy along with the orientating shear generated by the speed difference between the headbox jet speed and the dewatering (forming) fabric speed. The first method of continuous sheet forming and dewatering was the Fourdrinier dewatering table which is still the dominant tool used for paper manufacturing today. Since the time of its invention, its impact on sheet strength has been misunderstood or vaguely understood. Also, the ability to directly influence sheet strength through changing the drainage or shear rates produced during the Fourdrinier dewatering and forming process have also been misunderstood. Past technologies such as the VID, Deltaflo or Vibrefoil have been able to adjust drainage and turbulence on the Fourdrinier table. However, these technologies have been used prior to a sheet consistency on the Fourdrinier table of 1.5% or less. The impetus behind their design was simply to generate turbulence in a very short area in an effort to improve paper uniformity (formation) which was claimed to influence sheet strength.
It has been discovered through the use of the claimed improved Fourdrinier papermaking process that controlling drainage and turbulence from a paper dryness of 0.1% to 5% on a dewatering table has a far more significant impact of fiber orientation and paper strength. In addition, the previously described methods of adjusting the headbox shear in conjunction with adjusting drainage and turbulence in this zone to control fiber orientation and paper strength up to this point been has been unknown to anyone other than the inventors of the claimed improved process.
BRIEF SUMMARY OF THE INVENTION
An improved process of Fourdrinier papermaking is used for dewatering and paper quality control and achieved in the forming end of the Fourdrinier. The process uses a plurality of gravity and vacuum assisted drainage elements that are equipped with on-the-run adjustable angle and height dewatering foil blades starting from a paper dryness of 0.1% and extending all the way to 5% dryness. The foil blade angles and heights along with vacuum level are adjusted manually or automatically along the entire length of the Fourdrinier dewatering table until paper dryness of 5% is achieved.
The claimed invention uses a series of gravity assisted drainage elements in the beginning of the Fourdrinier dewatering table. These units are the forming board and hydrofoil section that are equipped with a combination of static and adjustable angle foil blades, as well as foil blades which are height adjustable depending on the paper grade being produced. A low-vacuum section is arranged on the dewatering table after the hydrofoil section. The low-vacuum section includes vacuum assisted drainage elements which are equipped with vacuum control valves, fixed angle and angle adjustable foil blades, as well as foil blades which are height adjustable depending on the paper grade being produced. A high-vacuum section is arranged between the low-vacuum section and a couch roll.
Adjusting the angle and height of the dewatering foil blades along with the vacuum level allows for control of the dewatering rate and turbulence (shear) produced from a paper dryness of 0.1% to 5% on the Fourdrinier dewatering table. Controlling drainage and shear along this entire range of dryness in conjunction with fiber orientation shear produced by the headbox has a direct influence on paper fiber orientation. This has a significant influence on paper strength.
Adjustable dewatering technologies are typically used on the Fourdrinier table in an area directly after the forming board or within a short distance of the forming board and dry the stock to a dryness content of 3.5%. Previously, the design and operation of a Fourdrinier has been focused on fiber orientation control to improve sheet strength.
Other technologies such as the dandy roll or top dewatering machines have been used at a dryness content of 1.5% or greater. However, their purpose has simply been water removal or paper formation improvement, not fiber orientation control liked the claimed invention. Moreover, none of the existing technologies are directed towards precisely controlling fiber orientation as in the disclosed manner.
It is an object of the invention to disclose an improved process for controlling the fiber orientation of paper stock to achieve a better quality paper than is currently produced on a Fourdrinier.
It is a further object of the invention to teach a Fourdrinier having adjustable on-the-run mechanisms for adjusting the height and angle of foils or blades to easily switch over operation of the Fourdrinier to produce paper of higher quality through controlling the orientation of the fibers.
Additional objects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned from practicing the invention. The objects and advantages of the invention will be obtained by means of instrumentalities in combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
Other objects and purposes of this invention will be apparent to person acquainted with apparatus of this general type upon reading the following specification and inspecting the accompanying drawings, in which:
FIG. 1 illustrates a Fourdrinier papermaking machine incorporating the present invention therein.
FIG. 2 is an enlarged view showing a formline element with stationary and adjustable height foil blades and which forms part of the forming board section of the Fourdrinier.
FIG. 3 shows a Hydroline element with adjustable angle and height foil blades and which forms part of the hydrofoil section of the Fourdrinier.
FIG. 4 shows a Varioline element with stationary and adjustable height foil units and being part of the low-vacuum section.
FIG. 5 shows a Vaculine element with stationary and angle adjustable foil blades and being part of the low-vacuum section.
FIG. 6A shows a detailed view of an adjustable angle foil blade mounted on a C-channel and with the leading edge of the angle adjustable blade raised to +1°. FIG. 6B shows the blade of FIG. 6A having a −3° separation from an underside of the forming fabric. FIG. 6C shows a detailed view of an adjustable height foil blade mounted on a T-bar and with the leading edge of the angle adjustable blade raised to +1°. FIG. 6D shows the blade of FIG. 6C having a −3° separation from an underside of the forming fabric.
FIG. 7A shows a detailed view of an adjustable height activity blade mounted on a C-channel and with the height being at 0 mm where it is in contact with the underside of the forming fabric. FIG. 7B shows the blade of FIG. 7A at a −5 mm height below the forming fabric. FIG. 7C shows a detailed view of an adjustable height blade mounted on a T-bar and with the height being at 0 mm where it is in contact with the underside of the forming fabric. FIG. 7D shows the blade of FIG. 7C at a −5 mm height below the forming fabric.
FIG. 8A shows a control subassembly for an angle adjustable blade taken from an end of the Fourdrinier. FIG. 8B shows a cutaway view of the drive that is actuated to adjust the angle of a respective blade.
FIG. 9A shows a control subassembly for the height adjustable blade taken from an end of the Fourdrinier. FIG. 9B shows a cutaway view of the drive that is actuated to adjust the height of a respective blade.
DETAILED DESCRIPTION OF THE INVENTION
The embodiments of the invention and the various features and advantageous details thereof are more fully explained with reference to the non-limiting embodiments and examples that are described and/or illustrated in the accompanying drawings and set forth in the following description. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale, and the features of one embodiment may be employed with the other embodiments as the skilled artisan recognizes, even if not explicitly stated herein. Descriptions of well-known components and techniques may be omitted to avoid obscuring the invention. The examples used herein are intended merely to facilitate an understanding of ways in which the invention may be practiced and to further enable those skilled in the art to practice the invention. Accordingly, the examples and embodiments set forth herein should not be construed as limiting the scope of the invention, which is defined by the appended claims. Moreover, it is noted that like reference numerals represent similar parts throughout the several views of the drawings.
For illustrative purposes only, the invention will be described in conjunction with a Fourdrinier papermaking machine although the invention and concept could also be applied to hybrid and gap formers. The invention is implemented in the wet section of the Fourdrinier and includes a forming board section 10 , a hydrofoil section 20 , and a low-vacuum section 30 . High-vacuum section 40 does not include automatically adjustable height blades or automatically angle adjustable blades. It should be noted that a headbox is known and is therefore not shown in FIG. 1 . Referring now to FIG. 1 , a Fourdrinier comprises a forming fabric 105 , a breast roll 106 and couch roll 107 . The forming fabric is continuous and travels between the breast and couch rolls 106 , 107 . The stock which comprises pulp fibers is deposited from the headbox to the top surface of the forming fabric 105 at a paper dryness ranging from 0.1% to 1%. Immediately following the headbox, the forming fabric passes over a forming board section 10 which comprises a formline element 11 .
As shown in FIGS. 1 and 2 , the forming board section 10 includes formline element 11 which includes a fixed ceramic lead blade 12 and a plurality of trailing blades 13 , 14 . The blades 13 , 14 are arranged beneath the forming fabric or wire and are fixed atop either stationary or adjustable C-bar or T-bar which extend from one side of the Fourdrinier to the other. The support bars preferably comprise fiber reinforced composite. The stationary bars are fixed. In the preferred embodiment, the formline element 11 includes three adjustable trailing blades 13 which may be raised and lowered or the angle adjusted as shown in the respective figures with the use of respective drive 17 A. The drives are arranged at opposite ends of a support bar and fixed. The drives arranged at opposite ends of the support bar operate in concert to lower or raise a respective blade. It should be noted that the air, hydraulic and electrical lines for actuating the drives are not shown for ease in understanding the drawings. It should be understood that it is contemplated that various other drives, pistons or motors including electric and hydraulic ones and their associated supply lines may be employed to practice the invention. The adjustable blades 13 are raised or lowered to cause them to intersect the underside of the forming fabric 105 at a predetermined height to influence the alignment of the fibers within the paper web. Two fixed trailing blades 14 are arranged between the height adjustable blades 13 , as shown. In a preferred embodiment, the height of the adjustable blades may be changed to ensure that the paper fibers are aligned in a desired direction. The forming board lead blade 12 is arranged near the breast roll and is stationary. A plurality of forming board trailing blades is arranged in an alternating sequence of adjustable height blades 13 and stationary blades 14 . The forming board trailing blades preferably comprise ceramic.
During this stage, some water is drained from the stock and a very thin wet sheet is carried over to various other dewatering devices such as foil blades in hydrofoil section 20 , until a sheet paper dryness of around 1% to 1.5% is achieved. Following this, the paper dryness is increased by the foil blades in the Varioline and Vaculine in the low vacuum section 20 to a dryness level of 5%. Next, a paper dryness of 8% to 10% is achieved in the elements of the low-vacuum section 30 and the sheet is transferred to the high-vacuum section 40 to achieve a paper dryness of 18% or greater. Finally, the sheet is transferred over the couch roll where additional dryness level is achieved.
A Fourdrinier composed of the previously described equipment is fitted with a plurality of adjustable angle and height foil blades starting from the forming board section 10 and partially through the low-vacuum section 30 . As the stock travels with the forming fabric 105 , it encounters the adjustable angle and height foil blades at various points along the dewatering table to manipulate the paper web and orient more fibers in a desired direction. On the forming board section 10 and the hydrofoil or gravity section 20 , the adjustable angle foil blades generate a vacuum pulse that dewaters the stock slurry. The amount of drainage produced along each adjustable angle foil blade is determined by the angle setting of the foil blade which can be typically varied between +2 and −4 degrees. A higher angle will produce more drainage.
Also within the forming board section and hydrofoil or gravity section of the papermaking process, the stock encounters adjustable height foil blades. These blades also drain water from the stock slurry. The amount of water drained by the adjustable height foil blades is determined by their height setting in relation to the forming fabric. At a setting of −5 mm, they do not touch the fabric and do not drain any water. At a setting of 0 mm, they are in the same plane as the forming fabric and will drain water. As the adjustable height foil blades are lowered from the fabric, the amount of drainage increases up until a point at which the static and dynamic vacuum forces generated by the adjustable height foil blade are overcome by the tension forces of the forming fabric. When this occurs, the fabric breaks its seal with the adjustable height foil blade and no dewatering occurs. The setting at which this occurs will vary based on the drainage characteristics of the stock, the stock consistency, and the speed of the forming fabric. As can be understood, changing the height settings will directly influence the fiber orientation.
The wet slurry will leave the hydrofoil section 20 at a consistency of around 1.5% depending on the paper grade and speed. From here, it travels to the initial vacuum assisted foil units in the low-vacuum section 30 which are referred to as the Varioline elements. In addition to natural gravity drainage, these Varioline elements also use a dynamic and an external vacuum source to create a vacuum which is drawn onto the lower side of the forming fabric 105 . This further increases drainage within these units. The Varioline elements are equipped with a plurality of stationary and adjustable height foil blades. Similar to the previous section, as the foil blades are lowered from the forming fabric, the drainage rate increases as discussed above.
Following the Varioline table elements, another set of vacuum assisted units is encountered by the underside of the forming fabric 105 . These table elements are the Vaculine elements which are equipped with adjustable angle foil blades. Again, as the angle of the foil blades is increased, the drainage rate will increase until a consistency of 5% is achieved.
In addition to controlling drainage, the adjustable angle and height foil blades in the previously described drainage units also control turbulence within the wet slurry. This is accomplished through deflection of the forming fabric from its original plane as it travels along the top surface of the adjustable angle foil blades and adjustable height foil blades. This deflection creates a series of accelerations within the stock slurry that results in turbulence and shear within the stock slurry. This turbulence keeps the fibers fluidized and mobile within the wet slurry so that they can be orientated in the cross-machine or machine direction, depending on what the finish paper property strength requirements are.
For example, if machine direction fiber orientation is desired, the headbox jet speed is operated in a rush or drag mode to promote an initial strong machine direction alignment of the paper fibers. From here, the foil blade angles and height, along with the vacuum levels on the vacuum assisted dewatering units are adjusted to produce a high early drainage rate in the initial sheet dewatering zone (0.1% to 2% paper dryness) to immediately freeze the machine direction fiber orientation produced by the headbox.
In addition to this, the foil blade angles, heights and vacuum levels are adjusted to produce a high amount of turbulence in this paper dryness zone (0.1% to 2%). This keeps the fibers from entangling with each other and allows the headbox shear to become more effective in orientating fibers in the machine direction. After 2% paper dryness, the angle and height and vacuum levels are adjusted to gradually achieve a paper dryness of 5%. However, the foil angle and height are adjusted to achieve only moderate turbulence levels to prevent disruption of the machine direction fiber orientation achieved earlier in the sheet dewatering and forming process.
For cross-machine direction fiber alignment, the process is completely reversed. The headbox stock jet is adjusted to produce a speed difference close to zero (square mode) to promote the highest possible cross-machine direction fiber orientation. However, due to friction created within the headbox nozzle, a certain unavoidable degree of machine direction fiber alignment is still always present in the fiber slurry when it lands on the dewatering fabric that cannot be reversed through normal fourdrinier dewatering equipment.
To break this natural machine direction fiber orientation up and produce the most random fiber orientation and highest amount of cross-machine direction fiber orientation, the claimed invention is operated as follows. First, the foil blade angles and heights along with the vacuum levels of the vacuum assisted dewatering elements are adjusted to significantly retard drainage in the early sheet forming zone (0.1% to 2% dryness). This is completely opposite of the previously described process. In addition to this, the angle height of the foil blades are adjusted to produce a very high degree of turbulence to prevent fiber entanglement and generate the most random fiber orientation possible for the highest level of cross-machine direction fiber alignment. After a dryness of 2% is achieved, the foil angle and height is adjusted to maintain this high level of turbulence all the way until a paper dryness of 5% is achieved. A very gentle early drainage along with high turbulence all the way until a dryness of 5% is achieved will create the most random fiber network resulting in the highest amount of cross-machine direction fiber alignment.
After passing through the forming board section, the paper stock is moved along to pass through a hydrofoil or gravity section 20 equipped with Hydroline elements 21 . Each Hydroline element 21 comprises height adjustable blades 13 and angle adjustable blades 22 which are alternately arranged as shown in FIG. 3 . Depending on the paper grade, Hydrolines may also be fixed with all height or angle adjustable blades. The angle adjustable blades are controlled through an angle adjustment mechanism 25 , 27 as shown in FIG. 8A . Height adjustable blades are controlled through a height adjustment mechanism 18 , 21 as shown in FIG. 9B .
FIG. 4 depicts a vacuum assisted unit or Varioline table element 51 with stationary or angle adjustable foil blades and adjustable height blades and being part of the low-vacuum section. The Varioline element 51 comprises a dewatering blade 32 followed by height adjustable blades 13 . A deckle is arranged blades and may comprise a poly material. A drop leg 34 extends down from the Varioline for draining purposes.
FIG. 5 shows a Vaculine element 41 that is part of the low-vacuum section 30 . Vaculine elements 41 are arranged downstream from the last Varioline element 51 . Each Vaculine element includes a fixed blade 14 arranged on stationary T-bar 55 at the front and back ends as shown. Adjustable angle blades 22 are arranged in the Vaculine element. Adjustable deckles are interposed between the fixed blades 14 and the adjustable angle blades 22 as shown. A drop leg 34 extends downward for draining purposes.
FIGS. 6A, 6B show a detailed view of an adjustable angle blade mounted on a C-channel. Blade 22 comprises a ceramic top 22 A having a yoke 22 B formed of fiberglass reinforced composite and having an offset front side as shown. The yoke 22 B is fitted atop an adjusting mechanism 25 . An underside of the angle adjusting mechanism 25 is secured within C-channel 76 via clamping bar 77 . Protective shield 79 is provided on the blade 22 to prevent items from being caught when the adjustment mechanism 25 is actuated. The C-channel is preferably formed from stainless steel and rests atop the frame of the Fourdrinier.
FIGS. 6C, 6D show a detailed view of an adjustable angle blade mounted on a T-bar. In this instance, the mounting means is a T-bar 55 instead of the C-channel and clamping bar of FIGS. 6A, 6B . The adjustment mechanism and remaining parts are the same and operate in similar fashion. The respective angles and their range are also the same.
FIGS. 7A, 7B show a detailed view of an adjustable height blade mounted on a C-channel. Height adjustable blade 13 includes an upper end having a leading and trailing edge of ceramic 13 A which is fixed in a yoke 138 preferably formed of fiberglass reinforced composite. A height adjustment mechanism 18 is arranged within the yoke 13 B. An underside of the height adjusting mechanism 18 is secured within C-channel 76 via clamping bar 77 . Protective shield 79 is provided on the blade 13 to prevent items from being caught when the height adjustment mechanism 18 is actuated. The C-channel is preferably formed from stainless steel and rests atop the frame of the Fourdrinier. The height adjustment mechanism 18 includes an adjustable T-bar 21 which extends across the Fourdrinier frame and onto which the blade 13 is attached as shown FIG. 9A . In this manner, the drive 17 A raises and lowers the T-bar 21 to adjust the height of the blade 13 in relation to an underside of the forming fabric 105 .
FIGS. 7C, 7D shows a detailed view of an adjustable height foil blade mounted on a T-bar. In this instance, the mounting means is a T-bar instead of the C-channel and clamping bar of FIGS. 7A, 7B . The adjustment mechanism is the same and operates in similar fashion. The respective heights and their range are also the same.
FIGS. 8A, 8B shows an angle adjustment mechanism 25 which is a control subassembly for an angle adjustable blade 22 . A rotating T-bar 27 is formed from fiber reinforced composite and is the same length as a substructure upon which it is mounted. The angle adjustment mechanism 25 is secured atop a C-channel. The drive 17 B is indexed to rotate blade 22 over the range of angles shown in FIGS. 6A-D . The blade 22 is attached to the top side of T-bar 27 which is arranged to rotate in a clockwise or counter clockwise direction. In this manner, the angle of the blade 22 relative to the underside of the forming fabric is controlled.
FIGS. 9A, 9B shows a height adjustment mechanism 78 which is a control subassembly for the height adjustable blade 13 . Blade 13 rests atop a T-bar having a drive 17 A that automatically raises and lowers the blade 13 to a desired height.
Tables 1 and 2 show blade angle and height settings for a paper grade with machine direction fiber alignment and a grade with cross-machine direction fiber alignment. The tables show a variety of angle adjustable and height adjustable blades which may be utilized in the respective regions of the wet end of the Fourdrinier to achieve synergistic results. It should be noted that in this instance seven blades are shown in each section with the abbreviations “H” or “A” indicating that the blade is either height or angle adjustable respectively. Moreover, the gravity units 1 - 3 correspond to the hydrofoil sections and are three Hydroline elements. Low vacuum units 1 - 3 correspond to Varioline elements. Low vacuum units 4 , 5 correspond to Vaculine elements.
TABLE 1
Machine Direction Fiber Alignment
Low
Low
Low
Low
Low
Vac-
Vac-
Vac-
Vac-
Vac-
Form-
Gravity
Gravity
Gravity
uum
uum
uum
uum
uum
ing
Unit
Unit
Unit
Unit
Unit
Unit
Unit
Unit
Blade
Board
1
2
3
1
2
3
4
5
1
H
−0.25 mm
A
−1.5°
H
−0.5 mm
A
−1.5°
H
−0.5 mm
H
−0.5 mm
H
−0.5 mm
A
−0.75°
A
−0.0°
2
A
−0.25°
H
−0.5 mm
A
−1.5°
H
−0.5 mm
H
−0.5 mm
H
−0.5 mm
H
−0.5 mm
A
−0.75°
A
−0.0°
3
H
−0.25 mm
A
−1.5°
H
−0.5 mm
A
−1.5°
H
−0.5 mm
H
−0.5 mm
H
−0.5 mm
A
−0.75°
A
−0.0°
4
A
−0.25°
H
−0.5 mm
A
−1.5°
H
−0.5 mm
H
−0.5 mm
H
−0.5 mm
H
−0.5 mm
A
−0.75°
A
−0.0°
5
H
−0.25 mm
A
−1.5°
H
−0.5 mm
A
−1.5°
H
−0.5 mm
H
−0.5 mm
H
−0.5 mm
A
−0.75°
A
−0.0°
6
A
−0.25°
H
−0.5 mm
A
−1.5°
H
−0.5 mm
H
−0.5 mm
H
−0.5 mm
H
−0.5 mm
A
−0.75°
A
−0.0°
7
H
−0.25 mm
A
−1.5°
H
−0.5 mm
A
−1.5°
H
−0.5 mm
H
−0.5 mm
H
−0.5 mm
A
−0.75°
A
−0.0°
TABLE 2
Cross-machine Direction Fiber Alignment
Low
Low
Low
Low
Low
Vac-
Vac-
Vac-
Vac-
Vac-
Form-
Gravity
Gravity
Gravity
uum
uum
uum
uum
uum
ing
Unit
Unit
Unit
Unit
Unit
Unit
Unit
Unit
Blade
Board
1
2
3
1
2
3
4
5
1
H
−0.0 mm
A
−0.0°
H
−0.0 mm
A
−0.5°
H
−1.0 mm
H
−1.25 mm
H
−1.5 mm
A
−1.5°
A
−2.0°
2
A
−0.0°
H
−0.0 mm
A
−0.25°
H
−0.0 mm
H
−1.0 mm
H
−1.25 mm
H
−1.5 mm
A
−1.5°
A
−2.0°
3
H
−0.0 mm
A
−0.0°
H
−0.0 mm
A
−0.5°
H
−1.0 mm
H
−1.25 mm
H
−1.5 mm
A
−1.5°
A
−2.0°
4
A
−0.0°
H
−0.0 mm
A
−0.25°
H
−0.0 mm
H
−1.0 mm
H
−1.25 mm
H
−1.5 mm
A
−1.5°
A
−2.0°
5
H
−0.0 mm
A
−0.0°
H
−0.0 mm
A
−0.5°
H
−1.0 mm
H
−1.25 mm
H
−1.5 mm
A
−1.5°
A
−2.0°
6
A
−0.0°
H
−0.0 mm
A
−0.25°
H
−0.0 mm
H
−1.0 mm
H
−1.25 mm
H
−1.5 mm
A
−1.5°
A
−2.0°
7
H
−0.0 mm
A
−0.0°
H
−0.0 mm
A
−0.5°
H
−1.0 mm
H
−1.25 mm
H
−1.5 mm
A
−1.5°
A
−2.0°
It is to be understood that the invention is not limited to the exact construction illustrated and described above, but that various changes and modifications may be made without departing from the spirit and the scope of the invention as defined in the following claims. While the invention has been described with respect to preferred embodiments, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in limiting sense. From the above disclosure of the general principles of the present invention and the preceding detailed description, those skilled in the art will readily comprehend the various modifications to which the present invention is susceptible. Therefore, the scope of the invention should be limited only by the following claims and equivalents thereof. | An improved method for producing paper from pulp includes a plurality of subassemblies arranged in the forming or wet section of a Fourdrinier. The Fourdrinier includes a dewatering table having a plurality of blades that are static and on-the run adjustable in height and/or angle to control orientation of paper fibers in the stock to create a superior quality of paper and improved paper strength characteristics. Gravity and vacuum assisted drainage elements are equipped with on-the-run adjustable angle and height dewatering foil blades starting from a paper dryness of 0.1% and extending all the way to 5% dryness. The result of this process and machine is to improve the paper quality, save fibers and chemicals and fulfill the required paper properties. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a divisional of U.S. patent application Ser. No. 11/641,600, filed on Dec. 19, 2006, which claims priority from European Patent Application No. EP 06 110 244.8 filed on Feb. 21, 2006, all of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The invention pertains to a clamping element for the clamping of a rod-shaped element of an articulation element, particularly a clamping element, of an articulation element for the stabilization of bone fractures. The invention also pertains to an articulation element with two clamping elements and with one at least two-piece locking device, and optionally an anti-rotation device.
U.S. Patent Publication 2003/0181911 describes a single-piece clamping element with two opposing cavities and one laterally open cavity to receive a clamping jaw forming a rod-shaped element and a hinge, which is arranged opposite the cavity, connecting the clamping jaws so that they are movable on top of each other, with each clamping jaw having one bore each aligned flush with one another.
This clamping element has the advantage that an articulation can be produced with two identical clamping elements arranged next to one another, inserting a connecting screw through the bore, which is screwed into an internally threaded nut to close the clamping jaws.
From U.S. Pat. No. 5,752,954 an articulation is known consisting of two times two individual clamping jaw elements and one central screw. This articulation allows the lateral insertion of one or two rod-shaped elements into the corresponding cavities. U.S. Pat. No. 5,752,954 has a spring, which spring tension allows the clipping in of the rod-shaped elements and holding the jaw elements on the rod-shaped elements before the articulation element is blocked. U.S. Pat. No. 6,616,664 provides for narrow lateral lever arms to hold laterally inserted rod-shaped elements before the articulation is blocked. U.S. Pat. No. 6,342,054 has an external spring.
SUMMARY OF THE INVENTION
Based on this state of technology, it is one role of the invention at hand to provide a two-piece clamping element which allows the lateral insertion of a rod-shaped element and which, when utilized dually, is directly applicable as an articulation element. It is another object of the invention to obtain a two-piece clamping element with advantages of a single-piece clamping element, e.g. the working connection of the two clamping jaws.
Another goal of the invention is the creation of a cost-effective disposable clamping element, particularly made of a synthetic material (such as plastic) injection molding, which does not have the structural disadvantages of X-ray transparent clamping elements as in U.S. Publication 2003/0181911. Especially it is an object of the invention to realize a disposable clamping element being able to support and transmit large pressure forces.
Based on the known state of technology, another role of the invention is also to provide an improved articulation element. Such an improved articulation element is shown in U.S. Patent Publication 2006/0039750 assigned to the assignee of the present invention.
A two-piece clamping element is provided comprising two separate non-integral opposing first and second clamping jaws forming a laterally open cavity to receive a rod-shaped element, with each clamping jaw having a bore aligned with one another.
A pivot bearing is arranged opposite the cavity bringing the two opposing clamping jaws in contact to one another and thereby making them movable towards and away from one another. Each clamping jaw has a bore, aligned with one another. The bores are arranged between the cavity and the pivot bearing.
A first clamping jaw has an anti-rotation device on its exterior or a receptacle for receiving an anti-rotation device.
An articulation element can be formed from two clamping elements in which the clamping elements are arranged on top of one another with their first clamping jaws adjacent one another. The articulation element has one at least two-piece locking shaft with a first part of the locking shaft insertable through a bore of the second clamping jaw of one clamping element, and with a second part of the locking shaft insertable through a bore of the first clamping jaw of the other clamping element. One or the other or both parts of the locking shaft being able to be brought in contact with one another through the bores in the first clamping jaws. The first and second clamping jaws of the clamping elements can be blocked with the locking device. The articulation element has an anti-rotation device is arranged between the first clamping jaws that are arranged on top of one another, the anti-rotation device having a central bore. The anti-rotation device is preferably a plate whose material is preferably harder than the material of the clamping elements and which has ridges formed on both sides of the plate. The anti-rotation device can also be a cylinder whose material in a floor and a lid area thereof is preferably harder than the material of the clamping elements, and which preferably consists of a flexible, compressible material in the solid material part, in particular synthetic foam. The locking device includes a cylindrical screw and a conical nut, the conical nut preferably has a stop shoulder for a self-locking screw, which can be inserted in an internal thread in the cylindrical screw. A hollow spring enveloping the locking device is used as an anti-rotation device or as an additional anti-rotation device.
By equipping the two-piece clamping elements with functionally different first and second clamping jaws, two clamping elements can be placed on top of one another each with their first clamping jaws, to form an articulation element in a simple manner.
BRIEF DESCRIPTION OF THE DRAWINGS
Now the invention is more closely described with reference to the drawings and with the aid of a number of embodiments:
FIG. 1 shows a perspective view of an articulation element with two clamping elements per a first embodiment of the invention,
FIG. 2 shows a different perspective view of the articulation element of FIG. 1 ,
FIG. 3 shows a cross-section view of the articulation element of FIG. 1 or 2 ,
FIG. 4 shows a perspective view of an articulation element with two clamping elements per a second embodiment of the invention,
FIG. 5 shows a different perspective view of the articulation element of FIG. 4 ,
FIG. 6 shows a cross-section view of the articulation element of FIG. 4 or 5 ,
FIG. 7 shows a top view of an anti-rotation device for an articulation element per FIG. 1 or 4 ,
FIG. 8 shows a perspective view of another anti-rotation device for an articulation element, and
FIG. 9 shows a partially sectioned lateral view of a part of a locking screw, a nut and a self-locking bolt for an articulation element per one of the FIGS. 1 to 6 .
DETAILED DESCRIPTION
FIGS. 1 to 3 show a first embodiment of an articulation element with two clamping elements 10 per the invention. FIGS. 1 and 2 show two perspective views at different angles from the top. The two-part clamping element has two clamping jaws 12 and 13 creating together one cavity 11 to receive a rod-shaped element. The cavity 11 is formed by transversely running grooves 14 . The outer edges 16 of the side facing clamping jaws 12 and 13 are slanted to simplify the lateral insertion of a rod-shaped element. Across from the cavity 11 and the slanted outer edges 16 , a pivotal bearing 17 is arranged, comprising complementary pivotal surfaces comprising semi-cylindrical portions 36 and complementary grooves 38 contacting clamping jaws 12 and 13 .
When the clamping element 10 is intended for a rod with 4 to 6 millimeters in diameter, the opening at the free ends has a diameter of, for instance, 2 millimeters in a resting position. If the clamping element 10 is intended for a rod with a diameter of 12 millimeters, the opening at the free ends has a diameter of, for instance, 9 millimeters in a resting position.
In the upper area of the clamping jaw 12 the area between cross ribs 21 has been excluded with the exception of a round screw receptacle 23 . Screw receptacle 23 , for instance, has a conical shoulder area or a step shoulder, whose purpose will be described later, which merges into a continuous bore in the top clamping jaw 12 , which can be seen in FIG. 3 .
In the lower clamping jaw 13 cross ribs 21 end in a ring flange 22 , which, for instance, may have a flat recessed ring shaped step, where a weight and material saving recess advantageous for injection molding can be connected, with a bore in the center.
This continuous bore is aligned flush with the abovementioned bore in top clamping jaw 12 . At the clamping element 10 , it runs vertically to the axis of the cavity 11 . The bore is cylindrical and in its interior, it may have guide ribs arranged in regular intervals. Of course, the number of guide ribs may be chosen freely, preferably between three or five ribs.
One clamping element 10 with the jaw parts 12 and 13 comprises a semi-cylindrical portions 36 running over the whole width of the jaw 12 and being directed to a complementary groove 38 in jaw 13 . The stops 36 and 38 may be chosen shorter or in smaller portions with intermediate regions; however, the shown embodiment providing for a long pivotal bearing 17 is preferred. The stops 36 and 38 are running parallel to the cavity 11 . Between the stops 36 and 38 and the vertically oriented bores for the screw is provided a pin 136 and a corresponding reception bore 138 . The pin 136 can be seen in the cross-sectional view of FIG. 3 , entering with play into the reception bore 138 , to ensure that the jaws 12 and 13 are not rotating one against the other and to allow an easy introduction of a larger rod into the cavity 11 whereas the complementary stop surfaces 36 and 38 can loose contact but are guided by elements 136 and 138 . The pin 136 can be symmetrical in view of his main axis but is preferably oblong in the transverse direction, e.g. parallel to surfaces 36 and groove 14 .
FIGS. 4 to 6 show a second embodiment of an articulation element with two clamping elements 20 per the invention. FIGS. 4 and 5 show two perspective views at different angles from the top. The two-part clamping element has two clamping jaws 12 and 13 creating together one cavity 11 to receive a rod-shaped element. All identical or similar features have received the same reference numerals as cavity 11 and grooves 14 . Across from the cavity 11 , a pivotal bearing 17 is arranged, comprising complementary pivotal surfaces comprising semi-cylindrical portions 36 and complementary grooves 38 contacting clamping jaws 12 and 13 .
One clamping element 20 with the jaw parts 12 and 13 comprises two semi-cylindrical portions 36 running on the left and on the right side of a passage 238 of the jaw 12 and being directed to two complementary groove portions 38 on both sides of a blocking pin 236 in jaw 13 . The stops surfaces 36 and 38 may also be chosen shorter; however, the shown embodiment providing for two rather long pivotal bearing surfaces 17 is preferred. The blocking pin 236 and the corresponding reception bore 238 are provided on the outer open side of the jaws 12 and 13 . The pin 236 is—seen from above—rectangular to ensure that the jaws 12 and 13 of the clamping element 20 can not rotate one against the other.
In the first embodiment of FIGS. 1 to 3 the pin 136 is provided in the jaw 12 whereas in the second embodiment of FIGS. 4 to 6 the blocking pin 236 is provided in the jaw 13 . This clearly shows that the features of the two embodiments can be mixed, the blocking pin 236 of FIG. 4 can be used within jaw 12 and the pin 136 of FIG. 1 can be used within jaw 13 with the complementary bores in the other jaws 13 and 12 , respectively. However, the represented embodiments are preferred.
A spiral or coil spring 119 is arranged between the two clamping elements 10 or 20 , which is supported by the spring receptacle 121 . The spring receptacle 121 can form a hemispherical area; it can also be level and smooth; in particular, it can be rough to ensure a greater resistance of the spring 119 against twisting. The spring 119 pushes the two clamping elements 10 or 20 away from one another and is intended to secure the twisting of the two clamping elements 10 or 20 against one another. It does not secure the forcing apart of the jaws 12 and 13 ; they open against the forces acting upon the clipping in of the rods 101 and 102 in a radial direction with respect to grooves 14 . The spring 119 can also be a disk spring package or another resilient element.
FIG. 7 shows a top view of an anti-rotation device for an articulation element per FIG. 1 . Anti-rotation device 90 , for instance, is a thin metal plate with a central bore 91 , a hub 92 and spokes 93 . The outer rim 94 , for instance, has successive punctured ridges 95 and recesses 96 . For instance, they are arranged so that recesses 96 are always arranged opposite the six spokes 93 in this case, with each of the ridges 95 located intermittently.
It is clear that, a simple punching process to manufacture the plates of the anti-rotation device 90 is used, that ridges 95 seen from above are recesses seen from below. Punctured ridges 95 and recesses 96 can be round, pyramidal or polygon shaped. They can run radially side by side in several rows, in a larger number than in FIG. 7 etc. In another alternate design, radial ribs can be used as well.
The anti-rotation device 90 is to be positioned between the two clamping elements 10 , 20 at the position 190 as indicated in FIGS. 1 , 2 , 4 and 5 . FIGS. 3 and 6 show that an anti-rotation device can also be achieved through the design of the material of the first clamping jaw 13 , comprising rough elements to avoid rotation between the contacting jaws 13 .
The anti-rotation device can also be a flexible synthetic foam element 199 as per FIG. 8 . Only upon the tightening of screw 103 the anti-rotation device 199 interlock and determine the angle position of the articulation element.
This is a flexible cylindrical element 199 with a central bore 198 for receiving screw 103 . It can be used in the place of an anti-rotation device 90 . The advantage is that its material on the bottom and lid surfaces 197 is harder and, in particular, can also be structured or span hard inserts to engage in a ring-shaped step. The clamping element 10 is then designed similar to the embodiment per FIG. 1 , only the depth and the sidewalls are intended to receive the anti-rotation device 199 . In the cylinder area, the element 199 is flexible to be compressed when screw 103 is tightened. The anti-twisting device is beveled and has conical slants 196 between the surface 195 and the lid or the floor area 197 .
It is advantageous that the material in the floor and lid area of the anti-rotation device 199 is harder than the material of the clamping elements utilized, and in the solid material preferably consists of a flexible, compressible material, particularly synthetic foam.
The diameter of the anti-rotation device 90 or 199 is 30 millimeters and the contact surface (radial width) for the outer rim 94 is 3 millimeters. Instead of placing the ridges on element 90 , the structures (ridges) can also be integrated in the material of the clamping jaw 13 , for instance radial grooves.
FIG. 9 shows a screw 103 which is to be inserted through the aligned bores, which can sit on the conical screw receptacle 23 with its conical flange 104 . For tightening, screw 103 for instance has a square drive head 105 . It is clear that instead of a square, a hexagon or a slit etc. can be utilized. Preferably, the shoulder 104 is designed to be complementary to the receptacle 23 . A nut 106 is attached from the other side. The nut 106 has a slightly conical sleeve 107 and a conical flange 108 as a covering cap. The shape of flange 108 corresponds to the shape of screw receptacle 23 of clamping element 10 or 20 . The sleeve 107 is inserted into one bore and, to the best advantage, protrudes into the other bore and/or through it. The sleeve 107 is fitted in the press fit; additionally, it can also have an external thread. It can be designed as a fit for one of the internal threads used in bore.
In another design version, not illustrated in the drawings, a clamping element is equipped with a tilting, but torsion rigid, bearing for the nut. The clamping jaw 12 again has the conically opening bore. This bore, however, has a recess on the side facing away from the cavity 11 , which can be a rectangular slit in particular. During the assembly, the cylindrical nut is inserted in the recess. A tolerance exists through the cylindrical nut, so that when a rod 102 is clipped into cavity 11 the top part 12 of the clamping element can be tilted as well. In order to ensure the fixation of screw 103 and to design the nut torsionally rigid, it has an appendage or projection, which protrudes into the said recess with lateral tolerance. In a lateral view of the clamping element, the projection has a tolerance in the recess to permit the tilting motion of top part 12 . In addition to the nut with projection, other design versions are possible, for instance, an L-shaped flattened nut, which, for example, has wobble rivets and is punched, so that an appendage protrudes into a corresponding nut in top part 12 and produces the torsion rigidity.
The nut 106 has an internal thread that fits the complementary external thread of screw 103 . Through the tightening of screw 103 opposite nut 106 , the two clamping elements 10 and 20 are pulled together. Then, by exerting pressure, a rod can be inserted laterally in the respective cavity. Since the diameters of the rods are larger than the opening at the free ends, it is protected from falling out. Through a roughening of grooves 14 , not illustrated in the drawings, it is also protected from a simple longitudinal displacement.
If screw 103 is tightened further, clamping jaws 12 and 13 are moved closer towards one another against the resetting force of the hinge bearing 17 and are finally completely blocked in their angled position through the use of the plate of anti-rotation device 90 placed between the clamp elements. At the same time, this fully secures the rods in grooves 14 against longitudinal displacement as well as against twisting by minimizing the cavity 11 . While self-locking screw 109 is not illustrated, it can be utilized here as well. Preferably the nut 106 is designed as a continuous sleeve.
When screw 103 is opened, nut 106 remains in the one clamping element. The anti-rotation device 90 has impressed itself into the softer material of jaw 13 . Said impression makes it preferable—with the exception of an immediate tightening of the screw in this or another place of an external fixator clamping element used for the same patient—to use said clamping element only once and to throw it away after use. The material used for the clamp may be PEEK (Poly Esther Ether Ketone), and may have chopped carbon fiber reinforcement for extra strength. This allows the two pieces of the polymeric clamp to be injection molded. The pressed in traces of the anti-rotation device in the step is a sign of use for the clamping element, so that the user can see that the reuse of the product can be excluded.
In the resting position of the clamping elements 10 and 20 , clamping jaws 12 and 13 urged together by the spring force and the distance of the slit 27 is reduced. When screw 103 is tightened, the slit is minimized. Through the central transfer of force via the screw and nut elements 104 and 108 on the identical areas, the slit 27 is minimized in its thickness until the groove 14 contacts the rod in the cavity 11 . Then the (upper) clamping jaw 12 with the ribs 21 deviates around the rod and the semi-cylindrical region 36 touches down on the complementary area 38 . When screw 103 is tightened further, the blocking effect sets in as of this time and the unit semi-cylindrical region 36 —complementary area 38 takes over the bearing function.
Instead of a screw 103 , another locking device can be used, for instance a clamping lever or a bayonet catch.
It is emphasized that the term embodiment in the previously mentioned description does not mean that only the elements described with respect to the respective clamping element or articulation element are subject of the invention. In particular, these are also combinations of the characteristics described in objects of various embodiments and FIGS. For instance, a clamping element is an object of the invention, which has the bore and nut per FIG. 3 , a counter nut 109 per FIG. 9 and non-skid elements 99 for the rods per FIG. 8 or a part thereof. A corresponding articulation element can be comprised of any two random above-mentioned clamping elements, if they can be utilized for the selected anti-rotation device.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims. | A two-piece clamping element comprises two separate, i.e., non-integral, opposing first and second clamping jaws forming a laterally open cavity to receive a pin or rod-shaped element. Each clamping jaw has a bore aligned with one another to receive a screw, wherein a pivot bearing is arranged opposite said cavity allowing the two opposing clamping jaws to come in contact to one another. The pivot bearing comprises at least one set of complementary part-cylindrical bearing surface portions. An anti-rotation pin extends between the two jaw members. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to apparatus facilitating through-the-wall transactions between an employee of a business establishment inside the wall, and a customer outside the wall, and more particularly to a device useful in an unsheltered exterior location but retaining the security, convenience, and communications features heretofore found desirable in pass-through devices.
2. Description of the Prior Art
The most pertinent prior art known to me is the apparatus disclosed in my U.S. Pat. No. 4,069,773 issued Jan. 24, 1978, and described in a sheet of literature entitled "Transaction Security Equipment" distributed by Creative Industries, Inc. of 959 North Holmes, Indianapolis, Ind. 46222. In addition to the combination pass-through and deal tray shown in that patent and the literature, there is also shown in the literature on the back side, a "Lazy Susan Pass Thru." While the device shown in my above-mentioned patent utilizes a horizontal axis for pivoting of the deal tray or plate 26, the "Lazy Susan" device uses a vertical axis.
The device shown in my aforementioned patent is preferably employed in a sheltered location, typically indoors. If utilized in an outdoors/indoors location, without shelter, there would be exposure to rain and snow and resulting water accumulation in the unit, which would not be acceptable.
The "Lazy Susan" version, with some modification, could conceivably be employed in an outdoor/indoor location, but the nature of the construction is such that the rotatable support shelf is entirely within the boundaries of the fixed housing. In contrast, the drive-up pass-through of the present invention has a pivoting shelf which extends outward towards the customer (beyond the frontal surface of the housing of the pass-through). Therefore, the new drive-up pass-through would make for more convenience for the customer in being able to more easily reach items on the shelf, when it is rotated outward.
SUMMARY OF THE INVENTION
Described briefly, in a typical embodiment of the present invention, a housing may be incorporated in an exterior building wall, with associated glazing around it, as desired. Vertical axis hinge means are mounted on the housing and support a shelf unit for swinging in a horizontal plane for a rear position where the shelf is open to the employee's side of the wall, through an intermediate position where it is normally disposed when not in use, to an open position where the shelf is accessible to the customer at the exterior of the wall. Upstanding walls are provided at two sides of the shelf and cooperate with an arcuate wall in the housing within the rotational limits imposed on the shelf, to preclude direct access from outside the wall to the inside of the wall for any attainable rotational position of the shelf.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of a building wall with the pass-through incorporated in it according to a typical embodiment of the present invention.
FIG. 2 is a schematic top plan view of the assembly with the shelf in open position.
FIG. 3 is a schematic top plan view of the assembly with the shelf in locked position.
FIG. 4 is a front view of the assembly with the shelf in locked position.
FIG. 5 is a section taken through the wall at line 5--5 in FIG. 2 and viewed in the direction of the arrows, and showing the side view of the pass-through with the shelf in open position.
FIG. 6 is an enlarged end view of a hinge bracket extrusion employed in the typical embodiment of the present invention.
FIG. 7 is a section through the hinge assembly and housing taken at line 7--7 in FIG. 2 and viewed in the direction of the arrows.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in detail, a brick veneer building wall is shown at 11, with the pass-through shown generally at 12, and glazing at 13 and 14 in the wall on opposite sides of the unit, and further glazing at 16 above the unit. The glazing may be of glass or plastic of the type, thickness, and strength needed depending upon the particular environment and degree of security desired. The assembly 12 is thus framed by the top course 17 of bricks, window frame members 18 and 19 at opposite sides of the unit, and window frame member 21 at the top of the unit. The housing 22 of the unit may be made of any of a variety of materials, formed and welded steel being one example, although other metals and possibly also plastics of suitable strength and durability, might also be used. At present, foam filled polyethylene shell construction seems preferable.
The housing includes a horizontal bottom wall, the top surface of which forms a stationary floor 23 of a shape which can be best perceived by comparison of FIGS. 2 and 3. An upstanding part-cylindrical wall 24 is provided at the left-hand side of the floor 23 and it subtends an arc of 90° about a vertical axis 26. Axis 26 is colinear with the axis of a hinge assembly 27 which includes a hinge bracket extrusion 27A of special cross section as best shown in FIG. 6, and a pair of spring loaded hinge pins 25 as best shown in FIG. 7. The pins 25 are urged by spring 30 into sockets formed in the housing floor 23 and ceiling 32. Nylon bushings 35 serve as thrust bearings at the upper and lower ends of the hinge bracket 27 so the hinge bracket can pivot freely about axis 26. A weather strip 27B is mounted to the right-hand wall 28, 29, 31 of the housing and seals against the extrusion, but permits the extrusion to turn freely while being sealed. This wall, 28, 29, 31 extends from the floor 23 to the ceiling 32 of the housing (FIGS. 4 and 7) as does the part-cylindrical wall 24.
The shelf assembly includes the sector-shaped bottom wall 36 having a part-cylindrical arcuate outer edge 37, centered about the axis 26. It also has upstanding walls 38 and 39 affixed to the base 36 and extending along the straight edges thereof and up to the upper edges 41 which are immediately adjacent and below the lower face 32 (ceiling) of the top wall of the housing. The lower edges of the shelf assembly walls are flush with the lower edge of the shelf 36 and immediately above the upper face 23 (floor) of the housing base. The arc subtended by edge 37 between walls 38 and 39 must be equal to or less than that subtended by the part-cylindrical housing wall 24. Hinge bracket 27A of the hinge assembly has longitudinally extending slots 27C and 27D snugly receiving walls 38 and 39, respectively. The walls can be fastened to it by screws or other suitable fasteners or adhesive. Also, a pull handle of a conventional U-shaped stirrup type 42 is provided on the inside face of the shelf wall 39. A cavity 43 is provided in the upper surface of the shelf 36 to conveniently receive and retain coins such as for currency change. A spring clip 45 is provided to secure currency bills to the shelf. It may typically be a tight coiled spring with one end secured to the shelf, and a ball on the other end to receive bills under it and clamp them to the shelf top under the urging of the spring.
A locking knob 44 (FIGS. 1, 3) is on shaft 46 threadedly received in the housing wall 24 and having a rubber tipped inner end 47 engageable with arcuate edge 37 of the shelf to lock the shelf in the position shown in FIG. 3 or any other position where the shelf edge is engageable by the lock tip 47.
Rotational limits of pivoting of the shelf are established by abutting engagement of wall 39 with wall 28 at one extreme, and wall 38 with wall 29 at the other extreme. The housing thus serves as a passageway which is always closed by one or the other of walls 38 and 39 which function in the passageway or opening, as doors in a doorway.
It is preferable that the two walls 38 and 39 of the shelf assembly be transparent, whereby they can serve as windows which may be particularly helpful to the driver of a vehicle whose window is approximately level with the window in the pass-through, but whose view through the window 16 in the wall, might be obscured. Also, it makes it possible for this pass-through to be used in an otherwise windowless wall. In addition, the provision of the transparent wall 39 enables the employee of the establishment to see what is placed on the shelf 36 by the customer, before the employee pulls the shelf from the open position to the rear position for access.
The shelf position shown in FIGS. 3 and 4, which is the locked position of the assembly, places the wall 38 as well as the hinge axis essentially co-planar with the exterior wall surface of the building. Weather strip such as at 48 along the sides and bottom of the shelf and walls minimizes opportunity for entry of wind, much less rain or snow, into the building when the assembly is in any rotational position. In addition, where the unit is used in an unsheltered location, the wall 37 serving as a door can, when opened to the position shown in FIGS. 1 and 2, clear from the shelf or ledge 23 any accumulation of snow which might have occurred during a period when the establishment has been closed.
The assembly can be secured in the wall of the building by any suitable fastening means and, in view of the provision of the hinge structure on the right, the part-cylindrical wall on the left, and the top and bottom walls of the housing, there is ample opportunity to secure the assembly to the building structure at both sides, top and bottom, with conventional fasteners.
Since the walls 38 and 39 of the unit actually serve as doors, and are intended to be able to serve to protect the employee of the establishment, they can be made of a material of sufficient thickness and strength to withstand impact of bullets or other projectiles to the degree deemed necessary for the particular type of establishment and level of security desired. They may be made of glass, or plastics, or suitable combinations thereof. The fact that the base 36 is mounted inside of the two walls, with the walls extending down to the bottom edge of the base 36, enables the base to serve as a structural fillet or web between the walls, to provide a suitably sturdy unit without the necessity of having also a top fillet, web or gusset. In this way, the unit can be useful to the occupant of a vehicle which is much higher than the conventional automobile. Such person can reach down and place items on and remove items from the shelf 36 without the interference that a top fillet or web would cause. In addition, with the provision of a window 16 above the assembly, such customer could, nevertheless, maintain visual contact with the employee working at the window.
By way of example, but not limitation, the overall height of the housing may be 16 inches, and the radius of the shelf 36 may be about 18 inches. The front edge 35 of shelf 23 and the vertical and horizontal front edges of the walls 24, 29-31, and 32 which cooperate with shelf edge 35 to form the front doorway entrance of the housing, project out from the outside face of the wall about 7 inches.
From the foregoing description, it should be recognized that the present invention is useful not only for fast food restaurants which are likely to be the primary end users of this pass-through, but also for other types of business establishments where a drive-up window facility is desirable. A few examples would include financial institutions, gasoline filling stations, beverage and grocery stores.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. In this regard where the terms employee and customer are used in the claims, they are used for convenience to reference typical circumstances, but not intended to limit coverage only to those installations where the person on one side is strictly speaking, a customer, and on the other, an employee. | A pass-through assembly includes a housing installable in a building wall structure as a finished complete unit. It has a sector-shaped shelf with upstanding transparent walls on the straight edges of the shelf and intersecting adjacent a vertical hinge. The walls cooperate with a part-cylindrical wall of the housing to provide doors on the assembly and preclude direct access from outside to the inside of the building wall. The housing and shelf are arranged for a normal closed position avoiding need for a sheltered location, but the unit is useful regardless of weather conditions. | 4 |
This application is a divisional of application Ser. No. 10/934,675 filed Sep. 3, 2004, now U.S. Pat. No. 6,969,553 (allowed).
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process for drawing gel-spun polyethylene multi-filament yarns and to the drawn yarns produced thereby. The drawn yarns are useful in impact absorption and ballistic resistance for body armor, helmets, breast plates, helicopter seats, spall shields, and other applications; composite sports equipment such as kayaks, canoes, bicycles and boats; and in fishing line, sails, ropes, sutures and fabrics.
2. Description of the Related Art
To place the invention in perspective, it should be recalled that polyethylene had been an article of commerce for about forty years prior to the first gel-spinning process in 1979. Prior to that time, polyethylene was regarded as a low strength, low stiffness material. It had been recognized theoretically that a straight polyethylene molecule had the potential to be very strong because of the intrinsically high carbon—carbon bond strength. However, all then-known processes for spinning polyethylene fibers gave rise to “folded chain” molecular structures (lamellae) that inefficiently transmitted the load through the fiber and caused the fiber to be weak.
“Gel-spun” polyethylene fibers are prepared by spinning a solution of ultra-high molecular weight polyethylene (UHMWPE), cooling the solution filaments to a gel state, then removing the spinning solvent. One or more of the solution filaments, the gel filaments and the solvent-free filaments are drawn to a highly oriented state. The gel-spinning process discourages the formation of folded chain lamellae and favors formation of “extended chain” structures that more efficiently transmit tensile loads.
The first description of the preparation and drawing of UHMWPE filaments in the gel state was by P. Smith, P. J. Lemstra, B. Kalb and A. J. Pennings, Poly. Bull., 1, 731 (1979). Single filaments were spun from 2 wt. % solution in decalin, cooled to a gel state and then stretched while evaporating the decalin in a hot air oven at 100 to 140° C.
More recent processes (see, e.g., U.S. Pat. Nos. 4,551,296, 4,663,101, and 6.448,659) describe drawing all three of the solution filaments, the gel filaments and the solvent-free filaments. A process for drawing high molecular weight polyethylene fibers is described in U.S. Pat. No. 5,741,451. The disclosures of these patents are hereby incorporated by reference to the extent not incompatible herewith.
Although gel-spinning processes tend to produce fibers that are free of lamellae with folded chain surfaces, nevertheless the molecules in gel-spun UHMWPE fibers are not free of gauche sequences as can be demonstrated by infra-red and Raman spectrographic methods. The gauche sequences are kinks in the zig-zag polyethylene molecule that create dislocations in the orthorhombic crystal structure. The strength of an ideal extended chain polyethylene fiber with all trans —(CH 2 ) n — sequences has been variously calculated to be much higher than has presently been achieved. While fiber strength and multi-filament yarn strength are dependent on a multiplicity of factors, a more perfect polyethylene fiber structure, consisting of molecules having longer runs of straight chain all trans sequences, is expected to exhibit superior performance in a number of applications such as ballistic protection materials.
A need exists for gel-spun multi-filament UHMWPE yarns having increased perfection of molecular structure. One measure of such perfection is longer runs of straight chain all trans —(CH 2 ) n — sequences as can be determined by Raman spectroscopy. Another measure is a greater “Parameter of Intrachain Cooperativity of the Melting Process” as can be determined by differential scanning calorimetry (DSC). Yet another measure is the existence of two orthorhombic crystalline components as can be determined by x-ray diffraction. It is among the objectives of this invention to provide methods to produce such yarns by drawing, and the yarns so produced.
SUMMARY OF THE INVENTION
The invention comprises a process for drawing a gel-spun multi-filament yarn comprising the steps of:
a) forming a gel-spun polyethylene multi-filament feed yarn comprising a polyethylene having an intrinsic viscosity in decalin at 135° C. of from about 5 dl/g to 35 dl/g, fewer than about two methyl groups per thousand carbon atoms, and less than about 2 wt. % of other constituents; b) passing the feed yarn at a speed of V 1 meters/minute into a forced convection air oven having a yarn path length of L meters, wherein one or more zones are present along the yarn path having zone temperatures from 130° C. to 160° C.; c) passing the feed yarn continuously through the oven and out of the oven at an exit speed of V 2 meters/minute wherein the following equations 1 to 4 are satisfied
0.25 ≦ L/V 1 ≦ 20, min
Eq. 1
3 ≦ V 2 /V 1 ≦ 20
Eq. 2
1.7 ≦ (V 2 − V 1 )/L ≦ 60, min −1
Eq. 3
0.20 ≦ 2 L/(V 1 + V 2 ) ≦ 10, min
Eq. 4
The invention is also a novel polyethylene multi-filament yarn comprising a polyethylene having an intrinsic viscosity in decalin at 135° C. of from about 5 dl/g to 35 dl/g, fewer than about two methyl groups per thousand carbon atoms, and less than about 2 wt. % of other constituents, the multi-filament yarn having a tenacity of at least 17 g/d as measured by ASTM D2256-02, wherein filaments of the yarn have a peak value of the ordered-sequence length distribution function F(L) at a straight chain segment length L of at least 35 nanometers as determined at 23° C. from the low frequency Raman band associated with the longitudinal acoustic mode (LAM-1).
In another embodiment, the invention is a novel polyethylene multi-filament yarn comprising a polyethylene having an intrinsic viscosity in decalin at 135° C. of from about 5 dl/g to 35 dl/g, fewer than about two methyl groups per thousand carbon atoms, and less than about 2 wt. % of other constituents, the multi-filament yarn having a tenacity of at least 17 g/d as measured by ASTM D2256-02, wherein filaments of the yarn have a value of the “Parameter of Intrachain Cooperativity of the Melting Process”, ν, of at least about 535.
In yet another embodiment, the invention is a novel polyethylene multi-filament yarn comprising a polyethylene having an intrinsic viscosity in decalin at 135° C. of from about 5 dl/g to 35 dl/g, fewer than about two methyl groups per thousand carbon atoms, and less than about 2 wt. % of other constituents, the multi-filament yarn having a tenacity of at least 17 g/d as measured by ASTM D2256-02, wherein the intensity of the (002) x-ray reflection of one the filament of the yarn, measured at room temperature and under no load, shows two distinct peaks.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is the low frequency Raman spectrum and extracted LAM-1 spectrum of filaments of a commercially available gel-spun multi-filament UHMWPE yarn (SPECTRA® 900 yarn).
FIG. 2( a ) is a plot of the ordered sequence length distribution function F(L) determined from the LAM-1 spectrum of FIG. 1 .
FIG. 2( b ) is a plot of the ordered sequence length distribution function F(L) determined from the LAM-1 spectrum of a commercially available gel-spun multi-filament UHMWPE yarn (SPECTRA® 1000 yarn).
FIG. 2( c ) is a plot of the ordered sequence length distribution function F(L) determined from the LAM-1 spectrum of filaments of the invention.
FIG. 3 shows differential scanning calorimetry (DSC) scans at heating rates of 0.31, 0.62 and 1.25° K/min of a 0.03 mg filament segment taken from a multi-filament yarn of the invention chopped into pieces of 5 mm length and wrapped in parallel array in a Wood's metal foil and placed in an open sample pan.
FIG. 4 shows an x-ray pinhole photograph of a single filament taken from multi-filament yarn of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In one embodiment, the invention comprises a process for drawing a gel-spun multi-filament yarn comprising the steps of:
a) forming a gel-spun polyethylene multi-filament feed yarn comprising a polyethylene having an intrinsic viscosity in decalin at 135° C. of from about 5 dl/g to 35 dl/g, fewer than about two methyl groups per thousand carbon atoms, and less than about 2 wt. % of other constituents; b) passing the feed yarn at a speed of V 1 meters/minute into a forced convection air oven having a yarn path length of L meters, wherein one or more zones are present along the yarn path having zone temperatures from about 130° C. to 160° C.; c) passing the feed yarn continuously through the oven and out of the oven at an exit speed of V 2 meters/minute wherein the following equations 1 to 4 are satisfied
0.25 ≦ L/V 1 ≦ 20, min
Eq. 1
3 ≦ V 2 /V 1 ≦ 20
Eq. 2
1.7 ≦ (V 2 − V 1 )/L ≦ 60, min −1
Eq. 3
0.20 ≦ 2 L/(V 1 + V 2 ) ≦ 10, min
Eq. 4
For purposes of the present invention, a fiber is an elongate body the length dimension of which is much greater than the transverse dimensions of width and thickness. Accordingly, “fiber” as used herein includes one, or a plurality of filaments, ribbons, strips, and the like having regular or irregular cross-sections in continuous or discontinuous lengths. A yarn is an assemblage of continuous or discontinuous fibers.
Preferably, the multi-filament feed yarn to be drawn comprises a polyethylene having an intrinsic viscosity in decalin of from about 8 to 30 dl/g, more preferably from about 10 to 25 dl/g, and most preferably from about 12 to 20 dl/g. Preferably, the multi-filament yarn to be drawn comprises a polyethylene having fewer than about one methyl group per thousand carbon atoms, more preferably fewer than 0.5 methyl groups per thousand carbon atoms, and less than about 1 wt. % of other constituents.
The gel-spun polyethylene multi-filament yarn to be drawn in the process of the invention may have been previously drawn, or it may be in an essentially undrawn state. The process for forming the gel-spun polyethylene feed yarn can be one of the processes described by U.S. Pat. Nos. 4,551,296, 4,663,101, 5,741,451, and 6,448,659.
The tenacity of the feed yarn may range from about 2 to 76, preferably from about 5 to 66, more preferably from about 7 to 51, grams per denier (g/d) as measured by ASTM D2256-97 at a gauge length of 10 inches (25.4 cm) and at a strain rate of 100%/min.
It is known that gel-spun polyethylene yarns may be drawn in an oven, in a hot tube, between heated rolls, or on a heated surface. WO 02/34980 A1 describes a particular drawing oven. We have found that drawing of gel-spun UHMWPE multi-filament yarns is most effective and productive if accomplished in a forced convection air oven under narrowly defined conditions. It is necessary that one or more temperature-controlled zones exist in the oven along the yarn path, each zone having a temperature from about 130° C. to 160° C. Preferably the temperature within a zone is controlled to vary less than ±2° C. (a total less than 4° C.), more preferably less than ±1° C. (a total less than 2° C.).
The yarn will generally enter the drawing oven at a temperature lower than the oven temperature. On the other hand, drawing of a yarn is a dissipative process generating heat. Therefore to quickly heat the yarn to the drawing temperature, and to maintain the yarn at a controlled temperature, it is necessary to have effective heat transmission between the yarn and the oven air. Preferably, the air circulation within the oven is in a turbulent state. The time-averaged air velocity in the vicinity of the yarn is preferably from about 1 to 200 meters/min, more preferably from about 2 to 100 meters/min, most preferably from about 5 to 100 meters/min.
The yarn path within the oven may be in a straight line from inlet to outlet. Alternatively, the yarn path may follow a reciprocating (“zig-zag”) path, up and down, and/or back and forth across the oven, around idler rolls or internal driven rolls. It is preferred that the yarn path within the oven is a straight line from inlet to outlet.
The yarn tension profile within the oven is adjusted by controlling the drag on idler rolls, by adjusting the speed of internal driven rolls, or by adjusting the oven temperature profile. Yarn tension may be increased by increasing the drag on idler rolls, increasing the difference between the speeds of consecutive driven rolls or decreasing oven temperature. The yarn tension within the oven may follow an alternating rising and falling profile, or it may increase steadily from inlet to outlet, or it may be constant. Preferably, the yarn tension everywhere within the oven is constant neglecting the effect of air drag, or it increases through the oven. Most preferably, the yarn tension everywhere within the oven is constant neglecting the effect of air drag.
The drawing process of the invention provides for drawing multiple yarn ends simultaneously. Typically, multiple packages of gel-spun polyethylene yarns to be drawn are placed on a creel. Multiple yarns ends are fed in parallel from the creel through a first set of rolls that set the feed speed into the drawing oven, and thence through the oven and out to a final set of rolls that set the yarn exit speed and also cool the yarn to room temperature under tension. The tension in the yarn during cooling is maintained sufficient to hold the yarn at its drawn length neglecting thermal contraction.
The productivity of the drawing process may be measured by the weight of drawn yarn that can be produced per unit of time per yarn end. Preferably, the productivity of the process is more than about 2 grams/minute per yarn end, more preferably more than about 4 grams/minute per yarn end.
In another embodiment, the invention is a novel polyethylene multi-filament yarn comprising a polyethylene having an intrinsic viscosity in decalin at 135° C. of from 5 dl/g to 35 dl/g, fewer than two methyl groups per thousand carbon atoms, and less than 2 wt. % of other constituents, the multi-filament yarn having a tenacity of at least 17 g/d as measured by ASTM D2256-02, wherein filaments of the yarn have a peak value of the ordered-sequence length distribution function F(L) at a straight chain segment length L of at least 40 nanometers as determined at 23° C. from the low frequency Raman band associated with the longitudinal acoustic mode (LAM-1).
In yet another embodiment, the invention is a novel polyethylene multi-filament yarn comprising a polyethylene having an intrinsic viscosity in decalin at 135° C. of from 5 dl/g to 35 dl/g, fewer than two methyl groups per thousand carbon atoms, and less than 2 wt. % of other constituents, the multi-filament yarn having a tenacity of at least 17 g/d as measured by ASTM D2256-02, wherein filaments of the yarn have a value of the “Parameter of Intrachain Cooperativity of the Melting Process”, ν, of at least 535.
In a further embodiment, the invention is a novel polyethylene multi-filament yarn comprising a polyethylene having an intrinsic viscosity in decalin at 135° C. of from about 5 dl/g to 35 dl/g, fewer than about two methyl groups per thousand carbon atoms, and less than about 2 wt. % of other constituents, the multi-filament yarn having a tenacity of at least 17 g/d as measured by ASTM D2256-02, wherein the intensity of the (002) x-ray reflection of one filament of the yarn, measured at room temperature and under no load, shows two distinct peaks.
Preferably, a polyethylene yarn of the invention has an intrinsic viscosity in decalin at 135° C. of from about 7 dl/g to 30 dl/g, fewer than about one methyl group per thousand carbon atoms, less than about 1 wt. % of other constituents, and a tenacity of at least 22 g/d.
Measurement Methods
1. Raman Spectroscopy
Raman spectroscopy measures the change in the wavelength of light that is scattered by molecules. When a beam of monochromatic light traverses a semi-transparent material, a small fraction of the light is scattered in directions other than the direction of the incident beam. Most of this scattered light is of unchanged frequency. However, a small fraction is shifted in frequency from that of the incident light. The energies corresponding to the Raman frequency shifts are found to be the energies of rotational and vibrational quantum transitions of the scattering molecules. In semi-crystalline polymers containing all-trans sequences, the longitudinal acoustic vibrations propagate along these all-trans seqments as they would along elastic rods. The chain vibrations of this kind are called longitudinal acoustic modes (LAM), and these modes produce specific bands in the low frequency Raman spectra. Gauche sequences produce kinks in the polyethylene chains that delimit the propagation of acoustic vibrations. It will be understood that in a real material a statistical distribution exists of the lengths of all-trans seqments. A more perfectly ordered material will have a distribution of all-trans seqments different from a less ordered material. An article titled, “Determination of the Distribution of Straight-Chain Segment Lengths in Crystalline Polyethylene from the Raman LAM-1 Band”, by R. G. Snyder et al, J. Poly. Sci. Poly. Phys. Ed., 16, 1593–1609 (1978) describes the theoretical basis for determination of the ordered-sequence length distribution function, F(L) from the Raman LAM-1 spectrum.
F(L) is determined as follows: Five or six filaments are withdrawn from the multi-filament yarn and placed in parallel alignment abutting one another on a frame—such that light from a laser can be directed along and through this row of fibers perpendicular to their length dimension. The laser light should be substantially attenuated on passing sequentially through the fibers. The vector of light polarization is collinear with the fiber axis, (XX light polarization).
Spectra are measured at 23° C. on a spectrometer capable of detecting the Raman spectra within a few wave numbers (less than about 4 cm −1 ) of the exciting light. An example of such a spectrometer is the SPEX Industries, Inc, Metuchen, N.J., Model RAMALOG® 5, monochromator spectrometer using a He—Ne laser. The Raman spectra are recorded in 90° geometry, i.e. the scattered light is measured and recorded at an angle of 90 degrees to the direction of incident light. To exclude the contribution of the Rayleigh scattering, a background of the LAM spectrum in the vicinity of the central line must be subtracted from the experimental spectrum. The background scattering is fitted to a Lorentzian function of the form given by Eq. 5 using the initial part of the Raman scattering data, and the data in the region 30–60 cm −1 where there is practically no Raman scattering from the samples, but only background scattering.
f
(
x
)
)
=
H
4
·
(
x
-
x
0
w
)
2
+
1
Eq
.
5
where:
x 0 is the peak position H is the peak height w is the full width at half maximum
Where the Raman scattering is intense near the central line in the region from about 4 cm −1 to about 6 cm −1 , it is necessary to record the Raman intensity in this frequency range on a logarithmic scale and match the intensity recorded at a frequency of 6 cm −1 to that measured on a linear scale. The Lorentzian function is subtracted from each separate recording and the extracted LAM spectrum is spliced together from each portion.
FIG. 1( a ) shows the measured Raman spectra for a fibermaterial to be described below and the method of subtraction of the background and the extraction of the LAM spectrum.
The LAM-1 frequency, is inversely related to the straight chain length, L as expressed by Eq. 6.
L
=
1
2
c
ω
L
(
Eg
r
ρ
)
1
/
2
Eq
.
6
where:
c is the velocity of light, 3×10 10 cm/sec ω L is the LAM-1 frequency, cm −1 E is the elastic modulus of a polyethylene molecule, g(f)/cm 2 ρ is the density of a polyethylene crystal, g(m)/cm 3 g c is the gravitational constant 980 (g(m)-cm)/((g(f)-sec 2 )
For the purposes of this invention, the elastic modulus E, is taken as 340 GPa as reported by Mizushima et al., J. Amer. Chem. Soc. 71, 1320 (1949). The quantity (g c E/p) 1/2 is the sonic velocity in an all trans polyethylene crystal. Based on an elastic modulus of 340 GPa, and a crystal density of 1.000 g/cm 3 , the sonic velocity is 1.844×10 6 cm/sec −1 Making that substitution in Eq. 6, the relationship between the straight chain length and the LAM-1 frequency as used herein is express by Eq. 7.
L
=
307.3
ω
L
,
nanometers
Eq
.
7
The “ordered-sequence length distribution function”, F(L), is calculated from the measured Raman LAM-1 spectrum by means of Eq. 8.
F ( L ) = [ 1 - exp ( hc ω L k T ) ω L 2 I ω ] , Eq . 8
arbitrary units
where:
h is Plank's constant 6.6238×10 −27 erg-cm k is Boltzmann's constant, 1.380×10 −16 erg/° K I ω is the intensity of the Raman spectrum at frequency ω L , arbitrary units T is the absolute temperature, ° K
and the other terms are as previously defined.
Plots of the ordered-sequence length distribution function, F(L), derived from the Raman LAM-1 spectra for three polyethylene samples to be described below are shown in FIGS. 2( a ), 2 ( b ) and 2 ( c ).
Preferably, a polyethylene yarn of the invention is comprised of filaments for which the peak value of F(L) is at a straight chain segment length L of at least 45 nanometers as determined at 23° C. from the low frequency Raman band associated with the longitudinal acoustic mode (LAM-1). The peak value of F(L) preferably is at a straight chain segment length L of at least 50 nanometers, more preferably at least 55 nanometers, and most preferably 50–150 nanometers.
2. Differential Scanning Calorimetry (DSC)
It is well known that DSC measurements of UHMWPE are subject to systematic errors cause by thermal lags and inefficient heat transfer. To overcome the potential effect of such problems, for the purposes of the invention the DSC measurements are carried out in the following manner. A filament segment of about 0.03 mg mass is cut into pieces of about 5 mm length. The cut pieces are arranged in parallel array and wrapped in a thin Wood's metal foil and placed in an open sample pan. DSC measurements of such samples are made for at least three different heating rates at or below 2° K/min and the resulting measurements of the peak temperature of the first polyethylene melting endotherm are extrapolated to a heating rate of 0° K/min.
A “Parameter of Intrachain Cooperativity of the Melting Process”, represented by the Greek letter ν, has been defined by V. A. Bershtein and V. M. Egorov, in “Differential Scanning Calorimetry of Polymers: Physics, Chemistry, Analysis, Technology”. P. 141–143, Tavistoc/Ellis Horwod, 1993. This parameter is a measure of the number of repeating units, here taken as (—CH 2 —CH 2 —), that cooperatively participate in the melting process and is a measure of crystallite size. Higher values of ν indicate longer crystalline sequences and therefore a higher degree of order. The “Parameter of Intrachain Cooperativity of the Melting Process” is defined herein by Eq. 9.
v
=
2
R
T
m
1
2
Δ
T
m1
·
Δ
H
0
,
dimensionless
Eq
.
9
where:
R is the gas constant, 8.31 J/° K-mol T m1 is the peak temperature of the first polyethylene melting
endotherm at a heating rate extrapolated to
0° K/min, ° K ΔT m1 is the width of the first polyethylene melting endotherm, ° K ΔH 0 is the melting enthalpy of —CH 2 —CH 2 — taken as 8200 J/mol
The multi-filament yarns of the invention are comprised of filaments having a “Parameter of Intrachain Cooperativity of the Melting Process”, ν, of at least 535, preferably at least 545, more preferably at least 555, and most preferably from 545 to 1100.
3. X-Ray Diffraction
A synchrotron is used as a source of high intensity x-radiation. The synchrotron x-radiation is monochromatized and collimated. A single filament is withdrawn from the yarn to be examined and is placed in the monochromatized and collimated x-ray beam. The x-radiation scattered by the filament is detected by electronic or photographic means with the filament at room temperature (˜23° C.) and under no external load. The position and intensity of the (002) reflection of the orthorhombic polyethylene crystals are recorded. If upon scanning across the (002) reflection, the slope of scattered intensity versus scattering angle changes from positive to negative twice, i.e., if two peaks are seen in the (002) reflection, then two orthorhombic crystalline phases exist within the fiber.
The following examples are presented to provide a more complete understanding of the invention. The specific techniques, conditions, materials, proportions and reported data set forth to illustrate the principles of the invention are exemplary and should not be construed as limiting the scope of the invention.
EXAMPLES
Comparative Example 1
An UHMWPE gel-spun yarn designated SPECTRA® 900 was manufactured by Honeywell International Inc. in accord with U.S. Pat. No. 4,551,296. The 650 denier yarn consisting of 60 filaments had an intrinsic viscosity in decalin at 135° C. of about 15 dl/g. The yarn tenacity was about 30 g/d as measured by ASTM D2256-02, and the yarn contained less than about 1 wt. % of other constituents. The yarn had been stretched in the solution state, in the gel state and after removal of the spinning solvent. The stretching conditions did not fall within the scope of equations 1 to 4 of the present invention.
Filaments of this yarn were characterized by Raman spectroscopy using a Model RAMALOG® 5, monochromator spectrometer made by SPEX Industries, Inc. Metuchen, N.J., using a He—Ne laser and the methodology described herein above. The measured Raman spectrum, 1, and the extracted LAM-1 spectrum for this material, 3, after subtraction of the Lorenzian, 2, fitted to the Rayleigh background scattering are shown in FIG. 1( a ). The ordered-sequence length distribution function, F(L), for this material determined from the LAM-1 spectrum and equations 7 and 8 is shown in FIG. 2( a ). The peak value of the ordered-sequence length distribution function, F(L), was at a straight chain segment length L of approximately 12 nanometers (Table I).
Filaments of this yarn were also characterized by DSC using the methodology described hereinabove. The peak temperature of the first polyethylene melting endotherm at a heating rate extrapolated to 0° K/min. was 415.4° K. The width of the first polyethylene melting endotherm was 0.9° K. The “Parameter of Intrachain Cooperativity of the Melting Process”, ν, determined from Eq. 9 was 389 (Table I).
A single filament taken from this yarn was examined by x-ray diffraction using the methodology described hereinabove. Only one peak was seen in the (002) reflection (Table 1).
Comparative Example 2
An UHMWPE gel-spun yarn designated SPECTRA® 1000 was manufactured by Honeywell International Inc. in accord with U.S. Pat. Nos. 4,551,296 and 5,741,451. The 1300 denier yarn consisting of 240 filaments had an intrinsic viscosity in decalin at 135° C. of about 14 dl/g. The yarn tenacity was about 35 g/d as measured by ASTM D2256-02, and the yarn contained less than 1 wt. % of other constituents. The yarn had been stretched in the solution state, in the gel state and after removal of the spinning solvent. The stretching conditions did not fall within the scope of equations 1 to 4 of the present invention.
Filaments of this yarn were characterized by Raman spectroscopy using a Model RAMALOG® 5, monochromator spectrometer made by SPEX Industries, Inc. Metuchen, N.J., using a He—Ne laser and the methodology described hereinabove. The ordered-sequence length distribution function, F(L), for this material determined from the LAM-1 spectrum and equations 7 and 8 is shown in FIG. 2( b ). The peak value of the ordered-sequence length distribution function, F(L), was at a straight chain segment length L of approximately 33 nanometers (Table 1).
Filaments of this yarn were also characterized by DSC using the methodology described hereinabove. The peak temperature of the first polyethylene melting endotherm at a heating rate extrapolated to 0° K/min, was 415.2° K. The width of the first polyethylene melting endotherm was 1.3° K. The “Parameter of Intrachain Cooperativity of the Melting Process”, ν, determined from Eq. 9 was 466 (Table I).
A single filament taken from this yarn was examined by x-ray diffraction using the methodology described hereinabove. Only one peak was seen in the (002) reflection (Table 1).
Comparative Examples 3–7
UHMWPE gel spun yarns from different lots manufactured by Honeywell International Inc. and designated either SPECTRA® 900 or SPECTRA® 1000 were characterized by Raman spectroscopy, DSC, and x-ray diffraction using the methodologies described hereinabove. The description of the yarns and the values of F(L) and ν are listed in Table I as well as the number of peaks seen in the (002) x-ray reflection.
Example of the Invention
An UHMWPE gel spun yarn was produced by Honeywell International Inc. in accord with U.S. Pat. No. 4,551,296. The 2060 denier yarn consisting of 120 filaments had an intrinsic viscosity in decalin at 135° C. of about 12 dl/g. The yarn tenacity was about 20 g/d as measured by ASTM D2256-02, and the yarn contained less than about 1 wt. % of other constituents. The yarn had been stretched between 3.5 and 8 to 1 in the solution state between 2.4 to 4 to 1 in the gel state and between 1.05 and 1.3 to 1 after removal of the spinning solvent.
The yarn was fed from a creel, through a set of restraining rolls at a speed (V 1 ) of about 25 meters/min into a forced convection air oven in which the internal temperature was 155±1° C. The air circulation within the oven was in a turbulent state with a time-averaged velocity in the vicinity of the yarn of about 34 meters/min.
The feed yarn passed through the oven in a straight line from inlet to outlet over a path length (L) of 14.63 meters and thence to a second set of rolls operating at a speed (V 2 ) of 98.8 meters/min. The yarn was cooled down on the second set of rolls at constant length neglecting thermal contraction. The yarn was thereby drawn in the oven at constant tension neglecting the effect of air drag. The above drawing conditions in relation to Equations 1–4 were as follows:
0.25 ≦ [L/V 1 = 0.59] ≦ 20, min
Eq. 1
3 ≦ [V 2 /V 1 = 3.95] ≦ 20
Eq. 2
1.7 ≦ [(V 2 − V 1 )/L = 5.04] ≦ 60, min −1
Eq. 3
0.20 ≦ [2 L/(V 1 + V 2 ) = 0.24] ≦ 10, min
Eq. 4
Hence, each of Equations 1–4 was satisfied.
The denier per filament (dpf) was reduced from 17.2 dpf for the feed yarn to 4.34 dpf for the drawn yarn. Tenacity was increased from 20 g/d for the feed yarn to about 40 g/d for the drawn yarn. The mass throughput of drawn yarn was 5.72 grams/min per yarn end.
Filaments of this yarn produced by the process of the invention were characterized by Raman spectroscopy using a Model RAMALOG® 5, monochromator spectrometer made by SPEX Industries, Inc., Metuchen, N.J., using a He—Ne laser and the methodology described hereinabove. The ordered-sequence length distribution function, F(L), for this material determined from the LAM-1 spectrum and equations 7 and 8 is shown in FIG. 2( c ). The peak value of the ordered-sequence length distribution function, F(L), was at a straight chain segment length L of approximately 67 nanometers (Table I).
Filaments of this yarn were also characterized by DSC using the methodology described hereinabove. DSC scans at heating rates of 0.31° K/min, 0.62° K/min, and 1.25° K/min are shown in FIG. 3 . The peak temperature of the first polyethylene melting endotherm at a heating rate extrapolated to 0° K/min, was 416.1° K. The width of the first polyethylene melting endotherm was 0.6° K. The “Parameter of Intrachain Cooperativity of the Melting Process”, ν, determined from Eq. 9 was 585 (Table I).
A single filament taken from this yarn was examined by x-ray diffraction using the methodology described hereinabove. An x-ray pinhole photograph of the filament is shown in FIG. 4 . Two peaks were seen in the (002) reflection.
TABLE I
L, nm
No. of
Ex. or
at
ν,
(002)
Comp.
Denier/
peak
dimension-
X-Ray
Ex. No.
Identification
Fils
of F(L)
less
Peaks
Comp.
SPECTRA ®
650/60
12
389
1
Ex. 1
900 yarn
Comp.
SPECTRA ®
1300/240
33
466
1
Ex. 2
1000 yarn
Comp.
SPECTRA ®
650/60
28
437
1
Ex. 3
900 yarn
Comp.
SPECTRA ®
1200/120
19
387
1
Ex. 4
900 yarn
Comp.
SPECTRA ®
1200/120
20
409
1
Ex. 5
900 yarn
Comp.
SPECTRA ®
1200/120
24
435
1
Ex. 6
900 yarn
Comp.
SPECTRA ®
1300/240
17
467
1
Ex. 7
1000 yarn
Example
Inventive
521/120
67
585
2
Fiber
It is seen that filaments of the yarn of the invention had a peak value of the ordered-sequence length distribution function, F(L), at a straight chain segment length, L, greater than the prior art yarns. It is also seen that filaments of the yarn of the invention had a “Parameter of Intrachain Cooperativity of the Melting Process”, ν, greater than the prior art yarns. Also, this appears to be the first observation of two (002) x-ray peaks in a polyethylene filament at room temperature under no load.
Having thus described the invention in rather full detail, it will be understood that such detail need not be strictly adhered to but that further changes and modifications may suggest themselves to one skilled in the art all falling with the scope of the invention as defined by the subjoined claims. | Gel-spun multi-filament polyethylene yarns possessing a high degree of molecular and crystalline order, and to the drawing methods by which they are produced. The drawn yarns are useful in impact absorption and ballistic resistance for body armor, helmets, breast plates, helicopter seats, spall shields, and other applications; composite sports equipment such as kayaks, canoes, bicycles and boats; and in fishing line, sails, ropes, sutures and fabrics. | 8 |
This application claims the benefit of U.S. Provisional Application No. 61/608,377, entitled “Network-Wide Active RAN Sharing in Cellular Networks,” filed on Mar. 8, 2012, and U.S. Provisional Application No. 61/758,986, entitled “Radio Access Network Sharing in Cellular Networks,” filed on Jan. 31, 2013, the contents of both of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to radio access network (RAN) sharing and more particularly to active RAN sharing.
The technology disclosed in this document, hereinafter called NetShare, aims to provide an effective RAN (radio access network) sharing technique for spectrum-sharing among several entities on cellular networks. We use the term entities to generally refer to mobile network operators (MNOs) that share the network, mobile virtual network operators (MVNOs), content providers, enterprises etc. Specifically, we focus on the problem of managing wireless resources across multiple basestations among multiple entities sharing the network. NetShare allows different entities to reserve aggregate resources on the cellular network.
NetShare ensures that an entity receives this reserved fraction of the wireless resources across a set of basestations in the cellular network.
In recent years, there have been a few efforts on wireless resource virtualization [1, 2, 3] that enforce resource reservations on every basestation (BS) independently. However, we believe that provisioning aggregate resources to the different entities across multiple basestations is an essential requirement for effective RAN sharing for the following reasons:
(1) The user distribution, average user channel conditions and user-traffic requirements of an entity may vary significantly across basestations even at fine-time scales. Hence, enforcing per-basestation resource reservation may not meet the requirements of an entity from a network perspective.
(2) It may be harder for entities to estimate average resource requirements on a per-basestation level as it varies over time and area [4]. Defining the resource requirement either over a specific geographical area that is potentially covered by several basestations, or based on the architectural hierarchy—for example, all basestations controlled by a specific network gateway—would be a realistic alternative.
No known solution has considered the problem of sharing resources across multiple base stations for several entities as we do in this work. NVS [1], VBTS [2] and LTEvirt [3] attempt to share resource on each individual base station.
[1] R. Kokku, R. Mahindra, H. Zhang, and S. Rangarajan. NVS: A Substrate for Virtualizing WiMAX Networks. In ACM MobiCom., September 2010. [2] G. Bhanage, R. Daya, I. Seskar, and D. Raychaudhuri. VNTS: A Virtual Network Traffic Shaper for Air Time Fairness in 802.16e. In ICC, 2010. [3] L. Zhao, M. Li, Y. Zaki, Timm-Giel, and C. Gorg. LTE Virtualization: From theoretical gain to practical solution In ITC, 2011. [4] U. Paul, A. P. Subramanian, M. Buddhikot, and S. R. Das. Understanding Traffic Dynamics in Cellular Data Networks. In IEEE Infocom, 2011.
BRIEF SUMMARY OF THE INVENTION
An objective of the present invention is to share resources across multiple base stations for several entities.
An aspect of the present invention includes a method implemented in an apparatus used in a radio access network (RAN) sharing system including a plurality of basestations. The method comprises estimating resource requirement or demand of one or more entities in each base station according to feedback from the plurality of basestations, computing resource allocation for said one or more entities, and enforcing the computed resource allocation using basestation-level virtualization.
Another aspect of the present invention includes an apparatus used in a radio access network (RAN) sharing system including a plurality of basestations. The apparatus comprises an estimation unit to estimate resource requirement or demand of one or more entities in each base station according to feedback from the plurality of basestations, a computing unit to compute resource allocation for said one or more entities, and an enforcing unit to enforce the computed resource allocation using basestation-level virtualization.
Still another aspect of the present invention includes a method used in a radio access network (RAN) sharing system. The method comprises transmitting feedback from a plurality of basestations, and computing resource allocation for one or more entities in each of the plurality of basestations according to the feedback, wherein the feedback includes per-flow MCS (modulation and coding scheme) information.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts NetShare's software Architecture.
FIG. 2 depicts NetShare's operation.
FIG. 3 depicts steps that NetShare performs to compute resource allocation.
FIG. 4 depicts a high-level block and/or flow diagram of an aspect of NetShare.
FIG. 5 depicts cellular network architecture.
FIG. 6 depicts an MOCN (multi operator core network) RAN-sharing model.
FIG. 7 depicts cases for NetShare.
FIG. 8 depicts tradeoff analysis of α and β.
FIG. 9 depicts resource distribution with NetShare.
FIG. 10 depicts resource isolation with NetShare
FIG. 11 depicts NetShare with user mobility (the demand and resource allocation of a single entity at a particular basestation over time with and without NetShare).
FIG. 12 depicts QoE (quality of experience) of users with NetShare.
FIG. 13 depicts tradeoff with α.
FIG. 14 depicts tradeoff with β.
FIG. 15 depicts a NetShare WiMAX prototype.
FIG. 16 depicts NetShare implementation details.
FIG. 17 depicts efficacy of NetShare.
FIG. 18 depicts NetShare with uplink Traffic.
FIG. 19 depicts current basestation schedulers.
FIG. 20 depicts NetShare's software Architecture.
FIG. 21 depicts tradeoff with l j b .
FIG. 22 depicts behavior of resource distribution.
FIG. 23 depicts a NetShare WiMAX prototype.
FIG. 24 depicts NetShare implementation details.
FIG. 25 depicts an alternate model.
DETAILED DESCRIPTION
NetShare is designed as a central solution that is deployed in a cellular gateway, e.g. a serving gateway in LTE (Long Term Evolution), or in an apparatus that is disposed between basestations and the cellular gateway. NetShare enables multiple entities to share the RAN of cellular networks such that they receive guaranteed resources.
NetShare optimally allocates wireless resources, for example, in the following steps:
(1) Based on the dynamic requirement for each entity at each basestation, NetShare optimally computes the resource allocation across all basestations for each entity. The allocation is computed, for example, such that it maximizes the overall revenue for the physical network owner.
(2) The formulated resource allocation problem may be infeasible due to many constraints across all entities and base stations. In this case, Netshare attempts to find a solution that only violates the individual upper bound and has minimum total violation. The solution has the least impact on the QoE (quality of experience) and SLA (service level agreement).
(3) NetShare leverages NVS [1] to enforce the computed allocation for each entity at every basestation. Here we chose NVS as an example, since it is a comprehensive basestation-level virtualization technique that provides downlink and uplink resource virtualization. Other systems can be utilized for this purpose.
NetShare allows a cellular network operator to share its network with other operators and virtual operators to save CAPEX/OPEX (capital expenditure/operational expenditure). NetShare also facilitates the operators to provide guaranteed resources for content providers and enterprises to improve QoE for their users generating additional revenue for the operator. NetShare can also improve the SLAs (service level agreements) for group-based data plans for the operator. NetShare allows sharing the resources on a group of basestations while allowing distributing the resources among the entities at each base station proportionally to the resource demand for each entity improving entities' resource utilization.
Referring to FIG. 1 , NetShare includes an optimal resource allocation algorithm as identified by 120 . NetShare may have three other novelties as identified by 110 , 130 and 140 .
Referring to FIG. 2 , NetShare performs the following three operations (steps 220 , 230 , and 240 ) every τ seconds:
In step 220 , to allocate resources to an entity proportional to its resource requirement or demand at every basestation, NetShare computes the demand for entity j (j=1, 2, . . . , J) at basestation b (b=1, 2, . . . , B) using:
d j b = ∑ i ∈ Q j b min ( β A i , S i ) T × R i ,
where d b j is the resource requirement or demand, Q b j is a set of flows that belong to entity j at basestation b, A i and S i are the arrival rate and maximum sustained rate, respectively, of flow i that belongs to entity j, β is a parameter, T is the total number of resource blocks in a base station in one second, and R i is the flow's MCS (modulation and coding scheme) that is obtained by feedback 140 from basestation. Netshare may set β>1 to ensure that it reacts to increase in resource demand of flows.
In step 230 , to compute the optimal resource allocation, NetShare performs the following steps: First, we formulate the problem as a constrained convex optimization problem. Second, we obtain a basically feasible solution to the formulated problem. Third, we apply the phase-one method to find a feasible solution. If the problem is not feasible, return the solution with minimum violation. Otherwise, finally apply the barrier method to find the optimal solution.
In step 240 , after NetShare computes the optimal allocation of wireless resources across basestations, it enforces these allocations on the different basestations using a basestation-level virtualization technology (e.g. NVS [1]).
To correctly estimate the resource requirement of an entity in a basestation, NetShare has to translate bandwidth requirement to resource requirement. To enable this, we define a feedback of per-flow MCS (Modulation and Coding Scheme) from the basestations to the gateway where we implement NetShare.
Step 230 in FIG. 2 is further explained referring to FIG. 3 , as follows:
In step 310 , our formulation of the problem may includes objective function g j (t) which represents the total utility an entity gets when it receives aggregate t resources, and three sets of constraints. First, each entity has lower bound L j and upper bound U j on the aggregate resources it receives. Second, each basestation has total (normalized) resource less than or equal to 1. Third, the resource allocated to entity j at basestation b has individual upper bound u b j and lower bound l b i . As an instance, individual lower bound l b j =αL j /B, where 0<α<1 and B is the number of basestations. Individual upper bound u b j is chosen to be proportional to the resource demand estimated at step 220 in FIG. 2 . However, our algorithm applies to arbitrarily-chosen bounds.
In step 310 , our formulation of the problem may include maximizing
∑ b = 1 B ∑ j = 1 J G j , b ( t j b )
such that
L j ≤ ∑ b = 1 B t j b ≤ U j for all j ,
∑ j = 1 J t j b ≤ f r ( b ) for all b , and l j b ≤ t j b ≤ u j b , for all b , j ,
where t b j is resource allocation for entity j (j=1, 2, . . . , J) at base station b (b=1, 2, . . . , B), G j,b (t b j ) is a utility function, L j and U j are lower and upper bounds on the aggregate resources, respectively, l b j and u b j are individual lower and upper bounds, respectively, and fr(b) represents normalized resources available at basestation b. G j,b (t b j ) can be expressed as follows:
G j,b ( t b j )= d b j ×log( t b j ).
Alternatively, G j,b (t b j ) may also be expressed as follows:
G j,b ( t b j )= d b j ×t b j .
In step 320 , to solve the formulated problem, we first find a basically feasible solution which is one that may only violate the individual upper bound. The solution can obtained via analysis as follows:
t j b = l j b + ( δ j + η j ) · 1 - ∑ j l j b B - ∑ j , b l j b ,
where t b j is resource allocation for entity j (j=1, 2, . . . , J) at base station b (b=1, 2, . . . , B),
δ j = L j - ∑ b l j b , and 0 ≤ η j ≤ min ( ( B - ∑ j L j ) / J , U j - L j ) .
The above solution assumes the following conditions are satisfied:
U j ≥ L j i ) ∑ j L j ≤ B ii ) ∑ j l j b ≤ 1 iii )
These constraints can be easily verified and if they are not satisfied, the parameters (e.g., the lower bounds and upper bounds) should be modified.
In step 330 , the phase-one method starts from a basically feasible solution obtained in 320 , and then applies the barrier method to solve Problem 2 described in the further system details A section. Problem 2 takes all the constraints from the originally formulated problem except replacing individual upper bound u b j with u b j +s b j , where s b j ≧0. The objective of Problem 2 is to minimize
∑ b , j s j b .
If the objective is 0, then we find a feasible solution to the original problem. Once a feasible solution is found, we return and continue to step 340 . If the optimal value of Problem 2 is greater than 0, the original problem has no feasible solution and we return a solution with minimum total violations on the individual constraints.
In step 340 , starting from the feasible solution developed in 330 , we apply the barrier method to find the optimal solution of the formulated problem, where the barrier function is the log-function as described in the further system details sections.
Step 120 in FIG. 1 is described also as follows: (1) The problem formulation in step 310 in FIG. 3 as well as the lower bound and upper bound selection. (2) Find a basically feasible solution in step 320 in FIG. 3 . This solution may only violate the individual upper bound. (3) When finding a feasible solution in step 330 in FIG. 3 , we do not relax all constraints as done in a typical phase-one application. Instead, we only relax the individual upper bound while always making sure all other constraints are satisfied. So if the problem is infeasible, we will return a solution that only violates the individual upper bound and has the minimum sum violation. (4) Find the optimal solution using barrier method with log function as the barrier function.
Referring to FIG. 4 , an aspect of NetShare is explained using a high-level block and/or flow diagram. In block 410 , base stations and gateways are in a cellular network and multiple entities share the cellular network. In block 420 , the aggregate wireless resources of a network of the basestations are sliced to provide guaranteed resource reservations to the entities. In block 430 , effective network-wide RAN sharing is performed in a cellular network.
Blocks 220 a , 230 a , and 240 a detail block 410 . In block 220 a , the resource requirement or demand of every entity in each basestation is estimated according to feedback from the basestations. In block 230 a , optimal resource allocation for each entity in every basestation is dynamically computed. In block 240 a , the computed allocation is enforced in every basestation using basestation-level virtualization techniques.
Blocks 310 a , 320 a , 330 a , and 340 a further detail block 230 . In block 310 a , the problem of network-wide resource allocation is formulated. In block 320 a , a basic feasible solution to the resource allocation problem is found. In block 330 a , a feasible solution to the resource allocation problem is found. In block 340 a , the optimal solution to the resource allocation problem is found.
This invention formulates the problem of sharing the wireless resources of networked base stations, and adapting the barrier method to solve the problem. Steps 110 , 130 , and 140 in FIG. 1 may be used for executing this problem.
The foregoing is to be understood as being in every respect illustrative and exemplary, but not restrictive, and the scope of the invention disclosed herein is not to be determined from the Detailed Description, but rather from the claims as interpreted according to the full breadth permitted by the patent laws. It is to be understood that the embodiments shown and described herein are only illustrative of the principles of the present invention and that those skilled in the art may implement various modifications without departing from the scope and spirit of the invention. Those skilled in the art could implement various other feature combinations without departing from the scope and spirit of the invention. | A method implemented in an apparatus used in a radio access network (RAN) sharing system including a plurality of basestations is disclosed. The method includes estimating resource requirement or demand of one or more entities in each base station according to feedback from the plurality of basestations, computing resource allocation for said one or more entities, and enforcing the computed resource allocation using basestation-level virtualization. Other methods, apparatuses, and systems also are disclosed. | 7 |
BACKGROUND
This invention relates to a method for the selective sorption of n-alkylbenzene from an alkylbenzene mixture with an oxide impregnated ZSM-5 sorbent.
The separation of n-alkylbenzenes from sec-alkylbenzenes may be difficult. More particularly, for example, n-propylbenzene cannot readily be separated from isopropylbenzene (i.e., cumene) by distillation.
The Kaeding U.S. Pat. No. 4,393,262, the entire disclosure of which is expressly incorporated herein by reference, describes a process for the selective production of isopropylbenzene by propylating benzene over a ZSM-12 catalyst. However, even with such selective preparations an undesirable amount of n-propylbenzene may be cogenerated.
SUMMARY
According to one aspect of the invention, there is provided a method for selectively sorbing n-alkylbenzene from an alkylbenzene mixture containing both n-alkylbenzene and sec-alkylbenzene, said method comprising contacting said alkylbenzene mixture with ZSM-5 having impregnated in the pore space thereof at least one difficultly reducible oxide, said contacting taking place under sufficient contacting conditions whereby n-alkylbenzene is sorbed into the pore space of said ZSM-5.
According to another aspect of the invention, there is provided a method for selectively sorbing n-propylbenzene from a propylbenzene mixture containing both n-propylbenzene and isopropylbenzene, said method comprising contacting said propylbenzene mixture with ZSM-5 having impregnated in the pore space thereof magnesium oxide, said contacting taking place under sufficient conditions whereby n-alkylbenzene is sorbed into the pore space of said ZSM-5.
According to another aspect of the invention, there is provided an improved process for the propylation of benzene with selective production of isopropylbenzene, said process comprising contacting mixtures of benzene and propylene with a crystalline zeolite catalyst at a temperature of between about 100° C. and the critical temperature, and a pressure of between about 10 5 N/m 2 and 6×10 6 N/m 2 , said zeolite being characterized by a silica/alumina mole ratio of at least about 12 and a constraint index within the approximate range of 1 to 12, said zeolite being ZSM-12, wherein the improvement is for removing n-propylbenzene impurities from said isopropylbenzene product, said improvement comprising contacting said isopropylbenzene product wth ZSM-5 having impregnated in the pore space thereof at least one difficulty reducible oxide, said contacting taking place under sufficient contacting conditions whereby n-propylbenzene is sorbed into the pore space of said ZSM-5.
DETAILED DESCRIPTION
The sorbent suitable for use in accordance with the present invention is ZSM-5. ZSM-5 may be identified by a characteristic X-ray diffraction pattern and is described in U.S. Pat. No. 3,702,886, the entire disclosure of which is incorporated herein by reference.
When ZSM-5 is prepared in the presence of organic cations, the intracrystalline free space of the freshly prepared ZSM-5 is occupied by organic cations from the forming solution. These organic cations are preferrably removed from the ZSM-5. This removal may be accomplished by heating the ZSM-5 in an inert atmosphere at 540° C. for one hour, for example, followed by base exchange with ammonium salts followed by calcination at 540° C. in air. More generally, it is desirable to remove these organic cations by base exchange with ammonium salts followed by calcination in air at about 540° C. for from about 15 minutes to about 24 hours.
Although ZSM-5 zeolites with a silica to alumina ratio of at least 12 are useful, it is preferred to use ZSM-5 zeolites having higher ratios of at least about 30.
When synthesized in the alkali metal form, the ZSM-5 zeolite is conveniently converted to the hydrogen form, generally by intermediate formation of the ammonium form as a result of ammonium ion exchange and calcination of the ammonium form to yield the hydrogen form. In addition to the hydrogen form, referred to herein as HZSM-5, other forms of the ZSM-5 zeolite wherein the original alkali metal has been reduced to less than about 1.5 percent by weight may be used. Thus, the original alkali metal of the zeolite may be replaced by ion exchange with other suitable ions of Groups IB to VIII of the Periodic Table, including, by way of example, nickel, copper, zinc, palladium, calcium or rare earth metals.
In practicing the desired sorption process, it may be desirable to incorporate the above described crystalline ZSM-5 zeolite in another material resistant to the temperature and other conditions employed in the process. Such matrix materials include synthetic or naturally occurring substances as well as inorganic materials such as clay, silica and/or metal oxides. The latter may be either naturally occurring or in the form of gelatinous precipitates or gels including mixtures of silica and metal oxides. Naturally occurring clays which can be composited with the zeolite includes those of the montmorillonite and kaolin families, which families include the sub-bentonites and the kaolins commonly known as Dixie, McNamee-Georgia and Flordia clays or others in which the main mineral constituent is halloysite, kaolinite, dickite, nacrite or anauxite. Such clays can be used in the raw state as originally mined or initially subjected to calcination, acid treatment or chemical modification.
In addition to the foregoing materials, the zeolites employed herein may be composited with a porous matrix material, such as alumina, silica-alumina, silica-magnesia, silica-zirconia, silica-thoria, silica-beryllia, silica-titania as well as ternary compositions, such as silica-alumina-thoria, silica-alumina-zirconia, silica-alumina-magnesia and silica-alumina-zirconia. The matrix may be in the form of a cogel. The relative proportions of zeolite component and inorganic oxide gel matrix on an anhydrous basis may vary widely with the zeolite content ranging from between about 1 to about 99 percent by weight and more usually in the range of about 5 to about 80 percent by weight of the dry composite.
In order to enhance the sorption selectivity of the ZSM-5 zeolites, the pore space of the zeolites is impregnated with difficulty reducible oxides. Oxides of this type can include oxides of phosphorus as well as those oxides of the metals of Groups IA, IIA, IIIA, IVA, VA, VIA, VIIA, VIIIA, IB, IIB, IVB, or VB of te Periodic Chart of the Elements (Fisher Scientic Company, Catalog No. 5-702-10) which serve to enhance the sorption selectivity properties of the ZSM-5 modified therein. The difficultly reducible oxides most commonly employed to modify the selectivity properties of the ZSM-5 zeolites are oxides of phosphorus and magnesium. Thus, the ZSM-5 zeolites can be treated with phosphorus and/or magnesium compounds in the manner described in U.S. Pat. Nos. 3,894,104; 4,049,573; 4,086,287; and 4,128,592, the disclosures of which are incorporated herein by reference.
Phosphorus, for example, can be incorporated into such ZSM-5 zeolites at least in part in the form of phosphorus oxide in an amount of from about 0.25% to about 25% by weight of the catalyst composition, preferably from about 0.7% to about 15% by weight. Such incorporation can be readily effected by contacting the zeolite composite with a solution of an appropriate phosphorus compound, followed by drying and calcining to convert phosphorus in the zeolite to its oxide form. Preferred phosphorus-containing compounds include diphenyl phosphine chloride, trimethylphosphite and phosphorus trichloride, phosphoric acid, phenyl phosphine oxychloride, trimethylphosphate, diphenly phosphinous acid, diphenyl phosphinic acid, diethylchlorothiophosphate, methyl acid phosphate and other alcohol-P 2 O 5 reaction products. Particularly preferred are ammonium phosphates, including ammonium hydrogen phosphate, (NH 4 ) 2 HPO 4 , and ammonium dihydrogen phosphate, NH 4 H 2 PO 4 . Calcination is generally conducted in the presence of oxygen at a temperature of at least about 150° C. However, higher temperatures, i.e., up to about 500° C. or higher are preferred. Such heating is generally carried out for 3-5 hours but may be extended to 24 hours or longer.
Magnesium oxide is another preferred difficultly reducible oxide which can be incorporated with the ZSM-5 zeolite in a manner similar to that employed with phosphorus. Magnesium can comprise from about 0.25% to 25% by weight preferably from about 1% to 15% by weight present at least in part as magnesium oxide. As with phosphorus, magnesium oxide incorporated is effected by contacting the zeolite with an appropriate magnesium compound followed by drying and calcining to convert magnesium to the zeolite to its oxide form. Preferred magnesium-containing compounds include magnesium nitrate and magnesium acetate. Calcination times and temperatures are generally the same as recited hereinbefore for calcination of phosphorus-containing catalysts.
In addition to treatment of the ZSM-5 zeolites to incorporate phosphorus and/or magnesium oxides as hereinbefore described in detail, such zeolites may also be modified in a substantially similar manner to incorporate thereon a variety of other oxide materials to enhance sorption selectivity. Such oxide materials includes oxides of boron (U.S. Pat. No. 4,067,920); antimony (U.S. Pat. No. 3,979,472); beryllium (U.S. Pat. No. 4,260,843); Group VIIA metals (U.S. Pat. No. 4,275,256); alkaline earth metals (U.S. Pat. No. 4,288,647); Group IB metals (U.S. Pat. No. 4,276,438); Group IVB metals (U.S. Pat. No. 4,278,827); Group VIA metals (U.S. Pat. No. 4,259,537); Group IA elements (U.S. Pat. No. 4,329,533); cadmium (U.S. Pat. No. 4,384,155); iron and/or cobalt (U.S. Pat. No. 4,380,685); Group IIIB metals (U.S. Pat. No. 4,276,437); Group IVA metals (U.S. Pat. No. 4,320,620); Group VA metals (U.S. Pat. No. 4,302,621); and Group IIIA elements (U.S. Pat. No. 4,302,622).
The ZSM-5 sorbents suitable for use in accordance with the present invention preferably have an average particle size of at least 1 micron. As referred to herein, the expression, average particle size, shall refer to the shortest diffusional path length of the particles, i.e., the shortest cross sectional dimension of the particles.
In accordance with the present invention the weight ratio of n-alkylbenzene sorbed to sec-alkylbenzene sorbed may be, e.g., at least 7:1 or even at least 12:1.
It will be readily understood that the impregnated zeolites suitable for use in accordance with the present invention are quite distinguished from zeolites which are merely ion exchanged. In ion exchanged zeolites the number of positive charges from the ion exchange material may be at most, substantially equal to the number of cationic sites in the framework of the zeolite. On the other hand, the number of positive charges in the cations of the difficultly reducible oxide impregnant of the present invention may or may not exceed the number of cationic sites in the framework of the ZSM-5. Accordingly, the ratio of the number of positive charges in the cations of the difficultly reducible oxide impregnant to the number of cationic sites in the framework of the ZSM-5 may be as small as, e.g., 0.1 and may be as large as, e.g., 2 or greater or even 5 or greater. It will be further understood that the number of positive charges in the cations of the difficultly reducible oxide impregnant equals the product of the number of these cations multiplied by the valency of these cations.
The optimal contacting conditions suitable for use in accordance with the present invention may be arrived at by a routine trial and error procedure, especially with reference to the specific embodiments of the Example and Comparative Examples set forth hereinafter. The optimal contacting conditions may vary, e.g., in accordance with the nature of the sorbent and the alkylbenzene mixture used. In some instances, room temperature and atmospheric pressure may be satisfactory. However, in other circumstances it may be desirable to use an elevated pressure and/or an elevated temperature, e.g., a temperature from about 50 to about 100 degrees C.
The alkylbenzene mixture may be in either the liquid or the vapor phase when contacted with the impregnated ZSM-5.
The alkylbenzene mixture which may be contacted with the impregnated ZSM-5 sorbents in accordance with the present invention may comprise, e.g., C 3 -C 6 alkylbenzenes, a particularly suitable alkylbenzene mixture is a mixture of isopropylbenzene and n-propylbenzene. The alkylbenzene mixture may be contacted with the impregnated ZSM-5 sorbent alone or in the presence of inert diluents.
The amount of impregnated ZSM-5 used in accordance with the present invention should be sufficient to sorb the desired amount of n-alkylbenzene. The weight ratio of said n-alkylbenzene in said alkylbenzene mixture to said ZSM-5 may be, e.g., about 1:1 or less.
The alkylbenzene mixture may contain, e.g., from about 0.1 to about 50 percent by weight of n-alkylbenzene.
Selective sorption experiments were carried out by mixing a solution containing n-alkylbenzene, sec-alkylbenzene and an internal standard, adamantane, with a proper amount of zeolites at room temperature or on a steam bath. The residual product was analyzed periodically on G.C. with a 25 meter SE-30 fused silica capillary column.
COMPARATIVE EXAMPLE A
A solution containing 1.535% i-proplybenzene (IPB), 1.62% n-propylbenzene (NPB) and 1.555% adamantane (ADM) in triisopropylbenzene (TIPB), 2.0 grams, was added to 1.0 gram of the hydrogen form of ZSM-5 (i.e., HZSM-5). By the hydrogen form of ZSM-5 is meant non-impregnated ZSM-5 having essentially all of the cationic sites occupied by hydrogen. The change of solution composition as a function of time is shown in Table 1. The amount of NPB in total propylbenzene (PB) fraction decreased from 51.3% in the starting material to 9.8% after 60 minutes. The ratio of NPB absorbed (%A NPB ) to IPB absorbed (%A IPB ), R, is always greater than 1. This indicated that NPB was more selectively absorbed by HZSM-5 than IPB.
TABLE 1______________________________________Catalyst: HZSM-5 Time, minutesWt % Compositions SM 0.5 5 10 30 60______________________________________NPB 1.620 1.704 0.744 0.449 0.159 0.056IPB 1.535 1.833 1.156 0.915 0.653 0.517ADM 1.555 1.902 1.846 1.888 1.924 1.991% NPB in PB 51.3 48.2 39.5 32.9 19.6 9.8 ##STR1## -- 6.1 1.7 1.5 1.4 1.3______________________________________
EXAMPLE 1
Two grams of the solution, as in Example 1, was added to 1 gram of magnesium oxide impregnated ZSM-5 (i.e., MgZSM-5). The magnesium modified ZSM-5 did not sorb much NPB or IPB at room temperature after 60 minutes in contact. The mixture was then heated to 60°-70° C. on a steam bath. NPB was selectively absorbed by the MgZSM-5 sorbent. Results are shown in Table 2. The amount of NPB in total propylbenzene fraction decreased from 51.3% to 18.3% after 30 hours. R is always greater than 1 for all the runs. The results clearly showed that NPB was selectively removed, the degree of selectivity being greater than that shown in Comparative Example A. The average particle size of the MgZSM-5 sorbent of this Example was within the approximate range of from about 1 to about 5 microns.
TABLE 2__________________________________________________________________________Catalyst: MgZSM-5Temperature, °C. -- RT RT 70 70 70 70 70 70Time SM 10 60 20 40 180 210 300 .sup. 30 hrsWt % CompositionNPB 1.620 1.613 1.825 1.396 1.267 1.013 0.902 0.935 0.356IPB 1.535 1.589 1.783 1.640 1.607 1.656 1.575 1.839 1.594ADM 1.555 1.693 1.921 1.751 1.726 1.787 1.677 1.931 1.573% NPB in PB 51.3 50.4 50.6 46.0 44.1 38.0 3.64 33.7 18.3 ##STR2## -- 1.9 1.5 4.6 5.2 7.5 9.9 15.3 infinity__________________________________________________________________________
COMPARATIVE EXAMPLE B
NaZSM-5 was prepared by ion exchanging HZSM-5 of SiO 2 /Al 2 O 3 of 70/1 with quantitative amounts of aqueous NaHCO 3 solution. The resulting NaZSM-5 contained 1.43% by weight of sodium. Two grams of the solution used in Comparative Example A and 1 gram of the calcined NaZSM-5 were mixed at room temperature. The solution composition, analyzed periodically, is shown in Table 3. In all the Runs, the amount of n-propylbenzene absorbed was higher than the amount of isopropylbenzene (R>1). The amount of n-propylbenzene decreased from 51.3% in the starting material to 4.7% after 49 minutes.
The averagae particle size of the NaZSM-5 sorbent of this Comparative Example was within the appropriate range of from about 0.5 to about 1 micron.
TABLE 3______________________________________Catalyst: NaZSM-5 TimeWt % Compositions SM 0.5 6 12 37 49______________________________________NPB 1.193 0.958 0.135 0.039 0.008 0.009IPB 1.129 1.110 0.459 0.310 0.193 0.182ADM 1.140 1.159 1.171 1.199 1.177 1.205% NPB in PB 51.4 46.6 22.727 11.2 4.0 4.7 ##STR3## -- 12.3 1.5 1.3 1.2 1.2______________________________________
COMPARATIVE EXAMPLE C
3A molecular sieve, available from Chemical Dynamic Corporation, ZSM-4 and ZSM-12 were also tested for selective sorption of NPB, using the same solution as in Comparative Example A. Results are shown in Tables 4, 5 and 6. In all runs, the amount of NPB sorbed was mush less than in Example 1 and Comparative Examples A and B. The total amount of % NPB in the solution did not change much.
TABLE 4______________________________________Catalyst:3A molecular sieve TimeWt % Compositions SM 0 5 10 30 60______________________________________NPB 1.620 1.933 1.913 1.841 1.737 1.961IPB 1.535 1.859 1.878 1.807 1.719 2.015ADM 1.555 1.844 1.889 1.851 1.783 2.004% NPB in PB 51.3 51.0 50.5 50.5 50.4 49.3______________________________________
TABLE 5______________________________________Catalyst: ZSM-4 TimeWt % Compositions SM 0 10 30 60______________________________________NPB 1.620 1.787 1.384 1.729 1.691IPB 1.535 1.710 1.411 1.766 1.681ADM 1.555 1.727 1.563 1.958 1.940% NPB in PB 51.3 51.1 49.5 49.5 50.1______________________________________
TABLE 6______________________________________Catalyst: ZSM-12 TimeWt % Compositions SM 0.5 5 10 30 60______________________________________NPB 1.620 1.896 1.606 1.558 2.566 1.315IPB 1.535 1.865 1.719 1.681 2.733 1.573ADM 1.555 1.936 1.891 1.893 2.976 1.875% NPB in PB 50.3 50.4 48.3 48.1 48.4 45.5______________________________________
COMPARATIVE EXAMPLE D
The NaZSM-5 catalyst was prepared as in Comparative Example B. 0.5 gram of the catalyst was added to a solution, 1.0 gram, containing 2.019% n-butybenzene (NBB), 2,263% sec-butylbenzene (SBB), 1.786% adamantane (ADM) in triisopropylbenzene solvent. The solution composition was analyzed periodically and is summarized in Table 7. The amount of NBB in butylbenzene (BB) fraction decreased from 47.2% in the starting solution to 1.5% after 164 minutes in contact with NaZSM-5. This indicates that the n-alkylbenzene was selectively absorbed by NaZSM-5.
TABLE 7__________________________________________________________________________Catalyst: NaZSM-5Time SM 0.5 7 17 24 35 64 164Wt % CompositionNBB 2.019 1.842 0.442 0.277 0.163 0.096 0.062 0.038SBB 2.263 2.240 1.662 1.707 1.775 1.629 1.561 2.581ADM 1.786 1.772 1.814 1.965 2.116 1.938 1.833 2.677% NBB in BB 47.2 45.1 21.0 14.0 6.2 5.6 3.8 1.5 ##STR4## -- 41 2.8 2.8 2.8 2.8 3.0 2.9__________________________________________________________________________
COMPARATIVE EXAMPLE E
A solution, containing 0.0506% NPB in 98.93% IPB, two grams, was added to 1 gram HZSM-5 catalyst. After 10 minutes, the content of NPB decreased to 0.009%, and the purity of IPB increased to 99.803%. The average particle size of the HZSM-5 sorbent of this Comparative Example was within the approximate range of from about 0.5 to about 1 micron.
COMPARATIVE EXAMPLE F
Two grams of the same solution used in Comparative Example E was added to one gram NaZSM-5, prepared as in Comparative Example B. After six minutes, the content of NPB decreased to 0.017%, and the purity of IPB increased to 99.632%.
COMPARATIVE EXAMPLE G
Two grams of the solution containing 0.975% NPB in 98.387% IPB was added to one gram HZSM-12 catalyst. After 16 hours in contact, the amount of NPB was 0.891 and purity of IPB was 98.757. This catalyst was not as selective for NPB sorption as in Comparative Examples E and F. | There is provided a method for the selective sorption of n-alkylbenzene, such as n-propylbenzene, from an alkylbenzene mixture, such as a mixture of n-propylbenzene and isopropylbenzene, with an oxide impregnated ZSM-5 sorbent. This method may be particularly useful in the purification of cumene product streams. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND
Drilling boreholes (e.g., for oil or natural gas wells) sometimes includes the use of drilling fluid, also known as “drilling mud.” Drilling fluid serves to provide counter-pressure against formation pressure as well as to lubricate the drill bit and carry cuttings for hole cleaning. Drilling fluid is typically pumped from a surface mud tank (or “mud pit”) down the drill pipe, so as to exit the drill bit at the end of the drill string. There, it provides its lubrication, sealing and cleaning functions. Thereafter, the drilling fluid flows up the annulus of the drill string and back to the surface. At the surface, the drilling fluid is cleaned of debris and returned to the reservoir, where it is re-used. Thus, drilling fluid flows in a loop, from the surface, to the bottom of the borehole, and back. This flow is referred to as drilling fluid “circulation.”
While it is normal to lose some drilling fluid in the circulation process, excessive lost drilling fluid is expensive in terms of unit mud costs (especially whole synthetic or low toxicity mineral oil mud) and non-productive time. It may pose safety related concerns, as drilling fluid is bulky, difficult to mix, difficult to store and excessive losses may reduce the counter balance effect against formation fluids. Thus, there is a need for diagnosing root cause(s) of, predicting, preventing and correcting, drilling fluid lost circulation events.
BRIEF SUMMARY
In accordance with some aspects of the present disclosure, a method of diagnosing a cause of a drilling fluid lost circulation event is disclosed. The method may include recording data regarding: a rate of drilling fluid loss at the time of the event; cumulative drilling fluid losses as a function of drilling depth; borehole material electrical resistivity as a function of drilling depth; a predicted pore pressure at the time of the event; a predicted fracture gradient at the time of the event; leak-off test behavior prior to or at the time of the event; porosity and permeability information of material at an estimated location of the event; a rate of drilling fluid loss at a time after a lost circulation pill treatment; a borehole image; gamma ray emissions of material at an estimated location of the event; a tectonic regime of material at an estimated location of the event; an equivalent circulation density at an estimated location of the event; borehole temperature as a function of drilling depth; drilling fluid salinity; presence of fractures at an estimated location of the event; fault conductivity at an estimated location of the event; drilling fluid gain when drilling fluid is not being pumped; borehole trajectory; and drill bit drag and penetration rate at the time of the event. The method may also include classifying, based on the data, the event as at least one of: seepage; borehole breathing; induced axial fracture; induced near-orthogonal fracture; natural fracture; vugulars; and ineffective isolation of casing shoe. The method may further include implementing measures, based on the classifying, to at least partially cure the event.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a schematic diagram representing several types of drilling fluid lost circulation causes.
FIG. 2 depicts an example graph of cumulative drilling fluid loss as a function of drilling depth.
FIG. 3 depicts an example plot of electrical resistance as a function of depth.
FIG. 4 depicts an example plot of pore pressure and fracture gradient as a function of depth.
FIGS. 5A-C depict three types of tectonic regimes.
FIGS. 6A-B depict example equivalent circulating density responses during a connection, when drilling fluid circulation is temporarily halted.
FIG. 7 depicts an example plot of temperature gradient as a function of depth.
FIGS. 8A-B depict two example Mohr diagrams.
FIG. 9 is a chart depicting an exemplary drill bit torque charted against time.
FIG. 10 is a flow diagram illustrating an example method according to an embodiment of the disclosure.
DETAILED DESCRIPTION
This disclosure proceeds as follows. Section I discusses causes of drilling fluid lost circulation events. Section II discusses observable physical parameters, and tools for their measurement, that affect drilling fluid circulation losses. Section III discusses correlating the observable parameters to drilling fluid lost circulation event causes. Section IV discusses remedies for the different types of drilling fluid lost circulation event causes.
I. Drilling Fluid Lost Circulation Event Causes
FIG. 1 is a schematic diagram representing several types of drilling fluid lost circulation causes. In particular, FIG. 1 depicts drill string 102 in borehole 104 . Represented schematically are several types of formations 106 - 116 that may cause drilling fluid circulation loss.
Drilling fluid circulation loss may occur via seepage into porous material such as gravel 106 and certain types of sand, e.g., high permeability sand 108 . Drilling fluid may be lost within the matrix permeability of a formation. Pores between formation grains permit drilling fluid to enter the formation and be lost from circulation.
Drilling fluid may be lost to vugular formations 110 or cavernous formations 112 . Such formations 110 , 112 arise as portions of a formation are dissolved or decomposed over geologic time. The voids may form in dolomite or limestone and may range in size from small worm holes to networks of very large caverns. Such voids may receive drilling fluid and cause circulation loss.
Drilling fluid may be lost to naturally occurring faults 114 or fractured formations 116 . Naturally occurring faults 114 and fractured formations 116 may appear in any type of formation, but are particularly common in carbonates. Many factors, such as fluid pressure, folding, faulting, release of lithostatic pressure, dehydration and cooling may result in brittle failure and natural fractures. They are commonly found in tectonically disturbed areas surrounding salt domes and along mountain fronts. Fractures may be activated through depletion of formation in the area of the fault.
Another cause of drilling fluid circulation loss is borehole breathing. Borehole breathing is defined as the condition when a limited amount of drilling fluid, typically on the order of a few tens of barrels, is lost when the drilling fluid pumps are on, and then a similar amount of drilling fluid is gained when the pumps are turned off. These gains and losses are typically not continuous and usually only occur at a time when the pumps are turned on or off.
Borehole breathing is often observed in locations where the operation pressure window (difference between the pore pressure and the fracture gradient) is very narrow or when the equivalent circulation density (ECD) is close to the fracture gradient and the temperature of the circulated drilling fluid is significantly lower than that of the formation temperature. It is likely that borehole breathing is associated with the opening and closing of induced fractures (discussed below) local to the well. This suggests that there are conditions set up by the presence of the well that have led to a lower fracture gradient near the well relative to the fracture gradient further away from the well. The different local fracture gradient may be due to thermal effects (e.g., drilling fluid significantly cooler than the formation) or chemical effects (e.g., drilling fluid significantly higher saline than fluid in the formation).
Borehole breathing should be distinguished from kick, which is characterized by a flow of formation fluids into the wellbore during drilling due to borehole pressure being less than that of formation fluids (due to, for example, use of drilling fluid of too low weight or motion in the drillstring or casing).
Another cause of drilling fluid lost circulation is induced axial (vertical) fractures. Mud weight, ECD, and pressure surge in the wellbore directly affect hoop stress and radial stress. (Hoop stress may be defined as circumferential stresses that follow the perimeter of the wellbore that result due to the presence of the wellbore; radial stress may be defined as stresses that point toward or away from the center of the borehole when viewed as a cross-section). For example, an increase in drilling fluid weight will cause a decrease in hoop stress and an increase in radial stress. Whenever hoop or radial stress becomes tensile (negative), the formation is prone to loss of circulation caused by induced axial fractures.
Induced axial fractures typically occur in the weakest formation. They may happen when the ECD is increased, while weighting up, tripping, using an excessive rate of penetration, when killing a kick, or as the result of a mud ring or other situation causing a temporary pressure surge that breaks down a weak formation. An induced axial fracture can occur in any formation type.
Induced axial fractures are related to borehole breathing. In borehole breathing, a local fracture is induced because the near wellbore fracture gradient is less than the far field fracture gradient, and the ECD is between those quantities. However, when the ECD exceeds both the near and far field fracture gradient, induced fractures continue to grow and significant loss of drilling fluid can occur. Typically, fracture length is a few feet to hundreds of feet, and fracture width (aperture) is less than one millimeter up to about 25 millimeters. However, fracture dimensions vary greatly.
Another cause of drilling fluid circulation loss is induced near-orthogonal (horizontal) fractures. Such fractures may be generated in the thrust/reverse stress region when overburden stress is overcome by high mud weight or ECD. The in-situ stress state (normal, strike-slip or over-thrust/reverse) may change with depth, geological structure (e.g., salt), depletion, and in different regions. At shallow locations (e.g., 2,500 feet or less), the horizontal stresses may exceed vertical stress. Abnormally high horizontal stress may exist in the subsalt formation.
Another cause of drilling fluid circulation loss is unplanned holes in the casing. While drilling directional and horizontal wells, casing wear is a potential problem. Factors related to casing wear include drillpipe hand banging, hole deviation, and, in particular, dogleg severity.
Another cause of drilling fluid circulation loss is ineffective isolation of the casing shoe. A casing shoe is the termination of a bottom section of casing, i.e., the bottom of a casing string. Casing shoes are typically cemented in place during a cement pumping job, which places cement around the bottom of the shoe, thereby isolating any new formation drilled out of that casing shoe from shallower formations behind the casing. If the cement job fails to effectively isolate the casing shoe from the shallower formation, drilling fluid lost circulation can occur.
II. Diagnostic Parameters and Tools
This section discusses many tools and associated parameters that may be used to diagnose the cause of a drilling fluid lost circulation event.
A first parameter regarding diagnosing drilling fluid lost circulation and root cause analysis is the rate of loss. This parameter is of fundamental importance, and may be measured in, e.g., barrels per hour (of lost fluid). In general, this parameter may be measured in terms of volume units per time units. This parameter may be determined by monitoring drilling fluid pumps and fluid levels in the surface drilling fluid storage pits.
A second parameter regarding diagnosing drilling fluid lost circulation and root cause analysis is cumulative loss as a function of drilling depth (for example, measured in barrels per foot). This parameter may be determined by monitoring the position of the drillstring and the drilling fluid pumps. Note that here, as well as in the rest of this disclosure, a first parameter as a function of a second parameter means that, for at least two different values of the second parameter, corresponding values of the first parameter are known. Typically, many pairs of values are known.
FIG. 2 depicts an example graph of cumulative drilling fluid loss as a function of drilling depth. In particular, FIG. 2 depicts drilling depth 202 on the y-axis and cumulative losses 204 on the x-axis. Note the substantial losses 206 occurring at about 14,300 feet.
A third parameter regarding diagnosing drilling fluid lost circulation and root cause analysis is electrical resistivity as a function of depth. In general, resistivity is a fundamental material property that represents how strongly a material opposes the flow of electrical current. Most rock materials are essentially insulators, while their enclosed fluids are generally conductive (with the exception of hydrocarbons). When a formation is porous and contains salty water, the overall resistivity will be low. When the formation contains hydrocarbons, the resistivity will be high. This parameter is typically used only with oil-based drilling fluids. It may be measured using a set of electrodes introduced into the borehole after drilling has occurred, or the electrodes may be present in the drill string itself. When lost circulation has occurred, a repeat measurement of resistivity may indicate where lost circulation has occurred as a function of oil based mud invading saline formations with a corresponding change in resistivity.
FIG. 3 depicts an example plot of electrical resistance as a function of depth. In FIG. 3 , the y-axis represents depth, and the x-axis represents ohms on a logarithmic scale, from 0.2Ω to 20Ω. Zone 302 corresponds to an induced fracture and subsequent drilling fluid lost circulation.
A fourth parameter regarding diagnosing drilling fluid lost circulation and root cause analysis is pore pressure and fracture gradient as a function of depth. As used herein, pore pressure means the pressure of fluids in a formation's pores; fracture gradient means the pressure required to induce a fracture. These parameters are particularly effective for determining the location of drilling fluid losses. Pore pressure and fracture gradient can be measured in some instances by using specialized tools or performing specific wellbore tests.
FIG. 4 depicts an example plot of pore pressure 402 and fracture gradient 404 as a function of depth. The x-axis represents equivalent mud weight, and the y-axis represents depth. Note that losses occurred in the ranges 1220-1420 m and 1660-1800 m.
A fifth parameter regarding diagnosing drilling fluid lost circulation and root cause analysis is porosity information. Such information includes porosity, permeability and pore throat size. Notably, any of these parameters may be derived from any other of these parameters, as is known to those of skill in the art. Accordingly, “porosity information” is used throughout this disclosure to refer to any, a combination, or all of these three parameters. Porosity information may be measured using tests run on formation core or from analysis on measurements made of the formation down-hole.
A sixth parameter regarding diagnosing drilling fluid lost circulation and root cause analysis is pill behavior. A “pill” according to this disclosure is a relatively small quantity (e.g., less than 200 barrels) of specialized (e.g., high viscosity) drilling fluid. Usually, rate of loss is reduced once a high-viscosity pill reaches a loss zone. Accordingly, tracking rate of loss as affected by pill position can assist in locating loss zones. Pill position itself may be determined by roughly estimating volumetric capacities of the drill string, open hole and cased hole sections and comparing them to the volumetric capacity of each stroke of the rig pumps and the pump rate.
A seventh parameter regarding diagnosing drilling fluid lost circulation and root cause analysis is borehole imaging. Borehole images may be generated by measuring something sensitive to the difference between rock and drilling fluid; such as density, acoustic velocity, resistivity or gamma rays (the latter being affected by the presence of different elemental isotopes). The measurement instrument may be lowered into the borehole after drilling, or may be attached to the drillstring itself. One application of such images is to locate and identify fractures as induced or natural, horizontal or vertical.
An eighth parameter regarding diagnosing drilling fluid lost circulation and root cause analysis is lithology. Here, “lithology” means identification of rock material. This parameter is related to diagnosing drilling fluid lost circulation and root cause analysis because different materials have different properties such as permeability, strength, stiffness and deformation. For example, high natural permeability is normal for gravels and coarse sandstone, while shale has a higher fracture strength than sandstones. Lithology can be obtained from gamma ray logs, which are used to characterize the type of rock or sediment in a borehole. Different types of rock emit different amount of gamma radiation in a predictable manner. For example, shales usually emit more gamma radiation than other sedimentary rock.
A ninth parameter regarding diagnosing drilling fluid lost circulation and root cause analysis is tectonic regime. Here, “tectonic regime” generally refers to whether the geological environment has a normal stress regime, a strike-slip stress regime, or a thrust (reverse) stress regime. These environments are determined by the relation between the horizontal stresses and the vertical stresses.
FIGS. 5A-C depict three types of tectonic regimes. In a normal tectonic regime 502 shown in FIG. 5A , S v >SH≧S h , where S v is total overburden stress, S h is minimum horizontal stress present (identified with fracture gradient in this disclosure), and S H is maximal horizontal stress present. In a strike-slip tectonic regime shown in FIG. 5B , S H ≧S v >S h . In a reverse tectonic regime shown in FIG. 5C , S H >S h S v .
A tenth parameter regarding diagnosing drilling fluid lost circulation and root cause analysis is annular pressure response to drilling fluid pump activation and deactivation. Dull, exponential responses indicate potential borehole breathing or induced near-wellbore fractures. Annular pressure may be measured by a PWD (Pressure While Drilling) tool in the drill string.
FIGS. 6A-B depict example ECD responses during a connection, when drilling fluid circulation is temporarily halted. Sharp responses for non-fractured rock shown in FIG. 6A indicate a lack of fluid loss, whereas dull, exponential responses for fractured rock shown in FIG. 6B indicate a fractured formation.
An eleventh parameter regarding diagnosing drilling fluid lost circulation and root cause analysis is near-wellbore formation temperature as a function of depth. Changes in temperature in the near-wellbore region occur at all times in the open hole. Formations near the bit may be cooled by the passage of cooler drilling fluid from the drill pipe. Further up in the hole section, formations may become warmed by the passage of hotter drilling fluid from below. When circulation stops for a period of time, near borehole temperatures revert to their in-situ values. All of these temperature changes cause an alteration in local stresses, which can affect lost circulation. When lost circulation occurs, abnormal deviations in the temperature gradient can be used to pinpoint the location of the lost zone. Temperature may be determined using a thermocouple or other conventional device, which may be lowered into the borehole after drilling or may be attached to the drill string itself.
FIG. 7 depicts an example plot of temperature gradient as a function of depth. The x-axis represents temperature gradient (degrees Fahrenheit per foot) and the y-axis represents depth. Temperature discontinuities 702 indicate potential locations of drilling fluid loss zones.
A twelfth parameter regarding diagnosing drilling fluid lost circulation and root cause analysis is drilling fluid salinity. Typically, drilling fluid salinity is selected by the well operator. Drilling fluid salinity affects osmotic pressure between the wellbore and surrounding material, and thus affects wellbore instability. Typically, an operator has control over salinity when the drilling fluid is mixed or received from a vendor.
A thirteenth parameter regarding diagnosing drilling fluid lost circulation and root cause analysis is seismic data, in particular, the location of natural faults. Such data may be gathered using known seismic techniques.
A fourteenth parameter regarding drilling fluid lost circulation is fault or natural fracture conductivity analysis. All rocks are faulted or fractured to some extent, and these can affect lost circulation. Stresses may be altered in the vicinity of faults, and zones of mechanical damage to the formation may extend for several hundred feet from the fault zone in some rock types. The orientation of the fault with respect to the regional stress will influence the likelihood of incurring losses into the fault when it is intersected by the wellbore. In order to analyze the conductivity of faults or fractures, in-situ stresses (overburden, maximum and minimum horizontal stresses) is first resolved into three principle stresses on fault or natural fracture planes through a coordinate transform. Then a 3D Mohr diagram can be developed. If the stresses lie above the critical frictional line (e.g., μ=0.6), the fault or natural fracture is in a critically stressed state. These fault or natural fractures are most likely conductive.
FIGS. 8A-B depict two example Mohr diagrams. FIG. 8A depicts hydraulically conductive fractures, and FIG. 8B depicts non-hydraulically conductive fractures. Each fault is represented by a dot. Critically stressed faults lie in the range between μ=0.6 and μ=0.9. Drilling through critically stressed faults may result in lost circulation and fault slip, causing tight hole problems. Most non-hydraulically conductive faults lie below the critical line μ=0.6.
A fifteenth parameter regarding diagnosing drilling fluid lost circulation and root cause analysis is drill bit depth when losses occur. Once the drill bit reaches a natural loss zone (e.g., unconsolidated sand, caverns, vugular formations), losses may occur. For losses into caverns or vugular formations, the bit drops through a void preceded by a drilling break.
A sixteenth parameter regarding diagnosing drilling fluid lost circulation and root cause analysis is connection or trip gas behavior. Connection or trip gas is gas that is introduced in the wellbore when the drilling fluid circulation pumps are cut off. In instances where borehole breathing is occurring, fracture opening and closing may cause gas infused mud to come into the wellbore when the pumps are shut off. This may manifest itself on surface as a connection or pumps-off gas event. Connection or trip gas may be detected by flame ionization detectors on the rig.
A seventeenth parameter regarding diagnosing drilling fluid lost circulation and root cause analysis is well trajectory. Well trajectory affects anisotropy including in-situ stress and rock mechanical properties. Drilling fluid lost circulation may occur when the well trajectory is in an adverse orientation with an in-situ stresses and naturally-occurring fractured or faulted formations. In particular, as borehole angle increases, the drilling fluid weight window between the upper limit (above which loss circulation occurs) and the lower limit) below which wellbore instability occurs) becomes more narrow in normal in-situ stress state (overburden>maximum horizontal stress>minimum horizontal stress). Wellbore trajectory should be optimized considering wellbore stability, lost circulation mitigation and reservoir management.
An eighteenth parameter regarding diagnosing drilling fluid lost circulation and root cause analysis is casing physical integrity, which may be determined by pressure testing. The behavior of the pressure build-up response can identify whether there is a leak in the casing. It is also used as a comparison to the integrity tests done on exposed formation as a baseline for predicting how the fluid test should ideally respond.
A nineteenth parameter regarding diagnosing drilling fluid lost circulation and root cause analysis is drill bit torque. Lost circulation may be accompanied by excessive torque and drag when the drill bit rotates or passes through the loss zone. Drilling a highly fractured zone where bit torque varies abnormally can be another indicator for identifying the zone of loss. Drill bit torque may be monitored from the surface using conventional torque measurement sensors.
FIG. 9 is a chart depicting an exemplary drill bit torque charted against time. A sudden change in torque 902 along with a drop in mud flow-out can indicate that abnormally high torque is being experienced when lost circulation is occurring.
A twentieth parameter regarding diagnosing drilling fluid lost circulation and root cause analysis is drilling fluid information. Such information includes drilling fluid type (e.g., water-based or oil based), drilling fluid rheology, and drilling fluid weight (density). Losses can be managed or prevented through proper formulation of drilling fluids. Meanwhile if loss occurs, root cause of losses can be better understood through analyzing formulation and performance of drilling fluid.
A twenty-first parameter regarding diagnosing drilling fluid lost circulation and root cause analysis is the location of the loss zone. Several parameters discussed above (e.g., cumulative loss as a function of drilling depth) may be used to make this determination.
It will be appreciated that the parameters identified above are not necessarily in any order of significance.
III. Mapping Parameters to Drilling Fluid Lost Circulation Causes
Section II above discusses a plethora of parameters and how they may be determined. This section discussed how to use knowledge of these parameters (or a portion thereof) to determine the cause (as discussed in Section I) of drilling fluid lost circulation.
A conclusion that lost circulation is due to seepage may be warranted if the observed parameters match those appearing in Table 1 below.
TABLE 1
OBSERVATIONS
TOOLS
Loss rate most likely less than 10 bph
< >
Rate of loss
Losses start as soon as high permeable
< >
Losses against depth/
formation penetrated by the bit.
lithology
Loss rate increases as more permeable
< >
Rate of loss
formation is exposed.
Losses against depth/
lithology
Torque & drag increases with event of
< >
Torque & drag
seepage losses
Permeable formation must be exposed.
< >
Porosity/Permeability/
Pore throat size
Pore throats are mismatched to
< >
Porosity/Permeability/
particle sizes.
Pore throat size
As represented in Table 1, the following parameters may be used to determine that lost circulation is due to seepage. The rate of loss is low (e.g., less than 10 barrels per hour). Cumulative losses reveal that losses start as soon as a high permeability formation is penetrated by the bit. The torque and drag of the drill bit increases relative to prior torque measurements. Pore information reveals that a permeable formation has been penetrated and that drilling fluid particle sizes are mismatched to pore size.
A conclusion that lost circulation is due to vugular or cavernous formations may be warranted if the observed parameters match those appearing in Table 2 below.
TABLE 2
OBSERVATIONS
TOOLS
Moderate to high loss rate (>10 bph)
< >
Rate of loss
Steep change in loss against depth curve
< >
Loss against depth
High resistivity generated at the loss zone
< >
Resistivity tool
when OBM is used
ECD < FG
< >
PP-FG prediction
Torque/Drag/ROP increases
< >
Torque/Drag/ROP
Vugs/Caverns can be observed in image logs
< >
Image logs
Usually occurs in carbonate formations
< >
Lithology
(chalk, limestone)
No stable hydrostatic pressure between
< >
PWD/ECD
losses and gains
Onset at first penetration (bottom of
< >
Bit depth location
the hole)
Total losses, no gain
< >
Loss/Gain behavior
As represented in Table 2, the following parameters may be used to determine that lost circulation is due to vugular or cavernous formations. The loss rate is moderate to high (e.g., more than ten barrels per hour). The cumulative losses as a function of depth change sharply. There is a high resistivity at the loss zone when oil-based drilling fluid is used. ECD is less than the fracture gradient. Drill bit torque, drag and penetration rate may suddenly increase. Image logs reveal vugulars or caverns. Lithology may show carbonate formations. Hydrostatic pressure is unstable between losses and gains. Losses start occurring when the drill bit first penetrates the suspected vugular zone. There is no evidence of drilling fluid gain.
A conclusion that lost circulation is due to natural faults may be warranted if the observed parameters match those appearing in Table 3 below.
TABLE 3
OBSERVATIONS
TOOLS
Typically rate of loss > 30 bph
< >
Rate of loss
Steep change in loss against depth curve
< >
Loss against depth
High resistivity generated at the loss
< >
Resistivity tool
zone when OBM is used
ECD < FG
< >
PP-FG prediction
Sinusoidal cross cutting fracture
< >
Image logs
Compliance behavior on PWD at
< >
PWD/ECD
connections
Significant loss occur once bit touches
< >
Bit depth location
the natural fracture
Loss is much greater than gain
< >
Loss/Gain behavior
Anomalous temperature at loss zone
< >
Temperature
crosses
surveys
Losses decrease when high viscosity fluid
< >
Pill behavior
reaches the loss zone
May be recognized through seismic analysis
< >
Seismic
As represented in Table 3, the following parameters may be used to determine that lost circulation is due to natural faults. The loss rate is high (e.g., more than 30 barrels per hour). There is a steep change in cumulative losses. There is a steep change in resistivity when using oil-based drilling fluid. ECD is less than the fracture gradient. Images reveal a sinusoidal fracture. There is compliance behavior on pressure while drilling at connections. Significant losses occur once the drill bit touches the loss zone. Lost drilling fluid greatly outweighs gained drilling fluid. Temperature at the loss zone is different from nearby formations. Losses decrease with high viscosity pill insertion. Seismic data may reveal a natural fault.
A conclusion that lost circulation is due to borehole breathing may be warranted if the observed parameters match those appearing in Table 4 below.
TABLE 4
OBSERVATIONS
TOOLS
More than 30 bph after pump on and
< >
Rate of loss
decreases quickly with time
High resistivity generated at the loss
< >
Resistivity tools
zone when OBM is used
ECD is close to FG at loss zone
< >
PP-FG prediction
Typically losses in shale formation
< >
Lithology
Compliance behavior on PWD at
< >
PWD/ECD
connections
Salinity of mud may be higher than
< >
Salinity information
that of shale formation
Usually gives back what was lost when
< >
Loss/Gain behavior
the ECD is reduced
Flow back rate decreases with time
< >
Loss/Gain behavior
Sometimes gives connection gas
< >
Loss/Gain behavior
As represented in Table 4, the following parameters may be used to determine that lost circulation is due to borehole breathing. When the pump is turned on, a large rate of loss is observed (e.g., more than thirty barrels per hour), which then decrease quickly with time. When oil-based drilling fluid is used, high resistivity is detected in the loss zone. ECD is close to the fracture gradient in the loss zone. Lithology typically reveals shale. There is compliance behavior on pressure while drilling at connections. Salinity of the drilling fluid may be higher than that of a shale formation. Lost drilling fluid is typically regained when ECD is reduced, with the flow back rate decreasing with time. There is sometimes connection gas.
A conclusion that lost circulation is due to induced vertical fractures may be warranted if the observed parameters match those appearing in Table 5 below.
TABLE 5
OBSERVATIONS
TOOLS
Typically rate of loss > 30 bph
< >
Rate of loss
Can be any point in the open hole
< >
Loss against depth
High resistivity generated at the loss
< >
Resistivity tool
zone when OBM is used
Losses starts with ECD > FBP (formation
< >
PP-FG prediction
breakdown pressure) and continues with
ECD > S h
Losses decrease when high viscous fluid
< >
Pill behavior
reaches loss zone
Symmetric fracture axial to the wellbore
< >
Image logs
Typically starts in sand or silt and spreads
< >
Lithology
in shale
Normal stress regime (S v >
< >
Tectonic region
S H > S h )
Abnormal ECD increase possibly due to
< >
PWD/ECD
pack-off, surge etc.
Abnormal temperature at loss zone
< >
Temperature surveys
Loss is much greater than gain
< >
Loss/Gain behavior
As represented in Table 5, the following parameters may be used to determine that lost circulation is due to induced vertical fractures. There is a high loss rate, e.g., greater than 30 barrels per hour. Location may be anywhere. High resistivity is obtained in the loss zone when oil-based drilling fluid is used. Losses start when ECD exceeds formation breakdown pressure and continues when ECD exceeds the minimum horizontal stress. Losses decrease when a high-viscosity pill reaches the loss zone. Images reveal a symmetric fracture axial to the wellbore. Induced vertical fractures typically start in sand or silt and spread to shale. The tectonic regime is normal. The loss circulation event may have been caused by an abnormal increase in ECD possibly due to a sudden restriction to flow (by cuttings etc.). There is an abnormal temperature in the loss zone. Lost drilling fluid exceeds gained drilling fluid.
A conclusion that lost circulation is due to induced horizontal fractures may be warranted if the observed parameters match those appearing in Table 6 below.
TABLE 6
OBSERVATIONS
TOOLS
Typically rate of loss > 30 bph
< >
Rate of loss
Can be any point in the open hole
< >
Loss against depth
High resistivity generated at the loss
< >
Resistivity tool
zone when OBM is used
Losses starts with ECD > FBP (formation
< >
PP-FG prediction
breakdown pressure) and continues with
ECD > S v
Losses decrease when high viscosity fluid
< >
Pill behavior
reaches loss zone
Typical starts in sand or silt and spreads
< >
Lithology
in shale
Reverse in-situ stress region (S H >
< >
Tectonic region
S h > S v )
Abnormal ECD increase possibly due to
< >
PWD/ECD
pack-off, surge etc.
Abnormal temperature at loss zone
< >
Temperature surveys
Loss is much greater than gains
< >
Loss/Gain behavior
As represented in Table 6, the following parameters may be used to determine that lost circulation is due to induced horizontal fractures. There is a high loss rate, e.g., greater than 30 barrels per hour. Location may be anywhere. High resistivity is obtained in the loss zone when oil-based drilling fluid is used. Losses start when ECD exceeds formation breakdown pressure and continues when ECD exceeds the minimum horizontal stress. Losses decrease when a high-viscosity pill reaches the loss zone. Induced vertical fractures typically start in sand or silt and spread to shale. The tectonic regime is usually reverse in-situ stress (maximum horizontal stress>minimum horizontal stress>overburden). The loss circulation event may have been caused by an abnormal increase in ECD possibly due to a sudden restriction to flow (by cuttings etc.). There is an abnormal temperature in the loss zone. Lost drilling fluid exceeds gained drilling fluid.
A conclusion that lost circulation is due to a hole in the casing may be warranted if the observed parameters match those appearing in Table 7 below.
TABLE 7
OBSERVATIONS
TOOLS
Loss rate varies depending upon the size and
< >
Rate of loss
location of the channel
Losses occur below fracture gradient expected
< >
PP-FG
at the shoe
Losses decreases when high viscous fluid
< >
Pill behavior
reaches the hole in casing
Will induce losses into a shallow formation
< >
Bit depth location
up the well
Casing can not hold pressure
< >
Casing test/packer
As represented in Table 7, the following parameters may be used to determine that lost circulation is due to a hole in the casing. The loss rate varies depending on the size and location of the channel. Losses occur below the fracture gradient expected at the shoe. Losses decrease when a high-viscosity pill reaches the loss zone. Losses may be induced into a shallow formation higher up on the wellbore. The casing itself fails a pneumatic pressure test.
A conclusion that lost circulation is due to ineffective isolation of the casing shoe may be warranted if the observed parameters match those appearing in Table 8 below.
TABLE 8
OBSERVATIONS
TOOLS
Loss rate will vary case by case depending
< >
Rate of loss
upon the size of the channel
Losses start when ECD is less than FG
< >
PP-FG prediction
at shoe
LOT would be lower than normal for
< >
LOT behavior
that depth
Slope of Leak Off is less than the slope
< >
LOT behavior
of casing test
Cannot use LOT to diagnose the low
< >
LOT/FIT analyzing
LOT when permeable formation is
tool Lithology
present below the shoe
Losses decrease when high viscous fluid
< >
Pill behavior
is at the shoe
Cooling effects behind the casing
< >
Temperature survey
As represented in Table 8, the following parameters may be used to determine that lost circulation is due to ineffective isolation of the casing shoe. The loss rate varies depending upon the size of the channel. Losses begin when ECD is less than the predicted fracture gradient at the shoe. The leak-off test (measure of the fracture strength of the formation under the casing shoe) is less that the predicted value, because it is actually measuring fracture strength of a shallower formation behind casing. The slope of the pressure build-up profile is less than that of the casing test because of the presence of the channel (transmitting pressure behind casing). Losses decrease when a high-viscosity pill reaches the shoe. The temperature at the casing shoe is lower than surrounding temperatures.
IV. Remedies and Preventative Measures
This section discusses various remedial and preventative measures that may be employed to treat or prevent each of the eight loss mechanisms discussed herein.
Losses due to seepage may be both remedied and prevented by introducing particle sizes that are matched to the pore throat size of the formation into the drilling fluid.
For losses due to vugulars or caverns, remedial measures are generally limited to cementing, e.g., using a squeeze cementing procedure.
Losses due to vugulars or caverns may be minimized or prevented by incorporating filament fibers into the drilling fluid, by using a high gel drilling fluid, or aerating the drilling fluid. Losses can also be prevented or managed via pills that can be placed across the vugular zone such as cross-linked polymers, high thixotropic fluid, and high fluid loss pills. Another prevention strategy includes the use of mud cap or Managed Pressure Drilling strategies.
For losses due to natural faults, the following remedial measures may be used. A filament fiber pill may be used as a temporary measure. A high fluid loss pill which may/may not develop compressive strength or a cross link polymer pill may also be used. Cement (e.g., a squeeze cementing treatment) is another remedial treatment.
Losses due to natural faults may be prophylactically managed by the use of a pre-treatment with a sealing agent.
For losses due to borehole breathing, the following remedial measures may be used. ECD should be reduced such that it is below the far-field fracture gradient. This could be achieved by making changes to: drilling fluid weight; rate of penetration; fluid viscosity; and RPM. Additionally, the drilling fluid may be heated.
For losses due to borehole breathing, the following preventative measures may be used. Similar to the remedial measures, ECD should be managed by adjusting: drilling fluid weight; rate of penetration; fluid viscosity; and RPM. Other preventative strategies include employing a flat rheology mud system, a dual gradient drilling system or a continuous circulating drilling system. ECD can also be managed by utilization of specialized ECD reduction tools or by swab/surge reduction tool. Salinity should also be adjusted to match that of the formation. Additionally, drilling fluid may be heated.
For losses due to induced vertical fractures, the following remedial measures may be used. ECD may be reduced by adjusting the weight of the drilling fluid, the rate of penetration or the drilling fluid flow rate. Cement with CaCO 3 or a resin with bridging solids may be squeezed into the fracture. Filament fibers incorporated into the drilling fluid may be used. A casing, liner or solid expandable tubing may be used.
For losses due to induced vertical fractures, the following preventative measures may be used. ECD may be reduced by adjusting the weight of the drilling fluid, the rate of penetration or the drilling fluid flow rate. A drilling fluid with CaCO 3 particles may be introduced to increase the fracture gradient of sand. A casing, liner or solid expandable tubing may be used.
For losses due to induced horizontal fractures, the following remedial measures may be used. ECD may be reduced by adjusting the weight of the drilling fluid, the rate of penetration or the drilling fluid flow rate. Filament fibers incorporated into the drilling fluid may be used. A high fluid loss pill which develops compressive strength may also be used for sand formations. A casing, liner or solid expandable tubing may be used.
For losses due to induced horizontal fractures, the following preventative measures may be used. ECD may be reduced by adjusting the weight of the drilling fluid, the rate of penetration and the drilling fluid flow rate. A casing, liner or solid expandable tubing may be used.
For losses due to a perforated casing, the following remedial measures may be used. A cement squeeze may be used. A casing patch may be used. A lost circulation material may be introduced.
For losses due to ineffective isolation of the casing shoe, the following remedial measures may be used. Cement or a pill containing a cross-linked polymer may be squeezed to plug off any channels. Filament fibers can be incorporated into the drilling fluid. A drilling fluid with CaCO 3 particles may be introduced. A high fluid loss pill which may/may not develop compressive strength or a cross link polymer pill may also be used for situations where the loss rate is moderate to high.
FIG. 10 is a flow diagram illustrating an exemplary method according to an embodiment of the disclosure. At block 1002 , data regarding an actual or potential drilling fluid lost circulation event are recorded. Section II discusses this step in detail. The recording may include recording on electronic media, paper media, or any other persistent medium. At block 1004 , the actual or potential drilling fluid lost circulation event is classified as being due to (or potentially due to) one of several causes. The causes are discussed in detail above in Section I; while techniques for classification based on the data gathered at block 1002 are discussed in detail above in Section III. At block 1006 , remedial or preventative measures are determined. This step is discussed in detail above in Section IV. At block 1008 , the remedial or preventative measures are applied. This step is discussed in detail above in Section IV.
Note that many of the steps recited herein may be automated using installed executable software. For example, the parameters discussed in Section II may be stored in an electronic database. Pattern matching algorithms, e.g., support vector machines, may be used to map the parameters to the causes discussed in Section I. The software may automatically retrieve stored data regarding remedies or preventative measures that correspond to the disclosed causes. The software may be implemented on a computer, such as a personal computer executing an operating system.
While the present disclosure has been described according to its preferred embodiments, it is of course contemplated that modifications of, and alternatives to, these embodiments, such modifications and alternatives obtaining the advantages and benefits of this disclosure, will be apparent to those of ordinary skill in the art having reference to this specification and its drawings. It is contemplated that such modifications and alternatives are within the scope of this disclosure as subsequently claimed herein. | In accordance with aspects of the present disclosure, techniques for predicting, classifying, preventing, and remedying drilling fluid circulation loss events are disclosed. Tools for gathering relevant data are disclosed, and techniques for interpreting the resultant data as giving rise to an actual or potential drilling fluid lost circulation event are also disclosed. | 4 |
RELATED APPLICATIONS
This application is related to and claims priority to U.S. patent Ser. No. 09/942,437 entitled “Dynamic Brightness Range for Portable Computer Displays Based on Ambient Conditions,” by Gettemy, filed on Aug. 29, 2001, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of portable computer systems, such as personal digital assistants or palmtop computer systems. Specifically, embodiments of the present invention relate to a portable computer system equipped with a dynamic brightness range control to maximize readability in various ambient lighting conditions and to prolong the lifetime of the display, the light and the battery.
2. Related Art
A portable computer system, such as a personal digital assistant (PDA) or palmtop, is an electronic device that is small enough to be held in the hand of a user and is thus “palm-sized.” By virtue of their size, portable computer systems are lightweight and so are exceptionally portable and convenient. These portable computer systems are generally contained in a housing constructed of conventional materials such as rigid plastics or metals.
Portable computer systems are generally powered using either rechargeable or disposable batteries. Because of the desire to reduce the size and weight of the portable computer system to the extent practical, smaller batteries are used. Thus, power conservation in portable computer systems is an important consideration in order to reduce the frequency at which the batteries either need to be recharged or replaced. Consequently, the portable computer system is placed into a low power mode (e.g., a sleep mode or deep sleep mode) when it is not actively performing a particular function or operation.
There are many other similar types of intelligent devices (having a processor and a memory, for example) that are sized in the range of laptops and palmtops, but have different capabilities and applications. Video game systems, cell phones, pagers and other such devices are examples of other types of portable or hand-held systems and devices in common use.
These systems, and others like them, have in common some type of screen for displaying images as part of a user interface. Many different kinds of screens can be used, such as liquid crystal displays, and field emission displays or other types of flat screen displays. Refer to FIGS. 1A–1D for examples of types of display screens.
As illustrated in FIG. 1A , a reflective display is shown including a display screen 110 having a reflective surface 130 so that the display is enhanced in bright external light 103 such as sunlight but requires a front light 120 in darker environments. The display screen 150 of FIG. 1B can also be transflective. It has a reflector 160 to reflect light from an external source 103 . This reflector 160 comprises holes 170 through which light from the backlight 140 can pass for lighting darker environments. FIG. 1C illustrates another type of display screen which is transmissive. The transmissive display screen 101 has no reflector so it requires a backlight 102 . When bright external light, such as sunlight, is present, this external light 103 competes with the backlight and it becomes difficult to see the transmissive display screen. Another non-reflective type of display is the emissive display screen as illustrated in FIG. 1D . Among the family of emissive display screens one finds Organic Light Emitting Diode (OLED), Organic Electro-Luminescent (OEL), Polymer Light Emitting Diode (Poly LED), and Field Emission Displays (FED). The emissive screen 190 contains light emitting elements and, therefore, requires no separate backlight. As with the transmissive screens, bright external light competes with the emitted light of the emissive display screen. Emissive and transmissive displays can not be viewed very well in the sun unless the brightness is turned very high. High brightness can reduce the life of the display and cause poor battery life performance.
One conventional approach to adjusting the brightness of the display with respect to the ambient light is to include photo detectors to adjust the brightness or to turn a backlight on or off. In this approach there is a fixed brightness range which does not always provide a comfortable viewing experience for the user.
Another conventional approach gives the user manual control of the amount of light being produced for the transmissive and emissive display screens. This approach is satisfactory for conscientious users who regularly monitor the brightness settings and manually adjust them accordingly. However, as is often the case, the user can set the display screen for maximum brightness so that the display is more easily read in sunlight, thereby not having to make frequent adjustments. In the case of the transmissive display, this frequently results in less than optimal battery and backlight lifetime experience. In the case of the emissive display, in addition to a reduced battery experience, the emissive material, usually either an organic or polymer, has a finite lifetime. This lifetime becomes severely shortened if the display screen is always turned to the maximum setting.
SUMMARY OF THE INVENTION
Accordingly, what is needed is a system and/or method that can provide a display which is readable in various ambient lighting conditions for a various types of display screens and which will provide the user with a pleasant battery experience and prolong the life of materials that would be harmed by excessive brightness. The present invention provides these advantages and others not specifically mentioned above but described in the sections to follow.
A portable computer system or electronic device which includes a lighted display device with dynamically adjustable range settings, a processor, a light sensor and a display controller is disclosed. In one embodiment, the processor implements the adjustment for the range settings based on prestored range configuration data and an ambient light information signal from the light sensor. In one embodiment of the present invention, the lighted display device is transmissive while in another embodiment the lighted display device is emissive.
In one embodiment of the present invention, the portable computer system or electronic device further includes a user adjustment for adjusting the light setting within the processor-implemented range setting for the display device. In another embodiment of the present invention, the user can change and control the configuration of the dynamically adjustable range settings. The dynamically adjustable range settings, in still another embodiment, can be overridden by the user, enabling the user to control the brightness of the display screen. In yet another embodiment, the relative position of the user-adjustable setting within a given range remains unchanged when the range setting changes.
In one embodiment of the present invention, the display controller implements an adjustment to the brightness of the display device according to the implemented range setting and user-adjustable setting within said range. In one embodiment this brightness adjustment is immediate while, in another embodiment, the brightness adjustment occurs over a longer time period, the time period being user-adjustable. In yet another embodiment, the time period for the brightness adjustment to occur is a fixed value.
Other features and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention:
FIG. 1A illustrates a reflective display screen for use with a portable computer system or electronic device.
FIG. 1B illustrates a transflective display screen for use with a portable computer system or electronic device.
FIG. 1C illustrates a transmissive display screen for use with a portable computer system or electronic device.
FIG. 1D illustrates an emissive display screen for use with a portable computer system or electronic device.
FIG. 2A is a topside perspective view of a portable computer system in accordance with one embodiment of the present invention.
FIG. 2B is a bottom side perspective view of the portable computer system of FIG. 2A .
FIG. 3 is a block diagram of an exemplary portable computer system upon which embodiments of the present invention may be practiced.
FIG. 4 is a perspective view of the display screen displaying the range and the user-controllable brightness adjustment according to one embodiment of the present invention.
FIG. 5 illustrates one embodiment of the present invention, showing examples of computer generated and on-screen displayed dynamically adjustable range settings for various ambient light conditions, with corresponding dynamically changing brightness settings.
FIG. 6 is a block diagram illustrating the process of changing the range setting and the brightness of the display according to one embodiment of the present invention.
FIG. 7 illustrates changing of brightness settings by a user and changing of brightness ranges by a processor.
DETAILED DESCRIPTION OF THE INVENTION
In the following detailed description of the present invention, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be recognized by one skilled in the art that the present invention may be practiced without these specific details or with equivalents thereof. In other instances, well-known methods, procedures, components, and circuits have not been described in detail as not to unnecessarily obscure aspects of the present invention.
Notation and Nomenclature
Some portions of the detailed descriptions, which follow, (e.g., process 600 of FIG. 6 ) are presented in terms of procedures, steps, logic blocks, processing, and other symbolic representations of operations on data bits that can be performed on computer memory. These descriptions and representations are the means used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. A procedure, computer executed step, logic block, process, etc., is here, and generally, conceived to be a self-consistent sequence of steps or instructions leading to a desired result. The steps are those requiring physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated in a computer system. It has proven convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like.
It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise, as apparent from the following discussions, it is appreciated that throughout the present invention, discussions utilizing the following terms refer to the actions and processes of a computer system or similar electronic computing device. These devices manipulate and transform data that is represented as physical (electronic) quantities within the computer system's registers and memories or other such information storage, transmission or display devices. The aforementioned terms include, but are not limited to, “scanning” or “determining” or “generating” or “identifying” or “comparing” or “sorting” or “selecting” or “implementing” or “displaying” or “initiating” or the like.
Exemplary Palmtop Platform
The embodiments of the present invention may be practiced on any electronic device having a display screen, e.g., a pager, a cell phone, a remote control device, or a mobile computer system. The discussion that follows illustrates one exemplary embodiment being a hand held computer system.
FIG. 2A is a perspective illustration of the top face 200 a of one embodiment of the portable computer system 300 of the present invention. The top face 200 a contains a display screen 105 surrounded by has a top layer touch sensor able to register contact between the screen and the tip of the stylus 80 . The stylus 80 can be of any material to make contact with the screen 105 . The top face 200 a also contains one or more dedicated and/or programmable buttons 75 for selecting information and causing the computer system to implement functions. The on/off button 95 is also shown.
FIG. 2A also illustrates a handwriting recognition area of the top layer touch sensor or “digitizer” containing two regions 106 a and 106 b . Region 106 a is for the drawing of alphabetic characters therein (and not for numeric characters) for automatic recognition, and region 106 b is for the drawing of numeric characters therein (and not for alphabetic characters) for automatic recognition. The stylus 80 is used for stroking a character within one of the regions 106 a and 106 b . The stroke information is then fed to an internal processor for automatic character recognition. Once characters are recognized, they are typically displayed on the screen 105 for verification and/or modification.
FIG. 2B illustrates the bottom side 200 b of one embodiment of the palmtop computer system that can be used in accordance with various embodiments of the present invention. An extendible antenna 85 is shown, and also a battery storage compartment door 90 is shown. A serial port 180 is also shown.
FIG. 3 is a block diagram of one embodiment of a portable computer system 300 upon which embodiments of the present invention may be implemented. Portable computer system 300 is also often referred to as a PDA, a PID, a palmtop, or a hand-held computer system.
Portable computer system 300 includes an address/data bus 305 for communicating information, a central (main) processor 310 coupled with the bus 305 for processing information and instructions, a volatile memory 320 (e.g., random access memory, RAM) coupled with the bus 305 for storing information and instructions for the main processor 310 , and a non-volatile memory 330 (e.g., read only memory, ROM) coupled with the bus 305 for storing static information and instructions for the main processor 310 . Portable computer system 300 also includes an optional data storage device 340 coupled with the bus 305 for storing information and instructions. Device 340 can be removable. Portable computer system 300 also contains a display device 105 coupled to the bus 305 for displaying information to the computer user.
In the present embodiment, portable computer system 300 of FIG. 3 includes communication circuitry 350 coupled to bus 305 . In one embodiment, communication circuitry 350 is a universal asynchronous receiver-transmitter (UART) module that provides the receiving and transmitting circuits required for serial communication for the serial port 180 .
Also included in computer system 300 is an optional alphanumeric input device 106 that, in one implementation, is a handwriting recognition pad (“digitizer”). Alphanumeric input device 106 can communicate information and command selections to main processor 310 via bus 305 . In one implementation, alphanumeric input device 106 is a touch screen device. Alphanumeric input device 460 is capable of registering a position where a stylus element (not shown) makes contact.
Portable computer system 300 also includes an optional cursor control or directing device (on-screen cursor control 380 ) coupled to bus 305 for communicating user input information and command selections to main processor 310 . In one implementation, on-screen cursor control device 380 is a touch screen device incorporated with display device 105 . On-screen cursor control device 380 is capable of registering a position on display device 105 where a stylus element makes contact. The display device 105 utilized with portable computer system 300 may utilize a reflective, transflective, transmissive or emissive type display.
In one embodiment, portable computer system 300 includes one or more light sensors 390 to detect the ambient light and provide a signal to the main processor 310 for determining when to implement a change in brightness range. Display controller 370 implements display control commands from the main processor 310 such as increasing or decreasing the brightness of the display device 105 .
Referring now to FIG. 4 , a perspective view of one embodiment of the portable computer system 400 is shown. The display screen 105 is displaying the user brightness setting which may be implemented as a graphical user interface. In this embodiment the user adjusts the on-screen displayed brightness setting between the low level 410 of the range and the high level 420 of the range by moving the slider 430 to the right for an increase in brightness or to the left for a decrease in brightness.
FIG. 5 illustrates three possible range settings and midpoint slide settings. The values are in candelas per square meter (cd/m 2 ), also called nits. These user interfaces are computer generated and displayed on the screen when the user desires to adjust the settings. Range 510 may be used when in a dark or dimly lit environment. Range 520 may be used in a normal office environment and range 530 may be used outdoors in direct sunlight. The units are measured in “nits”.
FIG. 6 is a block diagram illustrating one embodiment of the present invention. In step 610 one or more light sensors detect the ambient light and send a signal representing this information to the processor. The signal can be from a single sensor, or can be the average of signals from a plurality of sensors. The processor then, as shown in step 620 , accesses stored data which configures the ranges and determines if the ambient light signal requires a change to the brightness range. If a change to brightness range is required, the processor then implements the range change.
In step 630 of FIG. 6 , according to the present embodiment, the slider, which is on the user-adjustable range display of the display device, remains in the position to which the user last set it. Refer to FIG. 4 for an illustration of the slider 430 , the low range setting 410 , and the high range setting 420 .
In step 640 of FIG. 6 , the processor interprets the brightness setting of said slider position 430 relative to the low range setting 410 and the high range setting 420 . For example, referring to 510 of FIG. 5 , the midpoint setting for a brightness range of 5 nits to 65 nits is 35 nits, where the same midpoint setting for a brightness range of 20 nits to 300 nits, as shown on 530 of FIG. 5 is 160 nits.
Still referring to FIG. 6 , the processor sends a signal to the display controller which, in step 650 , implements the appropriate change to the brightness level over a time period specified by stored display configuration data so that brightness changes are not abrupt and therefore are transparent to the user.
At any time, the user can display the currently selected range setting and move the slider up or down to increase or decrease the brightness setting of the display. The computer processor will dynamically adjust the range when the ambient light changes sufficiently, keeping the brightness level commensurate with the slider position last selected relative to the new range setting. FIG. 7 illustrates user adjustments to the brightness settings and computer processor adjustments to the brightness range.
In step 710 of FIG. 7 , the brightness setting is at 35 nits on a range of 5 nits to 65 nits. The user adjusts the brightness setting up to a brightness of 55 nits, as shown in step 720 . When the user goes into a brighter environment, the computer processor adjusts the range to that of 20 nits to 100 nits, as illustrated by step 730 . The brightness setting for the previously set slider position is now 87 nits. The user now adjusts the setting down to a preferred level, e.g., 40 nits as shown in step 740 . Now, when the user enters a darker environment, the computer processor adjusts the range down, as shown in step 750 , so the setting for the previously set slider position is now 20 nits.
The present invention has been described in the context of a portable computer system; however, the present invention may also be implemented in other types of devices having, for example, a housing and a processor, such that the device performs certain functions on behalf of the processor. Furthermore, it is appreciated that these certain functions may include functions other than those associated with navigating, vibrating, sensing and generating audio output.
The preferred embodiment of the present invention, dynamic brightness range for portable computer displays based on ambient conditions, is thus described. While the present invention has been described in particular embodiments, it should be appreciated that the present invention should not be construed as limited by such embodiments, but rather construed according to the below claims. | A portable computer system that comprises adjustable brightness settings and brightness control for providing improved user readability and prolonged life of the display screen. The main processor can change the brightness range settings in response to a change in ambient light conditions. The user can also control the brightness of the display. The time required to implement a brightness change can be set to a value which can be configured by the user. | 6 |
This is a divisional of co-pending application Ser. No. 628,832 filed on July 9, 1984, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a novel agent for improving drainage of pulp slurry by adding the agent into the slurry.
In the paper making industry, various efforts have been made to increase the paper making rate thereby improving the productivity and lowering the production cost. For the reason, an agent for improving drainage of pulp slurry (pulp slurry drainage improver) has been widely used.
However a relationship between the increase of the paper making rate by use of the agent and the decrease of the formation on the dryer is quite delicate. Therefore a high level of techniques are required to improve the drainage of pulp slurry without impairing the uniformity of paper quality.
As the pulp slurry drainage improver, there has been used a highly polymerized polyethylene imine. However it has drawbacks that (1) in order to achieve desirable drainage, it is required to add it to pulp slurry in a relatively high amount and (2) it is rather toxic.
SUMMARY OF THE INVENTION
Extensive studies by the present inventors have revealed that the water drainage of pulp slurry can be amazingly improved without impairing the uniformity of paper quality by adding a specific poly-monoallylamine resin only in a small ratio into the pulp slurry, and the present invention was achieved on the basis of such finding.
Thus, the present invention provides a pulp slurry drainage improver comprising a poly-monoallylamine resin represented by the following formula: ##STR2## wherein X is Cl, Br, I, HSO 4 , HSO 3 , H 2 PO 4 , H 2 PO 3 , HCOO, CH 3 COO or C 2 H 5 COO, n is a number of 10 to 100,000, and m is 0 or 1, or a modified resin of the polymonoallylamine resin.
DETAILED DESCRIPTION OF THE INVENTION
The poly-monoallylamine resin or their modified resins usable in the present invention include homopolymers (A) of inorganic acid salts of monoallylamine obtained by polymerizing inorganic acid salts of monoallylamine, homopolymers (A') of monoallylamine obtained by removing inorganic acids from acid polymers (A), and homopolymers (A") of organic acid salts of monoallylamine obtained by neutralizing said polymers (A') with an organic acid such as formic acid, acetic acid, propionic acid, p-toluenesulfonic acid or the like; copolymers (B) obtained by copolymerizing inorganic acid salts of monoallylamine with a small quantity of polymerizable monomers (such as inorganic acid salts of triallylamine) containing two or more double bonds in the molecule, said copolymers (B) being soluble in water and identical with said polymers (A) in the properties other than those relating to molecular weight; and modified polymers (C) obtained by reacting the compounds (such as epichlorohydrin) containing two or more groups reactable with amino group in the molecule with said polymers (A), polymers (A'), polymers (A") or copolymers (B), said modified polymers (C) being soluble in water and identical with said polymers (A), (A'), (A") or (B) in the properties other than those relating to molecular weight.
The homopolymers (A) of inorganic acid salts of monoallylamine used in this invention can be prepared, for example, by polymerizing an inorganic acid salt of monoallylamine in a polar solvent in the presence of a radical initiator containing in its molecule an azo group and a group having a cationic nitrogen atom or atoms. The preparation examples are shown in the Referential Examples given later, but the details are described in the specification of Japanese Patent Applicaton No. 54988/83 (Japanese Patent Kokai (Laid-Open) No. 201811/83) filed by the present applicant.
These poly-monoallylamine resins and their modified resins are found to produce their effect in all types of fiber materials comprising cellulose as their base, but said resins can produce an especially significant practical effect when they are utilized in the field of waste paper (old newspaper) and unbleached kraft pulp. The amount of the resin required to be added for producing the desired effect is usually in the range of 0.005 to 1.0% by weight, preferably 0.01 to 0.5% by weight, based on the fiber material content of the pulp.
In practical use of the poly-monoallylamine resin or its modified resin of this invention, it may be treated in the same way as in the case of any ordinary drainage improving agent. The following method is typical example.
An aqueous solution of the resin stored in a tank is supplied into a mixer by a constant delivery pump and the resin solution is diluted into a low concentration. Such dilution is necessary for allowing uniform mixing of both fiber material and resin in a short contact time. Then, the resin solution is passed through a rotar-meter so that a required amount of the resin solution is added to the pulp slurry. The spot at which the resin solution is to be added to the pulp slurry should be decided by considering the contact time that will allow the pulp slurry to be carried on the wire at a time when the freeness has been maximized, but usually it is suggested to add the resin solution at a point just before the screen.
The preparation method of the poly-monoallylamine resin and its modified resin used in this invention will be illustrated below as referential examples.
REFERENTIAL EXAMPLE 1
Shown in this example is a method for producing poly-monoallylamine hydrochloride and poly-monoallylamine.
570 g (10 mol) of monoallylamine (a product by shell Chemicals of U.S.; boiling point: 52.5°-53° C.) is added dropwise into 1.1 kg of concentrated hydrochloric acid (35% by weight) under cooling and stirring at 5°-10° C. After said addition is ended, water and excessive hydrogen chloride are distilled off by using a rotary evaporator under a reduced pressure of 20 Torr. at 60° C. to obtain white crystals. These crystals are dried over drying silica gel under a reduced pressure of 5 Torr, at 80° C. to obtain monoallylamine hydrochloride (containing about 5% of water).
590 g (6 mol) of said monoallylamine hydrochloride and 210 g of distilled water are put into a 2-liter round flask equipped with a stirrer, a thermometer, a reflux condenser and a nitrogen gas inlet tube, and they are stirred and dissolved. Then 7 g of 2,2'-bis-(N-phenylamidinyl)-2,2'-azopropane-dihydrochloride, an azo-type initiator containing cationic groups, dissolved in 10 ml of distilled water, is added. The mixture is polymerized under stirring at 48°-52° C. while passing nitrogen gas therethrough. 10 hours thereafter, 7 g of said initiator dissolved in 10 ml of distilled water is further added to keep on with the polymerization. Heat generation ceases 5 hours thereafter, so stirring is stopped and standing polymerization is continued at 50° C. ±1° C. for additional 50 hours. There is resultantly obtained a colorless and transparent viscous solution (an aqueous solution of polymonoallylamine hydrochloride, hereinafter referred to as resin A-1 solution). Although this solution can be immediately used as a drainage improving resin solution in this invention, the solid polymer may be recovered from the solution by the following operation: 415 g of said resin A-1 solution is added into approximately 5 liters of methanol to form a white precipitate of the polymer, and this precipitate, without dried, is finely broken up in methanol and extracted with methanol for 15 hours by using a Soxhlet extractor, removing the unpolymerized monoallylamine hydrochloride. The precipitate is dried under reduced pressure at 50° C. to obtain 265 g of the polymer (yield: 90%). This polymer was identified as polymonoallylamine hydrochloride (hereinafter referred to as resin A-1) by elementary analysis, IR absorption spectral analysis and NMR spectral analysis. The intrinsic viscosity [η] of resin A-1 determined in a 1/1ON NaCl solution was 0.43 (g/100 ml).
Then an aqueous solution formed by dissolving 40 g of sodium hydroxide in 100 g of distilled water is added to 139 g of said resin A-1 solution under cooling. The resulting solution has a smell of amine, so the solution is lightly sucked off under reduced pressure to obtain a NaCl solution of poly-monoallylamine (hereinafter referred to as resin A-2 solution; actual resin concentration: about 18%). This solution can be directly used as a drainage improving resin solution in this invention, but the polymer (poly-monoallylamine) may be recovered from the solution by the following operation: 30 g of said resin A-1 is dissolved in 270 g of distilled water and passed through a strongly basic ion exchange resin (Amberlite IRA-402) to remove hydrochloric acid, and the filtrate is concentrated and freeze-dried, whereby 16.5 g of white poly-monoallylamine (hereinafter referred to as resin A-2) can be obtained.
REFERENTIAL EXAMPLE 2
This example shows the method of producing slightly bridged poly-monoallylamine hydrochloride by copolymerizing with a small quantity of triallylamine hydrochloride.
The same polymerization process as in Referential Example 1 is carried out by adding 10.5 g (6/100 mol) of triallylamine hydrochloride in addition to 590 g (6 mol) of monoallylamine hydrochloride. The amounts of water and catalyst are the same as in Referential Example 1. The polymerization gives a colorless and transparent viscous solution (hereinafter referred to as resin B-1 solution). This solution, in the form as it is, can be used as a drainage improving resin solution in this invention, but the polymer may be recovered in the same way as in Referential Example 1. That is, 210 g of resin B-1 solution is added to about 3 liters of methanol to precipitate resin B-1 and the latter is treated according to the method of Referential Example 1 to obtain 105 g of the polymer (resin B-1) (yield: about 75%). The values of elementary analysis, IR absorption spectrum and NMR spectrum of this resin B-1 were substantially equal to those of resin A-1.
Intrinsic viscosity [η] of resin B-1 determined in a 1/1ON NaCl solution was 0.96.
REFERENTIAL EXAMPLE 3
This example is the method of producing slightly bridged poly-monoallyamine by treating polymonoallylamine with epichlorohydrin.
0.1 g of epichlorohydrin is added to 100 g of a NaCl solution of polyallylamine (resin A-2 solution) (actual resin concentration: 18%) whose production method was shown in Referential Example 1, and the mixture is reacted under stirring at 30 ±2° C. for 2 hours, whereby the viscosity of the system increases to form a viscous solution. This solution (hereinafter referred to as resin C-1 solution) can be used immediately as a drainage improving resin solution in this invention.
Hereinafter, the present invention will be described in detail by way of the embodiments thereof, but it is to be understood that the present invention is not limited by these embodiments.
EXAMPLE 1
This Example shows the method and results of a drainage improvement test conducted on a pulp slurry prepared from wastepaper (old newspaper).
500 g of wastepaper (old newspaper) was immersed in water, washed in the usual way and the macerated by using a 10-liter test beater under the following conditions:
Liquor ratio: 1:10
Amount of sodium hydroxide added: 1% (in ratio to wastepaper)
Temperature: 50° C.
Time: 1 hour
The freeness C.S.F. (Canadian Standard Freeness) of the obtained slurry was 370 ml.
The pulp concentration at the time of addition of drainage imrpoving agent was adjusted to 2.5 g/l.
The following five types of poly-monoallylamine resin and, as a comparative sample, a polyethyleneimine (polymerization degree 1000, molecular weight 42,000) were used as the drainage improving agent for the test.
1. Resin A-1 solution (Referential Example 1), actual resin concentration: 64%
2. Resin A-1 (Referential Example 1), actual resin concentration: 95%
3. Resin A-2 solution (Referential Example 1), actual resin concentration: 18%
4. Resin B-1 solution (Referential Example 2), actual resin concentration: 50%
5. Resin C-1 solution (Referential Example 3), actual resin concentration: 18%
6. Polyethyleneimine (Comparative Example), actual resin concentration: 33%
Each resin was dissolved in or diluted with water to form an aqueous solution with an actual resin concentration of 2.5 g/l.
A measured amount of each pulp slurry was put into a 5-liter plastic container and a predetermined amount of each improving agent was added thereto under stirring. After allowing contact of the agent with the pulp for a given period of time, the freeness of the pulp slurry was measured in the usual way by using a Canadian standard freeness tester. The results are summarized in Table 1.
TABLE 1______________________________________Drainage Amount of pH at theimproving agent added time of Freenessagent (in % to pulp) addition (C.S.F. ml)______________________________________No agent -- 7.6 340added1. Resin A-1 0.03 7.4 445solution 0.06 7.4 465 0.09 7.4 4652. Resin A-1 0.03 7.5 462 0.06 7.4 482 0.09 7.4 4483. Resin A-2 0.03 7.6 530solution 0.06 7.6 482 0.09 7.6 4654. Resin B-1 0.03 7.4 536solution 0.06 7.4 520 0.09 7.4 4855. Resin C-1 0.03 7.6 542solution 0.06 7.6 502 0.09 7.6 4836. Polyethylene 0.03 7.4 400imine 0.06 7.6 443 0.09 7.6 503______________________________________ Note: Amount of agent added (in % to pulp) was calculated in terms of pure resi matter.
EXAMPLE 2
The same test as in Example 1 was conducted by using unbleached draft pulp. The freeness of the pulp slurry used was 30 ml in CSF. The results are shown in Table 2.
TABLE 2______________________________________Drainage Amount of pH of theimproving agent added time of Freenessagent (in % to pulp) addition (C.S.F. ml)______________________________________No agent -- 7.1 300added1. Resin A-1 0.03 7.4 383solution 0.06 7.4 392 0.09 7.5 3902. Resin A-1 0.03 7.3 420 0.06 7.4 443 0.09 7.4 4203. Resin A-2 0.03 7.5 460solution 0.06 7.4 440 0.09 7.5 4254. Resin B-1 0.03 7.5 477solution 0.06 7.4 454 0.09 7.4 4265. Resin C-1 0.03 7.5 486solution 0.06 7.5 464 0.09 7.4 4726. Polyethylene 0.03 7.4 364imine 0.06 7.5 370 0.09 7.6 426______________________________________ Note: Amount of agent added (in % to pulp) was calculated in terms of pure resi matter.
As apparent from the above-shown test results, the pulp slurry drainage improver of this invention shows an excellent water-draining performance at a small rate of addition in comparison with the conventional polyethyleneimine. | Drainage of pulp slurry can be markedly improved without impairing the uniformity of paper quality by adding to the pulp slurry a poly-monoallylamine resin represented by the formula: ##STR1## wherein X is Cl, Br, I, HSO 4 , HSO 3 , H 2 PO 4 , H 2 PO 3 , HCOO, CH 3 COO or C 2 H 5 COO, n is a number of 10 to 100,000, and m is 0 or 1, or a modified resin of the poly-monoallylamine resin. | 3 |
FIELD OF THE INVENTION
This invention relates to an apparatus and method for detecting borehole wall discontinuities using an acoustic pulse echo technique. More particularly, this invention relates to an apparatus and method for detecting vertically oriented borehole discontinuities such as fractures.
BACKGROUND OF THE INVENTION
Techniques for the acoustic detection of fractures have been described in the art. These techniques involve the generation of an acoustic wave in the earth formation surrounding the borehole and detecting the degree of attenuation of an acoustic wave as it is strongly influenced by fractures in the path of the acoustic wave. Typically, the shear wave is recognized as not being transmitted through an open or fluid filled fracture. Hence, any crack or fissure in the earth formation in the path of a shear wave will strongly attenuate it. Known techniques for fracture detection thus involve transmitting an acoustic pulse into the formation and detecting the acoustic attenuation of the received waveform portion where the shear wave ought to be. A strong attenuation indicates the presence of a fracture and the orientation of the acoustic transmitter-receiver system relative to the borehole indicates the orientation of the fracture. Prior art patents which describe such transmissive attenuation type fracture detection techniques are the U.S. Pat. No. 2,943,694 to Goodman; U.S. Pat. No. 3,406,776 to Henry; U.S. Pat. No. 3,474,878 to Loren; U.S. Pat. No. 3,775,739 to Vogel and U.S. Pat. No. 3,794,976 to Mickler.
These prior art detection techniques involve reliance upon the transmissive influence by fractures, whose presence are deduced either from the absence of a shear signal or its very small amplitude when in view of the knowledge of the lithology of the formation, greater shear amplitudes would be expected. Since the receiver waveform from such fracture detection does not provide a positive indication of a signal representative of a fracture, its detection is more difficult.
Acoustic pulse-echo techniques have been described in the art to investigate boreholes; see, for example, U.S. Pat. No. 3,883,841 to Norel et al and U.S. Pat. No. 4,255,798 to Havira. These latter techniques involve the generation of an acoustic pulse to cause reflections from material interfaces in the path of the pulse. The reflections are then processed to evaluate the cement bond.
In the U.S. Pat. No. 3,502,169 to Chapman, a sonic borehole televiewer device is described to obtain a visual presentation of the wall of the borehole. An acoustic transmitter is used, operating in a frequency range of the order of about 2 MHz, to direct acoustic pulses at the borehole wall. The acoustic reflections from the wall are plotted as a function of azimuth, or circular scan to present a visual indication of wall fractures, cracks, as well as distinctions between hard and soft formations.
The U.S. Pat. No. 3,474,879 to Adair describes an acoustic pulse echo technique for scanning surface characteristics of a borehole with a rotationally mounted receiver-transmitter acoustic transducer. An acoustic beam generated by this transducer is directed at an angle relative to the borehole wall. The beam glances off with relatively little reflections in case of a smooth borehole wall, but when the beam is incident upon a wall discontinuity such as a cavern fracture or a rock interface, a detectable acoustic reflection is generated. The U.S. Pat. No. 3,464,513 to Roever teaches use of a similar system as in the Adair patent except that a plurality of stationary transducers are used to scan the periphery of the borehole wall.
The scanning of acoustic beams may be done mechanically as taught in the Adair patent or electronically as shown in the Roever patent or in U.S. Pat. No. 3,693,415 to Richard. Various techniques have been proposed to electronically steer an acoustic beam, see for example the U.S. Pat. No. 3,732,945 to Lavigne. An acoustic transceiver employing a flat array of transducers to enable the retrieval of a fish lost within a borehole is described in U.S. Pat. No. 3,935,338 to Aldrich et al.
SUMMARY OF THE INVENTION
In a borehole investigation technique in accordance with the invention, acoustic pulses are introduced by a tool mounted transmitter towards the borehole wall at a beam forming frequency and in such direction so as to promote the excitation of transverse acoustic waves in the borehole wall. The transverse acoustic waves do not traverse a fluid filled fracture, which, in response to the preferentially excited transverse waves causes a reflection towards an acoustic receiver on the tool. The acoustic receiver, which is located in the vicinity of the transmitter, or may be the same transducer as the transmitter, detects the acoustic reflections and produces a waveform signal representative thereof. The waveforms may then be recorded or further processed as indicative of reflected transverse waves to identify the presence of the fractures.
As described with respect to one form of the invention, acoustic pulses are introduced in the borehole medium by an acoustic transmitter operating at such frequency as to produce an acoustic beam whose principal direction lies in a reference plane. The reference plane for the purpose of detecting vertical fractures is generally transverse to the longitudinal axis of the borehole. The acoustic beam is further so oriented within the reference plane to direct the beam with a predetermined angle relative to the normal to the surface of the borehole wall region upon which the beam is incident so as to promote the generation of transverse waves such as shear or pseudo Rayleigh waves. The transverse waves travel away from the incidence region generally in a direction dictated by the incident acoustic beam. A highly angled fluid filled borehole wall discontinuity in the path of such transverse waves causes a substantial acoustic reflection which may then be detected by a sonic receiver.
Since the fractures of interest may occur over a range of inclination angles relative to the longitudinal borehole axis, the acoustic reflections produced by transverse waves travel away from the fractures in different directions. These directions are determined by the angle of incidence of the transverse waves with a normal to the fracture. Thus, for inclined fractures of interest, the primary or maximum amplitude reflections are not likely to be returned to the sonic receiver. In another form of the invention, therefore, the transmitter acoustic beam is further scanned so as to enhance detection of highly angled fractures over a desired range of inclination angles.
With the acoustic investigation technique in accordance with the invention, highly angled fractures are positively identified with a strong signal thus also enabling a precise determination of the location of such fractures in the borehole wall.
It is, therefore, an objection of the invention to provide a method and apparatus for the detection of borehole wall discontinuities such as highly angled fractures, cracks and edges of voids in a positive manner. It is still further an object of the invention to detect borehole wall discontinuities and precisely determine their positions on the borehole wall.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other advantages and objects of the invention can be understood from the following description of several embodiments described in conjunction with the following drawings.
FIG. 1 is a horizontal section view of a tool located in a borehole for the detection of borehole wall discontinuities in accordance with the invention;
FIG. 2 is a perspective view of a portion of an apparatus in accordance with the invention for the detection of borehole wall discontinuities;
FIG. 3 is a top plan view partially broken away of the apparatus shown in FIG. 2;
FIG. 4 is a horizontal section of tool pads employed on a borehole wall with an apparatus in accordance with the invention;
FIG. 5 is a simplified vertical schematic representation of a fracture detection technique with an apparatus in accordance with the invention;
FIG. 6 is a front schematic view of a transducer array employed in accordance with the invention;
FIG. 7 is a perspective schematic view of a transducer and portion of a borehole wall having a highly angled borehole wall discontinuity;
FIG. 8 is a schematic view of a fracture detection technique taken in a plane which is transverse to the axis of the borehole;
FIG. 9 is a schematic block diagram of a signal processing network used to form a log of reflections attributable to high angled fractures detected in accordance with the invention; and
FIG. 10 is a block diagram of a technique for controlling and operating an acoustic transducer in a beam scanning mode in accordance with the invention.
DETAILED DESCRIPTION OF EMBODIMENTS
With reference to FIGS. 1-3, a borehole 10 is shown formed in an earth formation 12. The borehole 10 may be a perfectly round hole, but in practice it is likely to have discontinuities in the form of short fissures such as 14 or a cavity such as 16. The borehole 10 also intersects discontinuities in the form of long fractures, which may be generally horizontally inclined such as when different earth layers are traversed by the borehole 10 or vertically inclined.
Of particular interest in the detection of natural gas or petroleum are borehole wall discontinuities in the form of vertically oriented fractures such as shown at 18. Such vertical fractures may be aligned with a radial of the borehole axis 20 such as fractures 18.1, 18.2 and 18.3, while other vertically oriented fractures such as 18.5, 18.6 and 18.7 intersect the borehole wall 22 chordally or tangentially.
According to one technique of this invention, an acoustic beam of energy is directed from a tool 24 carrying acoustic transducers 26.1-26.4. The tool is suspended from a cable 28 in borehole 10. Cable 28 is connected to surface located equipment 29 from which electrical power is obtained and to which measurements made with tool 24 are transmitted.
The acoustic transducers 26.1-26.4 are formed so as to be able to emit acoustic energy with a directivity as suggested by the beam 30.1 emanating from face 32.1 of transducer 26.1 in FIG. 1. The transducers 26.1-26.4 further are selected to be able to produce such beam-shaped acoustic energy in the form of short pulses. In this manner reflections produced by borehole wall discontinuities can be detected and waveform signals indicative thereof produced from the transducers during intervals between acoustic pulses. The formation of an acoustic beam is well known and is among other factors a function of the surface area of the emitting face 32 of transducers and frequency.
The operating frequency is selected sufficiently high so that the acoustic wavelengths employed enable formation of a beam, yet the frequency is sufficiently low to reduce the attenuation from borehole fluids such as drilling mud. An operating center frequency of the order of about 500 KHz may be used with a rectangular transducer face 32 surface area of about an inch wide by one and a half inch high. The transducers 26 are mounted on tool 24 so that their acoustic beams 30 are directed at a predetermined angle θ relative to the normal 34 to the borehole region upon which beams 30 are incident. The angle θ is so selected that the acoustic beams 30 promote generation of transverse waves in the borehole wall in a manner as taught, for example, by the previously identified U.S. Pat. No. 3,775,739 to Vogel. The transverse wave may be a shear wave or a pseudo-Rayleigh wave, both of which travel along the surface of a borehole wall 22.
In order to preferentially excite transverse waves in the borehole wall, the transducers 26 are so oriented that the sine of angle θ is approximately equal to the ratio of the velocity of sound in the borehole liquid to the velocity of the transverse wave to be execited. This angle may thus vary, but when it is about 40° transverse waves are normally enhanced over a wide range of earth formation conditions. With an angle θ of about 40° the transducers 26 are located near the periphery of tool 24 and, if necessary, are mounted on pads 36.1, 36.2 as shown in FIG. 4.
In the operation of tool 24, short duration acoustic pulses are regularly generated by transducers 26, for example in the manner and of the type as shown in the U.S. Pat. No. 4,255,798 to Havira. Each acoustic pulse directs acoustic energy at the borehole wall 22 so as to promote the generation of a transverse wave. The transverse waves travel along the borehole wall away from the region such as at 38 upon which the acoustic beam 30 is incident.
When a fracture, such as 18.2 is in the path of the transverse wave, the liquid at the fracture interface is unable to pass the transverse wave, which is, therefore, reflected. The acoustic reflection, in turn, introduces acoustic compressional waves at the boundary with the borehole fluid. Since the transducer 26.1 is oriented to optimize sensitivity to transverse waves traveling along the borehole wall, a waveform signal representative of the transverse wave is obtained at the output of transducer 26.1. The reflections represent positive indications of the presence of fractures. FIG. 5 shows a simplified planar view of a path 40 followed by a transverse wave generated by a transducer 26.1. When a fracture such as 18.1 parallel to the borehole axis is encountered and is perpendicular to path 40, a reflection travels along the path 40 but in the direction indicated by arrow head 42 and is incident upon the face 32.1 of transducer 26.1.
The borehole may be inclined relative to the vertical of the earth and the fractures of interest may have inclinations relative to the earth vertical while still being of sufficient interest. The fractures of interest also may not all lie in a plane parallel to the borehole axis and may be in fact inclined with an inclination angle α with respect to the borehole axis 20 such as fracture 18.2. The transverse wave incident upon detection of such fracture 18.2 with a transverse wave traveling along path 40 is difficult because a reflection returns along a path such as 44, which depending upon the size of the inclination angle α may result in avoiding incidence upon transducer 26.1 and thus detection.
Detection of inclined fractures thus depends upon the operating beam width of transducer 26.1. This tends to be a function of frequency and at a center frequency of about 500 KHz is quite narrow, of the order of about seven degrees between the half power points. At such beam width, fracture inclination angles of only several degrees are detected since the reflections are reflected at twice the angle of inclination.
Although a plurality of transducers 26 could be employed with differently inclined fractures, a preferred technique in accordance with the invention employs a transducer 26.1 with an electronically steerable beam. This is obtained by using an array 48 of acoustically energizable and sensitive strip-shaped elements 50 with the array distributed along the direction in which the acoustic beam is to be scanned.
FIGS. 2 and 6 illustrate a transducer 26.1 on which the piezoelectric elements in the form of parallel rectangular shaped strips 50 are used. The number of elements 50 may vary, though five may be sufficient to yield an ability to scan over an angular range of ±20° relative to a plane which is substantially perpendicular to borehole axis 20. Such scan range is deemed sufficient to detect mot fractures of interest. The elements 50 are shown as exposed, though in practice they are protected by an appropriate acoustic coupling layer, which is deleted for clarity though shown in the view of FIG. 4. Techniques for forming such array of acoustic materials are known in the art; see, for example, the previously mentioned U.S. patents to Roever, Aldrich et al and others. As an example, the elements 50 may have a width, W, of 0.1 inches, a length, 1, of about one inch and separated from each other with a spacing, s, of about 0.010 inch. The transducers 26 are mounted adjacent the peripheral surface of the tool 24 so that the desired angle of incidence of the acoustic beam on the borehole surface 22 can be obtained. Since the acoustic beam is scanned, the portion of tool 24 in front of the arrays 48 is flared upward at 51 above the arrays 48 and downwardly at 53 below the arrays. The flare angles are selected sufficiently large to avoid interference with the steered acoustic beams and reflections caused thereby.
In practice the acoustic path followed by the acoustic pulses and reflections is not the simplified planar representation as shown in FIG. 5, but a more complex path 52 as illustrated in Fig. 7. There, acoustic pulses are launched at the borehole wall 22 along an initial path 54 through the borehole with a tool 24 as shown in FIG. 2 or through an acoustic coupling layer 56 as illustrated in FIG. 4 until the acoustic energy is coupled into the borehole wall 22 at a region 38. The acoustic coupling layer may be formed of an appropriate impedance matching material as is well known in the art.
Acoustic waves then propagate away from region 38, generally along a path 58.1 and in a direction determined by the angle of incidence of the acoustic pulse at region 38. The path 58 lies along a circular portion of the normally cylindrical borehole wall 22 in the case of a direction for path 54 which lies in a plane which is perpendicular to the borehole axis 20.
When, however, the beam direction 54 is scanned by the array 48, such as along a plane parallel with the borehole axis, the resulting travel paths 58.2 and 58.3 are non-circular so that at least one set of preferentially enhanced transverse waves traveling along 58.2 may intersect a fracture such as 18.1 along a perpendicular direction thereto.
With the use of a scannable acoustic beam, fractures may be detected over a range of inclination angles depending upon the orientation of the transducers 26. In the embodiment of tool 24 in FIG. 2, the transducers are oriented to detect vertical fractures having high inclination angles as measured relative to a plane which is perpendicular to the borehole axis. The tool 24 is held within the center of the borehole 10 with centralizers (not shown) which are well known in the art. In FIG. 4 a tool 24' is used employing wall engaging pads and in which transducers such as 26 are mounted to scan for and detect vertical fractures.
Scanning of the acoustic beam of transducer 26 is obtained by controlling the time when each element 50 in the array 48 is activated during a transmit mode, or sampled during a receive mode.
With reference to FIGS. 8 and 9, a network 70 is shown for generating a log 72 to indicate borehole wall discontinuities as a function of depth. The log 72 may be made by storing signals on a magnetic medium or in the memory of a data processor or a visible record as shown in FIG. 9 may be formed. A pulse network 74 provides transducer 26 with electrical drive pulses on line 76 while disabling a receiver amplifier 78 with a signal, T, on line 80. At the end of a transmitter pulse, the disabling signal on line 80 is removed and reflection signals representative of acoustic reflections on line 76 from transducer 26 are amplified by amplifier 78.
The amplified reflection signals are applied to a fullwave rectifier 82 whose output 84 is compared by a comparator 86 with a threshold value on line 88 from a threshold network 90. In the event the threshold value is exceeded, a reflection signal appears on output line 92 which is applied to recorder 94 with which log 72 is formed. The reflection signal on line 92 has an amplitude representative of the amplitude of the acoustic reflections. In this manner the magnitude and time of arrival of reflections as recorded on log 72 are indicative of the distance of transducer 26 from a borehole wall discontinuity such as fracture 18.1.
Log 72 is formed of a time log 96 on which reflections 98 from fractures are recorded. In addition, a scan angle log 100 is employed to indicate the inclination angle of the fracture. For the time-log 96 the recorder 94 is provided with a time sweep signal representative of the time following a common event such as a transducer acoustic pulse, t o , to thus indicate the time interval when a reflection from a borehole wall discontinuity is detected relative to this common event. The time sweep signal commences its sweep signal with the actuation of the transducer 26 and terminates a predetermined maximum time, t m , thereafter. The time sweep signal may be obtained with a generator 101 or a signal processor 102. The duration of the time-sweep signal is selected sufficiently long to enable the recording of reflections which exceed the threshold level from threshold network 90 and may occur over the operating range of the transducers. The successive arrivals of the reflections or the intervals of time relative to the common event may thus be used to indicate the relative inclination of a discontinuity such as a fracture with respect to the direction of logging by tool 24 in the borehole.
The signal processor 102 is preferably employed for controlling scan angles as well as generate signals indicative of the scan angle at which recorded reflections 100 were detected when a beam scanning mode is employed. Alternatively to the use of a sweep signal from the sweep generator 101, the signal processor 102 can produce a sweep signal on line 104 as a function of the acoustic wave velocity in the earth formation for the depth at which the transducers 26 are located for a more accurate indication on log 96 as to the angular location and inclination of fractures on borehole wall 22.
FIG. 8 illustrates how the path length 54 through the borehole medium in case of a tool as in FIG. 2 or through the coupling layer 56 in case of a pad arrangement as in FIG. 4 can be estimated. The two-way travel time of the acoustic pulse along path 54 can be calculated using the scan angle φ and the known velocity of an acoustic pulse through the borehole medium. The velocity of transverse waves in the earth formation along path 58 may be generally known from acoustic velocity or travel time interval (ΔT) measurements in units such as microseconds per foot as a function of depth for borehole 10. Hence, either signals representative of ΔT and depth measurements are applied to a signal processor 102 on lines 106, 108 or stored in memory associated with the signal processor.
One technique for determining the azimuth of a fracture includes a measurement of the time lapsed between the detection of a reflection and the generation of the acoustic pulse which produced it. This measurement may be made inside signal processor 102 with a clock 110 applied to drive a register 112 which is reset to a particular value each time the transducer 26 is activated with the signal on line 80.
Hence, when an acoustic reflection is detected and a reflection signal indicative thereof occurs on line 92, an AND gate 114 is enabled to transfer the count of register 112 via transfer logic network 116 to a control and processing unit 118 in signal processor 102. While this transfer occurs, an inhibit network 120 is activated to inhibit further transfers for a time estimated sufficient for the reflection signal to pass.
A signal indicative of the length of path 58 to a borehole discontinuity may then be derived by subtracting the two way travel time of the acoustic energy along path 54 and dividing the remainder by the interval travel time of the acoustic transverse waves for the particular earth formation depth.
The signal processor 102 may transform the length of path 58 to an azimuth position for the fracture 18.1 based upon the known placement of transducer 26 on the tool 24 and the known path length 54 by using known geometric relationships. An azimuth signal may then be produced on a line 122 and applied to recorder 94 to record the angular position of the detected borehole wall discontinuity.
The network 70 has been described for use with a single transducer 26. In such case a single fracture 18.1 along the path 58 can be detected, fractures such as 18.2 lying behind the first fracture are less likely to be detected. Accordingly, as shown in the embodiment for tools 24, 24' in FIGS. 2 and 4, a plurality of transducers 26 are employed to each investigate a portion of the borehole wall for discontinuities. Network 70 is correspondingly expanded to accommodate the signals to and from additional transducers.
FIG. 10 illustrates one technique 130 for controlling the beam scanning mode for a transducer 26 having an array 48 of separately energized strip elements 50. The elements 50 are sequentially energized with slight delay intervals depending upon the desired direction of the acoustic beam. Following activation of the elements 50, they are used in a receive mode and combined in accordance with direction determining delays. The receive mode is active for a time period sufficient to detect the presence of borehole wall discontinuities within a predetermined distance from the transducer 26. This distance is strongly affected by the amount of attenuation. Normally, a two way travel distance limit of about six inches may be imposed so that the number of transducers 26 employed to investigate the entire borehole wall may be correspondingly increased depending on the perimeter length of the borehole.
In the technique 130 of FIG. 10, a signal processor, such as 102 of FIG. 9, is employed to control and set the delays needed to scan the acoustic beam during the transmit mode and combine the receiver outputs during the receive mode. Each element 50 in the transducer array 48 is connected to a separately energized drive circuit 132 and separate amplifier such as 78 in FIG. 9.
The drive circuits 132 in turn are energized by pulses from individual registers 134, each of which produce an output pulse for one acoustic beam pulse at the appropriate delay time as a function of preset delay counts from counters 136. The preset delay counts are selected to, for example, step the acoustic beam through fixed scan positions, e.g. eight for a maximum scan range of about forty degrees (±20° relative to a plane such as which is perpendicular to the borehole axis 20).
At 138 the respective sets of delays needed to scan the acoustic beam are stored for various array beam angles and at 140 the discrete scan angles for the acoustic beam are selected so that the corresponding delays can be output at 142 in the proper sequence to the delay preset counters 136.
The registers 134 are then activated at 144 so that each produces an output pulse to a drive circuit 132 at the proper delayed instant while the receiver gates are inhibited. A short delay at 146 is provided following the generation of an acoustic pulse. The receiver gates 78 are then enabled at 148 and the receiver outputs are passed through variable delay lines 150 having delays set at 149 in correspondence with the delays previously employed in counters 136. The outputs from the delay lines 150 are combined in a summing network 152 to provide a single receive waveform signal from transducer 26 for the particular array scan angle. The combined waveform may then be converted to digital form with an analog to digital converter 154 and the waveform stored in memory at 156.
At 158 the stored waveform is scanned for a peak value indicative of the presence of a fracture. At 160, the time position of the detected peak in the waveform is transformed to a distance to the fracture from the receiver and this measurement, together with the peak amplitude and scan angle are recorded at 162.
Following the receive mode, a slight delay is implemented at 164 followed by a return at 166 to step 140 for an acoustic investigation for the next successive beam scan angle position.
The receiving mode may be implemented by sampling each of the waveform signals obtained from a strip element 50 for the interval of interest and then storing the samples in a memory of signal processor 100. The stored samples of different waveforms may then be combined with time shifts which correspond with the delays set for the waveforms in counters 136. This technique may be performed within a signal processor located either downhole in tool 20 or above ground.
Having thus described an apparatus and method for the detection of fractures, the advantages of the invention can be understood. Variations from the described embodiments can be made without departing from the scope of the invention. | Apparatus and methods are described for detecting fractures in a wall of a borehole penetrating an earth formation. An acoustic transducer produces pulses of acoustic energy at beam forming frequencies with the direction of the beam being so oriented as to preferentially excite transverse waves in the wall of the borehole. Discontinuities such as fractures cause a reflection of the transverse waves and these in turn are detected so that a positive identification of fractures is obtained. Fractures having various inclination angles are detected by employing apparatus and methods for scanning the acoustic beam while maintaining its orientation which preferentially enhances transverse waves. In this manner the transverse waves may be directed perpendicular to the fractures to enhance detectable reflections. A transducer employing an array of individually excitable acoustic elements is described with associated controls. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application Ser. No. 61/800,255, filed Mar. 15, 2013, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates generally to electrically connecting a composite core conductor. More particularly, the present invention relates to a crimp die for connecting a composite core of a conductor to an electrical connector. Still more particularly, the present invention relates to a method of connecting a composite core of a conductor to an electrical connector.
BACKGROUND OF THE INVENTION
The vast majority of high voltage transmission conductors used includes strands of high strength steel surrounded by multiple strands of aluminum wire. The steel strands are the principle load bearing component holding up the wire, while the softer, more elastic aluminum strands include the majority of the electrical power transport component. Many variations of transmission wire operating at between approximately 115 kv to 800 kV involve this basic design concept and have these two basic components.
More recently, a composite core conductor having a fiberglass and epoxy resin core covered by aluminum wire has emerged as a substitute for the steel support stranding in high voltage transmission conductors. However, the outer surface of the composite core is difficult to mechanically connect to a compression tube of a connector member. The outer surface of the composite core is sensitive, such that a scratch on the outer surface can lead to a fracture of the composite core. Due to the sensitivity of the composite core, composite core conductors are not crimped and are usually connected with wedge connectors such as is disclosed in U.S. Pat. No. 7,858,882 to De France, which is hereby incorporated by reference in its entirety. Accordingly, a need exists for an electrical connector in which a composite core conductor is crimped thereto without damaging the outer surface of the composite core.
A conventional crimp die 2 is shown in FIGS. 1-3 . A plurality of planar surfaces 3 form a crimp surface of the die 2 . For example, the crimp surface of each conventional die 2 is comprised of three planar surfaces 3 , as shown in FIG. 3 . The planar surfaces 3 form a substantially hexagonal crimping area during the crimping process and result in a gap 4 between the dies 2 and a tubular portion 5 in which the composite core 26 is disposed, as shown in FIG. 2 . The resulting gap 4 can detrimentally affect the outer surface of the composite core 26 as the crimp is not completely controlled. Additionally, the planar surfaces 3 provide a smaller area of compression 65 between the planar crimp surfaces 3 and the outer surface of the tubular portion 5 in which the composite core 26 is disposed. Furthermore, the planar surfaces 3 of the crimp die 2 apply compressive forces on tubular portion 5 at angles of 31 degrees from a horizontal axis 6 through a center of the core 26 and vertically at 90 degrees from the horizontal axis 6 , as shown in FIG. 1 . Three areas of compression are formed with each die 2 . Accordingly, a need exists for a crimp die providing better crimp control of a composite core conductor.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an improved electrical connector in which a composite core of a composite core conductor is crimped to the electrical connector.
Another object of the present invention is to provide an improved electrical connector member in which a composite core conductor is more easily and inexpensively crimped to an electrical connector.
Another object of the present invention is to provide an improved crimping die that crimps the composite core to an electrical connector without damaging an outer surface of the composite core.
Another object of the present invention is to provide an improved crimping die proving improved crimp control when crimping a composite core conductor.
The foregoing objectives are basically attained by an electrical connector including a coupling portion and a tubular portion extending from the coupling portion. A conductor has a non-metallic core surrounded by electrically conductive strands and has a connecting portion of the core extending axially beyond the strands. The connecting portion is received in the tubular portion. A crimped portion on the tubular portion radially engages the connecting portion and secures the conductor to the tubular portion. The crimped portion is formed by concave surfaces on internal surfaces of crimping dies. The concave surfaces have different radii of curvature than remaining portions of the internal surfaces
The foregoing objectives are also basically attained by a method of crimping a conductor. A portion of electrically conductive strands surrounding a non-metallic core of the conductor is removed from the core. The exposed core of the conductor is inserted in a substantially tubular portion extending from a coupling portion of an electrical connector. The substantially tubular portion is crimped to the core to form a first crimped portion. The first crimped portion is formed by concave surfaces on internal surfaces of crimping dies. The concave surfaces have different radii of curvature than remaining portions of the internal surfaces.
Objects, advantages, and salient features of the invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses an exemplary embodiment of the present invention.
As used in this application, the terms “front,” “rear,” “upper,” “lower,” “upwardly,” “downwardly,” and other orientational descriptors are intended to facilitate the description of the exemplary embodiments of the present invention, and are not intended to limit the structure thereof to any particular position or orientation.
BRIEF DESCRIPTION OF THE DRAWINGS
The above benefits and other advantages of the various embodiments of the present invention will be more apparent from the following detailed description of exemplary embodiments of the present invention and from the accompanying drawing figures, in which:
FIG. 1 is an end elevational view of a conventional die crimping a composite core of a composite core conductor;
FIG. 2 is an end elevational view of the conventional die of FIG. 1 showing a gap between the dies prior to crimping;
FIG. 3 is an end elevational view of a conventional die for crimping a composite core;
FIG. 4 is an end elevational view of a die crimping a composite core of a composite core conductor in accordance with an exemplary embodiment of the present invention;
FIG. 5 is an end elevational view of the die of FIG. 4 prior to crimping;
FIG. 6 is a perspective view of a die of FIG. 4 ;
FIG. 7 is a side elevational view of the die of FIG. 6 ;
FIG. 8 is an end elevational view of the die of FIG. 7 ;
FIG. 9 is an end elevational view of the die of FIG. 4 showing a contact area of the die;
FIG. 10 is an enlarged end elevational view of the contact area of FIG. 9 ;
FIG. 11 is an end elevational view of the die of FIG. 4 with a composite core disposed therein;
FIG. 12 is a side elevational view in partial cross-section of an assembled electrical connector in accordance with an exemplary embodiment of the present invention;
FIG. 13 is an exploded side elevational view of the electrical connector of FIG. 12 prior to assembly;
FIG. 14 is a side elevational view of a composite core conductor;
FIG. 15 is an end elevational view of the composite core conductor of FIG. 14 ;
FIG. 16 is a side elevational view partially in section of an eyebolt of the electrical connector of FIG. 12 ;
FIG. 17 is an end view of the eyebolt of FIG. 16 ; and
FIG. 18 is a side elevational view in cross-section of an outer sleeve of the electrical connector of FIG. 12 ;
Throughout the drawings, like reference numerals will be understood to refer to like parts, components and structures.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
The present invention generally relates to an electrical connector 21 for receiving a composite core conductor 23 , as shown in FIG. 12 , and a crimp die 25 , as shown in FIGS. 4-11 , for crimping a composite core 26 of the composite core conductor 23 to the electrical connector 21 . The electrical connector 21 reduces the number of components used in existing electrical connector assemblies, thereby reducing inventory and costs. The crimp dies 25 and 46 of the crimp die set 47 substantially prevent damage to an outer surface 41 of the composite core 26 during the crimping process.
The composite core conductor 23 , as shown in FIGS. 14 and 15 , includes a composite core 26 covered by a plurality of aluminum conductors 27 . The composite core 23 is preferably made of a combination of fiber glass and epoxy resin. The plurality of aluminum conductors 27 are wrapped around the composite core 26 . The composite core 26 reduces the weight of the composite core conductor 23 compared to traditional steel core conductors, such that more aluminum conductors can be used, thereby increasing electrical power capacity without increasing the outer diameter of the conductor. Additionally, the more lightweight composite core conductors 23 reduce sag associated with traditional steel core conductors.
The electrical connector 21 includes an eyebolt 28 having a substantially tubular portion 29 having an open first end 30 and an eyelet 31 connected to a second end 32 , as shown in FIGS. 12, 16 and 17 . An opening 44 in the eyelet 31 allows the electrical connector 21 to be connected to a support, such as a transmission tower. A ridge section 33 is disposed on an outer surface 42 of the tubular portion 29 between the first and second ends 30 and 32 . A cavity 34 having an inner surface 35 extends inwardly from the first end 30 of the eyebolt 28 . Preferably, the eyebolt 28 is unitarily formed as a single piece and is made of metal, such as steel or aluminum.
The tolerances of the tubular portion 29 are preferably extremely tight to more precisely control the inner and outer diameters thereof. The inner diameter preferably has a tolerance of 0.001 inches. The outer diameter preferably has a tolerance of 0.002 inches. By more precisely controlling the inner and outer diameters of the tubular portion 29 , better control of the crimp between the tubular portion 29 and the core 26 of the composite core conductor 23 is achieved, thereby substantially preventing damage to the composite core during crimping.
An outer sleeve 36 is substantially tubular and has an outer surface 45 and first and second ends 37 and 38 , as shown in FIGS. 12 and 18 . A passageway 39 having an inner surface 40 extends from the first end 37 of the outer sleeve 36 to the second end 38 , as shown in FIG. 18 . Preferably, the diameter of the passageway 39 is substantially constant. Preferably, the outer sleeve 36 is unitarily formed as a single piece and is made of an electrically conductive metal, such as aluminum.
A crimp die 25 in accordance with an exemplary embodiment of the present invention is shown in FIGS. 6-11 . First and second dies 25 and 46 form a die set 47 to crimp composite core conductors 23 . Preferably, the first and second dies 25 and 46 are substantially identical.
The crimp die 25 has a crimping area 7 including first and second crimping surfaces 8 and 9 and a non-crimping surface 10 , as shown in FIGS. 6-11 . The crimping area 7 extends between first and second substantially planar contact surfaces 48 and 49 , as shown in FIGS. 6 and 8 . An outer side surface 50 of the die 25 is adapted to be received by a crimping tool (not shown) and extends externally between the first and second substantially planar contact surfaces 48 and 49 . Substantially planar front and rear surfaces 51 and 52 extend between the first and second planar contact surfaces 48 and 49 and are bounded by the outer side surface 50 . Front and rear shoulders 53 and 54 are formed in the front and rear surfaces 51 and 52 , as shown in FIGS. 6 and 8 . Beveled surfaces 63 and 64 extend along upper edges of the front and rear surfaces 51 and 52 to accommodate flashing or protrusions during the crimping process.
The non-crimping surface 10 is disposed between the first and second crimping surfaces 8 and 9 . The crimping surfaces 8 and 9 are concave. Center points 55 and 56 of the radii of the first and second crimping surfaces 8 and 9 are spaced from a center point 57 of the radius of the non-crimping surface 10 , as shown in FIG. 10 , such that the crimping surfaces 8 and 9 have a different radius than the radius of the non-crimping surface 10 . Accordingly, the crimping surfaces 8 and 9 have a different radius of curvature than the non-crimping surface 10 . Preferably, the radii of the first and second crimping surfaces 8 and 9 are longer than the radius of the non-crimping surface 10 . As an example, the radius of the first and second crimping surfaces 8 and 9 is 0.36 inches and the radius of the non-crimping surface 10 is 0.25 inches.
Preferably, the two concave crimping surfaces 8 and 9 are approximately 90 degrees apart on the crimping surface 7 , as shown in FIG. 4 . As shown in FIGS. 9-11 , the concave crimping surfaces 8 increase the contact area 43 between the crimping surface 7 and the tubular portion 29 . The crimps are applied approximately 180 degrees apart on the outer surface of the tubular portion 29 between diametrically opposite concave crimping surfaces 8 and 9 of opposing dies 25 .
To assemble the electrical connector 21 , a portion of the aluminum conductors 27 are removed from the conductor 23 to expose only the composite core 26 , as shown in FIGS. 13 and 14 . The exposed composite core 26 is inserted in the cavity 34 of the tubular portion 29 of the eyebolt 28 , as shown in FIG. 12 . The tubular portion 29 and the composite core 26 are then crimped together in a crimping area 13 , as shown in FIG. 12 .
The dies 25 and 46 of FIGS. 6-11 are used to crimp the tubular portion 29 to the composite core 26 to create a solid crimp connection without damaging the outer surface of the composite core 26 . The crimp tool applies forces vertically on the crimp dies 25 and 46 as indicated by arrows 58 and 59 in FIG. 11 . The crimping surfaces 8 and 9 are formed having two different radii such that such that the angle of compression is approximately 45 degrees, as shown in FIG. 4 . Accordingly, applying forces 58 and 59 obliquely to the dies 25 and 46 results in crimping forces being applied at 45 degree angles due to the crimping surfaces 8 and 9 having a different radius than the non-crimping surface 10 . As shown in FIG. 5 , crimping forces are diametrically opposed such that the crimping forces are applied approximately 180 degrees apart. The concave crimping surfaces 8 and 9 having two different radii portions increases the contact area between the crimping surfaces 8 and 9 and the tubular portion 29 of the eyebolt 28 , as shown in FIG. 11 . Additionally, the compression dies 25 and 26 apply crimping forces that are diametrically opposed (approximately 180 degrees apart) relative to a longitudinal axis 6 of the composite core such that the composite core 26 is compressed to a substantially circular shape, as shown in FIGS. 4 and 5 . The compression dies 25 also have very close tolerances. The applied compression forces in the conventional dies, shown in FIGS. 1 and 2 , result in the core 26 being compressed to an oval shape that could detrimentally affect performance of the conductor.
Additionally, the tubular portion 29 has very close tolerances on the inner diameter and outer diameter thereof such that a proper amount of travel (or force) is applied during crimping. As shown in FIG. 4 , close tolerances allow the contact surfaces 48 and 49 to engage during the crimping process, thereby ensuring a proper crimp is obtained. As shown in FIG. 1 , a gap 4 remains between the opposing dies 2 during the crimping process such that the crimp is not accurately controlled during the crimping process, thereby resulting in under- and over-crimping. The crimp dies 25 and 46 substantially prevent over crimping that can damage the composite core 26 and substantially prevent under crimping that can have a detrimental effect on performance. Accordingly, a better crimp can be obtained that does not substantially damage the outer surface of the composite core 26 .
As shown in FIGS. 6 and 8 , the crimping surfaces 8 and 9 of the crimp dies 25 and 46 are concave compared to the planar surfaces 3 of the conventional crimp dies 2 shown in FIGS. 1-3 . The crimping surface of the conventional dies 2 is comprised of three planar surfaces 3 , as shown in FIG. 3 . The planar surfaces 3 result in a gap 4 between the crimp dies 2 , as shown in FIG. 1 . As shown in FIG. 3 , there is no gap between the crimp dies 25 and 46 during the crimp process when the crimp dies 25 and 46 have fully traveled. Additionally, the planar surfaces 3 provide a smaller area of compression between the surfaces 3 and the composite core 26 and a smaller angle of compression (approximately 31 degrees, as shown in FIG. 1 ).
The concave crimping surfaces 8 and 9 in accordance with exemplary embodiments of the present invention as shown in FIGS. 6-11 , provide a larger area of compression 60 , as shown in FIG. 11 , and a larger angle of compression (approximately 45 degrees). The dies 25 and 46 also increase the angle of compression to approximately 45 degrees from the 31 degree angle of compression shown in FIG. 1 for the conventional crimp dies 2 .
The applied crimping forces 61 are diametrically opposed such that, in combination with the mating contact surfaces 48 and 49 substantially eliminating a gap between the dies 25 and 46 during the crimping process, that the composite core 26 is compressed to a substantially rounded shape. Accordingly, the crimp dies 25 and 46 substantially prevent crimps that damage or otherwise detrimentally affect the composite core 26 . Accordingly, a better crimp can be obtained that does not substantially damage the outer surface of the composite core 26 .
The crimping surfaces 8 and 9 provide a non-damaging indent on the inner surface 35 of the tubular portion 29 of the eyebolt, as shown in FIG. 16 . A plurality of the crimps are performed on the outer surface 42 of the tubular portion 29 in a composite core crimping area (first crimping area) 13 , which extends for substantially the length of the cavity 34 in the tubular portion 29 , as shown in FIG. 12 . When the composite core 26 has been crimped to the tubular portion 29 , the outer sleeve 36 is disposed over the tubular portion 29 , as shown in FIG. 12 . A first end of the outer sleeve 36 abuts a flange 62 of the eyebolt 28 and a second end of the outer sleeve extends beyond the open end of the tubular portion 29 of the eyebolt 28 .
The outer sleeve 36 is then crimped in second and third crimping areas 11 and 12 , as shown in FIG. 12 , thereby securing the conductor 23 to the electrical connector 21 . The outer sleeve 36 is crimped to the eyebolt 28 in the second crimping area 11 . The outer sleeve 36 is crimped to the conductor 23 in the third crimping area 12 . Any suitable crimping dies can be used for the crimping process in the second and third crimping areas 11 and 12 . The outer sleeve 36 is not crimped in the first crimping area 13 in which the tubular portion 29 of the eyebolt 28 is crimped to the composite core 26 . The eye bolt 28 can be anchored to any type of structure. The structure may include, but is not limited to, a pole, a building, a tower, or a substation.
The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the scope of the present invention. The description of the exemplary embodiments of the present invention is intended to be illustrative, and not to limit the scope of the present invention. Various modifications, alternatives and variations will be apparent to those of ordinary skill in the art, and are intended to fall within the scope of the invention as defined in the appended claims and their equivalents. | An electrical connector for a composite core conductor and a method of controlling crimping thereof includes a coupling portion and a tubular portion extending from the coupling portion. A conductor has a non-metallic core surrounded by electrically conductive strands and has a connecting portion of the core extending axially beyond the strands. The connecting portion is received in the tubular portion. A crimped portion on the tubular portion radially engages the connecting portion and secures the conductor to the tubular portion. The crimped portion is formed by concave surfaces on internal surfaces of crimping dies. The concave surfaces have different radii of curvature than remaining portions of the internal surfaces. | 7 |
The present invention concerns a new compound derived from p-chlorophenoxyacetic acid, the p-chlorophenoxyacetate of 1-aminoadamantine-2-ethanol of structural formula I ##STR2##
The scope of the present invention also embraces the salts thereof, which are of pharmacological interest; its method of preparation; the pharmaceutical compositions containing it; and its therapeutic applications.
The compound I and its salts are new agents which are active on the central nervous system, being of use in the treatment of various pathological conditions of the system.
The conditions for which the new p-chlorophenoxyacetic acid derivatives are recommended include:
Neuropsychic asthenia; problems of attention; memory defects; difficulty in learning; disorders in the capacity for mental concentration; mental involution in senility; amnesia; assistance in the treatment of Parkinson's disease; physical and mental debility; a propensity to a state of depression; irritability and lack of social adaptation due to depression; neuronal hypoxia; cerebral metabolism inadequacies; acute vascular complications; nervous sequelae to cerebral circulatory disorders; vascular, toxic and traumatic comas; and cerebral atherosclerosis.
The active agents according to the present invention may be administered in any of the pharmaceutically typical modes of administration such as tablets, pills, dragees, capsules, injectable solutions and the like, including, but not limited to, the following examples:
Tablets of 50-500 mg of active principle, taken from 2 to 8 times a day.
Syrups of 10 to 200 mg/ml of active principle.
To prepare the p-chlorophenoxyacetate of 1-aminoadamantine-2-ethanol according to the present invention, the esterification reaction is carried out between the acylic compound of the following structural formula II ##STR3## wherein X can be an OH group or a halogen atom (Cl or Br), and the 1-aminoadamantine-2-ethanol of the structural formula III ##STR4## in a suitable inert solvent.
The salts of the compound I are obtained by the same procedure, noting that in order to finalize the reaction, the resulting product is treated with the stoichiometric quantity of the acid in question (hydrochloric, sulphuric, tartaric, etc.)
The novel features which are considered as characteristic for the 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.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Some examples of the method of preparation of the compounds of formula I are detailed below. All such details that are not essential to the invention are considered variables and not limitative thereto.
EXAMPLE 1
Preparation of the p-chlorophenoxyacetate of 1-aminoadamantine-2-ethanol, starting from a p-chlorophenoxyacetic acid halide
22 g (0.11 mol) of 1-aminoadamantine-2-ethanol dissolved in 250 ml of benzene are poured into a 500 ml flask fitted with a mechanical stirrer, using a decanting funnel. 23 g (0.11 m) of p-chlorophenoxyacetyl chloride are added in drops while stirring, the mixture then being stirred for 30 minutes. 120 ml of a 10% solution of sodium carbonate is then added, and the resulting mixture is stirred for 10 minutes. The organic phase is decanted, and the benzene is then removed by distillation. The residue is crystallized with petroleum ether. This yields 37 g (93%) of a white solid.
Elemental analysis: Calculated: C 66.01; H 7.15; Cl 9.77; N 3.85. Found: C 66.2; H 7.05; Cl 9.68; N 3.78.
EXAMPLE 2
Preparation of the p-chlorophenoxyacetate of 1-aminoadamantine-2-ethanol, starting from p-chlorophenoxyacetic acid
In a 1 liter flask, provided with a Dean-Stark separator tube and reflux refrigerant, a mixture of 20.5 g (0.011 m) of p-chlorophenoxyacetic acid, 22 g (0.11 m) of 1-aminoadamantine-2-ethanol, 98 g of conc. sulphuric acid and 700 ml of toluene is heated to boiling point over a period of 24 hours. At the end of this period, the mixture is treated with an acqueous solution of 5% sodium carbonate to an alkali pH, and is then washed with water. The mixture is then dried on anhydrous sodium sulphate, and the toluene is removed by distillation at reduced pressure. The crude product so obtained is crystallized with petroleum ether. The yield is 35.2 g (88%) of a white solid.
Elemental analysis: Calculated: C 66.02; H 7.15; Cl 9.77; N 3.85. Found: C 66.1; H 7.10; Cl 9.75; N 3.80.
EXAMPLE 3
Preparation of the chlorhydrate of p-chlorophenoxyacetate of 1-aminoadamantine-2-ethanol
A solution of 60 g (0.16 m) of p-chlorophenoxyacetate of 1-aminoadamantine-2-ethanol in 300 ml of ether is subjected to the passage of HCl gas until the precipitation of a solid product is completed. It is left to cool in a refrigerator over a period of 6 hours and it is then filtered. The resulting solid is recrystallized with a mixture of ether and methanol. 61 g (92%) of the product are obtained.
Elemental analysis: Calculated: C 60.00; H 6.75; Cl 17.75; N 3.50. Found: C 60.2; H 6.70; Cl 17.8; N 3.55.
In a similar manner and by using the stoichiometric quantities of the acid in question, the following salts are obtained.
______________________________________ ELEMENTAL ANALYSISEXAMPLE SALT Calculated Found______________________________________4 Sulphate C: 52.00 C: 52.1 H: 6.07 H: 6.11 Cl: 7.69 Cl: 7.65 N: 3.03 N: 3.1 S: 6.93 S: 6.895 Tartrate C: 56.1 C: 56.3 H: 6.23 H: 6.19 Cl: 6.91 Cl: 6.88 N: 2.73 N: 2.756 Phosphate C: 52.00 C: 52.3 H: 6.28 H: 6.31 Cl: 7.69 Cl: 7.70 N: 3.03 N: 3.0 P: 6.72 P: 6.80______________________________________
The following pharmacological activities have been evalulated:
Nootropa activity
Tests were carried out on rats using the technique estimating the loss of memory induced by electric shock, the loss of memory being determined as related to the number of errors made in seeking the outlet from an acquatic labyrinth (Giurgea C. J. Pharmacol (Paris) 3, 1, 17, *1972).
The compound I according to the present invention showed itself to be notably active, giving a 46.5% protection against the loss of memory, as is shown in the Table 1, hereunder.
Activity on learning
This activity was studied by the test of learning in the acquatic labyrinth (Giurgea C. J. Pharmacol (Paris) 3, 1, 17 (1972), the learning resulting in a decrease in the errors made and the time spent in reaching the exit. In another learning test (conditioning cage) the animals placed in the cage receive an electric shock, wich can be avoided by passing from one cell to another. Sara, S. J. and Col. Psychopharmacol (ber.) 25, 32, (1972). The compound I has resulted in an increased learning facility as may be seen in the Table 1.
Anti-depressant activity
This activity was evaluated by the method of examining the desperation behavior in mice (Porsalt, T. D., Arch. Int Pharmacodyn 229, 327 (1977).
A state of despair was induced by placing the animal in a cylinder containing water, and from which escape was impossible, the animal then finding itself obliged to treadmill continually. After a period of vigorous activity, the mouse assumes a characteristic immobile posture, which behavior is capable of reduction by the use of various types of pharmaceutical anti-depressants. It was shown that the administration of the compound I resulted in moderate anti-depressant effects, as is shown in the Table I.
Anti-cataleptic activity
This activity was the subject of Morpurgo tests (Arch. Int. Pharmacodyn, 137, 84 (1962), based on antagonizing the cataleptic condition in rats, induced by fluphenazine.
The compound I slightly reduced the cataleptic activity of the fluphenazine, as is shown in the Table I.
TABLE 1______________________________________Results of the pharmacological activity of Compound I: EVALUA-TEST PARAMETER TION______________________________________Nootropa Protection from memory loss due to 46.5%activity electric shock. p < 0.01 (number of errors) Decrease with respect to the control 51.6% in the errors made in the acquatic p < 0.01 labrinth. (5th day)Learning Increase with respect to the control 14.4%activity in the conditioning cage. (learning) p < 0.001 facility)Anti- Protection with respect to the 45.9%depressant control. p < 0.001activityAnti- Protection against catalepsy by 25.6%cataleptic fluphenazine p < 0.01activity______________________________________
Toxicity of the compound I according to the present invention is determined using the Irwin or "screening" multi-dimensional test (Phsychopharmacologia (Berl), 13, 222-257 (1968). There was no evidence as to effects of non-toxic doses. Toxic doses caused death accompanied by trembling and clonic convulsions.
The LD 50 of the compound I in the rat and the mouse is shown in the following table:
______________________________________ANIMAL RAT MOUSERoute i.p. p.o. i.p. p.o.______________________________________LD.sub.50 value 360 >4000 415 >4000mg/kg______________________________________ (i.p. = intraperitoneal route; p.o. = oral route)
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 compounds differing from the types described above.
While the invention has been illustrated and described as embodied in a p-chlorophenoxyacetic acid derivative, its method of preparation, the pharmaceutical compositions containing it and its use in human medicine, 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 new compound derived from p-chlorophenoxyacetic acid, the p-chlorophenocetate of 1-aminoadamantine-2-ethanol of the following structural formula I: ##STR1## as well as its pharmaceutically acceptable salts, possessing properties for the treatment of various pathological conditions of the central nervous system. Also disclosed are its method of preparation; pharmaceutical compositions containing the said compounds; and the treatment of various pathological conditions of the central nervous system with the use of the said compositions. | 2 |
BACKGROUND TO THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to woven fabrics, and fabric for wicking sweat or moisture away from the skin.
[0003] 2. Background Information
[0004] There is an on-going requirement to make clothing, especially sports clothing, diapers and incontinent apparel and so forth more comfortable and healthier to wear and use, even though considerable moisture or liquids may be liberated by the wearer in normal use. It is known to provide composite textile materials that comprise distinct layers of materials having respective appropriate characteristics so that moisture, or liquid, migrates or drains quickly away from an inner surface of the material in contact with the skin of a wearer. The liquid may be retained in a second outer layer in the case of a diaper or evaporate normally from an outer surface of the material where there is only one layer, in the case of sports clothing, say. Examples of known textile materials can be found in U.S. Pat. Nos. 6,509,285, 6,432,504, 6,427,493, 6,341,505, 6,277,469, 5,315,717, 5,735,145 and 4,411,660.
[0005] The typical approach to the producing woven fabrics having moisture management properties is one of trial-and-error whereby new designs are manufactured and tested until a satisfactory performance is achieved. In the area of technical textiles the manufacturer is often seeking to address a number of different design requirements in addition to moisture management characteristics, these include properties such as flexibility, durability, and thermoregulatory characteristics, many of which can be modeled by different analytical methods. It would therefore be advantageous to provide a technique allowing manufacturers to reliably produce new woven fabrics with satisfactory moisture management properties.
SUMMARY OF THE INVENTION
[0006] In one aspect the invention provides a technique for producing a woven moisture management fabric having quantities of hydrophilic and hydrophobic yarns, comprising:
a. selecting an initial fabric design comprising a yarn crossing scheme, yarn cross section for each yarn, and yarn spacing in the warp and weft directions; b. creating a model of the yarns of the fabric design; c. identifying a plane of the fabric in which warp and weft yarns generally lie; d. identifying a repeating unit cell of the model or a discrete multiple of unit cells; e. identifying, from orthographic projection onto respective planes substantially parallel to the plane of the fabric, a first side view and an opposing second side view of the unit cell or the discrete multiple of unit cells; f. calculating and summing the projected areas of each yarn in one of the first and second side views to determine a total projected area; g. calculating and summing the projected areas of each hydrophilic yarn in the first and second side views respectively to determine a total projected area of hydrophilic yarn; h. calculating and summing the projected areas of each hydrophobic yarn in the first and second side views respectively to determine a total projected area of hydrophobic yarn; i. if the total projected area of hydrophobic yarn on one of the first and second side views is between 40% and 70% of the total projected area, and total projected area of hydrophilic yarn on the other of the first and second side views exceeds 50% of the total projected area, then manufacturing a fabric according to the fabric design, j. or otherwise varying at least one of: the quantities of hydrophilic and hydrophobic yarns, yarn crossing scheme, yarn cross section for each yarn and yarn spacing; and repeating steps b to i.
[0017] In another aspect there is provided a technique for producing a woven moisture management fabric having a design including quantities of hydrophilic and hydrophobic yarns, comprising:
a. selecting an initial fabric design comprising a yarn crossing scheme, yarn cross section for each yarn, and yarn spacing in the warp and weft directions; b. summing the areas or structure cross points of each hydrophilic yarn on first and second sides of the fabric to determine a hydrophilic area; c. summing the areas or structure cross points of each hydrophobic yarn on first and second sides of the fabric to determine a hydrophobic area; d. if the hydrophobic area on one of the first and second sides is between 40% and 70% of a total area, and the hydrophilic area on the other of the first and second sides exceeds 50% of the total area, then manufacturing a fabric according to the fabric design, e. or otherwise varying at least one of: the quantities of hydrophilic and hydrophobic yarns, yarn crossing scheme, yarn cross section for each yarn and yarn spacing; and repeating steps b to d.
[0023] In a still further aspect the invention provides a technique for producing a woven moisture management fabric having quantities of hydrophilic and hydrophobic yarns, comprising:
a. summing the areas or structure cross points of each hydrophilic yarn on first and second sides of the fabric to determine a hydrophilic area; b. summing the areas or structure cross points of each hydrophobic yarn on first and second sides of the fabric to determine a hydrophobic area; c. if the hydrophobic area on one of the first and second sides is between 40% and 70% of a total area, and the hydrophilic area on the other of the first and second sides exceeds 50% of the total area, then manufacturing a fabric according to the fabric design.
[0027] According to the invention there is provided a woven fabric comprising a generally uniform woven structure consisting of hydrophobic and hydrophilic materials, the woven structure having an inner exposed surface of hydrophobic and hydrophilic materials that is between 40% and 70% the hydrophobic material, and having an outer exposed surface of hydrophobic and hydrophilic materials that is predominantly the hydrophilic material.
[0028] Preferably, the hydrophobic material is polypropylene.
[0029] Preferably, the hydrophobic material is polyester.
[0030] Preferably, the hydrophobic material is natural fiber selected from cotton, wool, silk and linen, and which are treated with a water repellent agent.
[0031] Preferably, the water repellent agent is HYDROPHOBL CF.
[0032] Preferably, the water repellent agent is SiO x nano water repellence agent.
[0033] Preferably, the hydrophilic material is absorbent yarn made from synthetic fiber.
[0034] Preferably, the synthetic fiber is coolmax or coolplus.
[0035] Preferably, the hydrophilic material is absorbent yarn made from natural fiber.
[0036] Preferably, the natural fiber is one of cotton, silk, wool or linen.
[0037] Preferably, the natural fiber is treated with a hydrophilic finishing agent with nano particles such as TiO 2 and ZnO for creating nanostructures.
[0038] Preferably, the woven fabric structure is one of plain weave, twill weave or sateen weave.
[0039] The fabric can be used in components of clothing including sports wear, casual wear, uniform and pants. It can also be used in components of a diaper, or household articles such as bed sheet, covers and pillows.
[0040] Further aspects of the invention will become apparent from the following description, which is given by way of example only.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] Embodiments of the invention will now be described with reference to the accompanying drawings in which:
[0042] FIG. 1 illustrates the structure of denim cotton yarn of a woven fabric according to the invention,
[0043] FIG. 2 illustrates the structure of polypropylene of a woven fabric according to the invention,
[0044] FIG. 3 is a typical measuring curve of the woven fabric,
[0045] FIGS. 4 to 11 illustrate how difference percentage points/areas on the inner surface of polypropylenes or coolmax influence the measurement results of one-way transfer of the fabric and over all moisture management properties;
[0046] FIG. 12 is the typical measurement curve of the fabric in which the hydrophobic yarn is pure cotton pre-treated by nano water repellent agent;
[0047] FIG. 13 a is a plan view of a portion of a plain weave fabric;
[0048] FIG. 13 b is a side elevation of the fabric portion of FIG. 13 a;
[0049] FIG. 13 c is a schematic of the fabric portion of FIG. 13 a;
[0050] FIGS. 13 d and 13 e are first and second opposing side views of a unit cell of the fabric of FIG. 13 a;
[0051] FIG. 14 a is a side elevation of a portion of a second woven fabric;
[0052] FIGS. 14 b and 14 c are first and second opposing side views of the fabric of FIG. 14 a;
[0053] FIG. 15 is a graph illustrating the variation of area ratios calculated by the method of the invention with a one-way transfer index measuring the wicking ability of the fabric.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0054] According to a preferred embodiment of the invention a flat woven fabric with moisture management properties for use in garments includes inner and outer surfaces. The inner surface is, in use, worn next to the skin of a wearer, and has a high proportion of hydrophobic areas or structure points and a low proportion of hydrophilic areas or structure points. In the preferred embodiment the hydrophobic areas occupy 40%-70% of the inner surface. The outer surface, positioned away from the wearers skin, has a high proportion of hydrophilic areas or structure points. The hydrophilic fibers/yarns transfer any liquid or moisture from the inner side of the fabric to the outer side.
[0055] The low proportion of hydrophilic points/areas on the inner surface allows quick absorption of liquid water and enable wicking actions, while the high proportion of hydrophobic points/areas on the inner surface is able to keep the surface relatively dry and prevent the liquid water wicking back to the inner surface.
[0056] The terms hydrophobic and hydrophilic are comparative terms and depend upon selection of fibers and yarn with different surface tension, contact angle, shape of cross section, diameters of fibers, chemical and physical finishing, and so forth. Thus it will be understood that the terms “hydrophobic” and “hydrophilic” are used in the specification and claims as relative terms. This means that the Woven fabric is made up of materials that are hydrophobic and hydrophilic relative to one another rather than necessarily having such properties in comparison to a norm or some industrial standard, for example.
[0057] A wide range of hydrophobic yarns can be selected for the fabric. Such yarns can be synthetic yarns, like polypropylenes, etc., or natural fibers finished with the use of chemicals or nano technology to enhance their hydrophobic properties. Examples include cotton yarns finished by water repellent agent, Ciba's HYDROPHOBL CF, or Zhousan Mingri nano-technology company's water repellent agent. In the preferred embodiment polypropylene is chosen for the hydrophobic yarn.
[0058] Likewise, hydrophilic yarns can be selected from a wide range of synthetic yarns or fibers. Examples include coolmax, coolplus, natural yarns/fibers such as cotton, or yarns finished with the use of chemicals or nano technology to modify their hydrophilic properties by hydrophility finishing agent such as FZ agent. In the preferred embodiment coolmax is chosen for the hydrophilic yarn.
[0059] The moisture management properties of the fabric depend on the proportion of the hydrophobic areas or points on the inner surface. For polypropylene hydrophobic yarn used with pure cotton hydrophilic yarn the range of polypropylenes structure points on the inner surface should be 40% to 70% for optimum moisture management.
[0060] A series of woven fabrics with different percentage of hydrophobic points/areas were developed and measured. As an example, the structure of a fabric, WMMF006, is designed as shown as in FIGS. 1 and 2 . The warp yarn is 100D polyester. The structure of the fabric in FIG. 1 is 20S denim cotton yarn, and the structure of the fabric in FIG. 2 is 83.3dex polypropylene. The pattern arrangement is polypropylene:cotton:polypropylene=1:1:1. The content of fabric is cotton 45%, polypropylene 25%, polyester 30% and the structure is 100D×(20 s +83.3 dtex)/55.1 ends/cm×90 ends/cm.
[0061] The moisture management properties of the fabric were tested using a moisture management tester to determine moisture management indexes. The fabric is sandwiched between two plates. Electrical conductors arranged in concentric opposing pairs are used to measure changes in electrical resistance of the fabric. A quantity of water (or other chosen liquid) is poured down a guide pipe and changes of resistance measured against time. From this data, specific indexes are determined, in a repeatable fashion, and used for determining moisture management characteristics of the fabric. Details of the tester can be found inventors U.S. Pat. No. 6,499,338. The typical measuring curve of the woven fabric is shown in FIG. 3 .
[0062] FIG. 4 shows the influence of percentage of inner surface structure points of polypropylenes on the fabric one way transfer property.
[0063] FIG. 5 shows the influence of percentage of inner surface structure point of polypropylenes on the fabric overall moisture management capacity.
[0064] FIG. 6 shows the influence of percentage of inner surface structure point of coolmax on the fabric one way transfer property.
[0065] FIG. 7 shows the influence of percentage of inner surface structure point of coolmax on the fabric overall moisture management capacity.
[0066] FIG. 8 shows the influence of percentage of inner surface area of polypropylene on the fabric one-way transfer property.
[0067] FIG. 9 shows the influence of percentage of inner surface area of polypropylene on the fabric overall moisture management capacity.
[0068] FIG. 10 shows the influence of percentage of inner surface area of coolmax on the fabric one-way transfer property.
[0069] FIG. 11 shows the influence of percentage of inner surface area of coolmax on the fabric overall moisture management capacity.
[0070] In an alternative embodiment of the invention polypropylenes or coolmax is replaced by is pure cotton yarns pre-treated by a nano water repellent agent as hydrophobic yarn. The typical measurement curve for this alternative embodiment is shown in FIG. 12 .
[0071] The fabric according to the invention can more easily transport the liquid water from the inner surface to the outer surface than the normal fabrics, such as pure cotton fabric, and so maintain the comfort feeling during the wearing, especially under the heavy sweating rate.
[0072] Where in the foregoing description reference has been made to integers or elements having known equivalents then such are included as if individually set forth herein.
[0073] Referring to the drawings, woven fabric is composed of two sets of interlacing, mutually orthogonal (warp and weft) yarns. FIGS. 13 a and 13 b show a plain weave in which one warp yarn and one weft yarn cross at a time, the warp yarns running vertically and the weft yarns running horizontally. Additionally, the plain weave is illustrated in the yarn crossing scheme schematic FIG. 13 c . The space between two adjacent vertical lines 1 illustrates a warp yarn, and the space between every two adjacent horizontal lines 2 illustrates a weft yarn. To mark the crossing points, the relevant square is marked by solid black, that is the crossing of the warp and weft yarns, at all places where the warp yarns overlie the weft yarns. Accordingly, the white squares indicate weft yarns lying on top.
[0074] FIGS. 13 a and 13 b illustrate a model of yarns of a fabric design having moisture management properties and defined by:
the crossing scheme yarn cross section for each yarn (diameters d 1 for the warp yarns and d 2 for the weft yarns) yarn spacing (S 1 and S 1 are the linear spacings of the yarns in the warp and weft directions respectively) the hydrophilic and hydrophobic properties of each yarn
[0079] The method of the invention exploits the periodicity of the repeating pattern of the crossing scheme in a woven fabric to isolate a repeating moisture management unit cell. Assuming the warp yarns 4 a , 4 b are hydrophilic and the weft yarns 5 a , 5 b are hydrophobic then the moisture management unit cell 3 is bordered in FIG. 13 a by the dashed rectangle 3 and shown separately in FIGS. 13 d and 13 e . A moisture management unit cell (abbreviated to “unit cell” herein) refers to the smallest repeating volume of a material which fully characterises the structure. The unit cell 3 has a rectangular border of dimension S 1 ×S 2 , more specifically the unit cell 3 is bounded by the longitudinal centre lines of the warp yarns 4 a , 4 b and the weft yarns 5 a , 5 b around a central opening 6 . Overall properties for the fabric are calculated by making certain assumptions about the internal geometry of the unit cell 3 .
[0080] While this example shows the unit cell 3 being the same as the smallest repeating geometric unit of the fabric which defines the geometry, this will not always be the case since the model also depends on the hydrophilic and hydrophobic properties of the yarn. For example, if only every tenth warp yarn was hydrophilic the unit cell would be correspondingly enlarged to fully characterise the structure.
[0081] It is assumed each yarn has a constant cross-section throughout its length. Each yarn is a bundle of filaments and the yarn cross-sectional area is determined by the number of filaments as well as yarn and fabric manufacturing parameters. However for any given fabric construction knowing the linear density of the yarn (its weight per unit length) as used in the manufacture of the fabric, and the density of the yarn (its weight per unit volume) or its specific density (ratio of the volume of yarn to that of the same weight of water) allows determination of the unknown yarn cross-sectional area which is required to model each yarn within the unit cell 10 .
[0082] For the purposes of the invention it has been found that yarns should be assumed to have a circular cross-section. Thus, knowing the cross-sectional area, the diameter can be determined for this feature of the model. This assumption however is not essential to the method, and where the shape assumed by the yarns in the fabric is known, this shape can be approximated in the model.
[0083] In the examples illustrated it is also assumed in the crossing schemes shown that the weft yarns 5 a , 5 b undulate, their centrelines lying in parallel planes. It is assumed there is no undulation in the warp yarns 4 a , 4 b , which are parallel and coplanar. Using a Cartesian system of coordinates (x, y, z), for example, if the warp yarns are elongated parallel to the y-axis and spaced apart from the weft yarns at each crossing point in the z-direction, the undulating centreline of each weft yarn lies in a plane parallel to the xz-plane.
[0084] The fabric may be modelled as a planar sheet with the warp and weft yarns generally lying in a plane of the fabric 7 (see FIG. 13 b ). Under the assumption that there is no undulation in the warp yarns the common plane of the longitudinal centrelines of all warp yarns 4 a , 4 b (or the xy-plane in the Cartesian system) defines this plane of the fabric 7 . This assumption however is also not essential to the method. If the model assumes that the centrelines of both warp and weft undulate then the plane of the fabric 7 remains the xy-plane for undulations in the mutually perpendicular xz- and yz-planes respectively.
[0085] Considering the model thus created the unit cell 3 has first and second opposing sides 8 , 9 . FIG. 1 d shows the first side view of the unit cell 3 , which is made by the engineering drawing technique of orthographic projection, for example from the view shown in FIG. 1 b , projected onto a plane parallel to the plane of the fabric 7 . FIG. 13 e shows the opposing view of the second side 9 . From FIGS. 13 d and 13 e the total projected area (A tot ) of the yarns 4 a , 4 b , 5 a , 5 b is calculated from the following formula:
A tot =d 2 S 1 +d 1 S 2
[0086] The method requires identifying yarns which are hydrophilic and hydrophobic, then calculating and summing the projected areas of each hydrophilic and each hydrophobic yarn in the first and second side views to determine a total projected area of each hydrophilic and each hydrophobic yarn.
[0087] As the warp yarns 4 a , 4 b are hydrophilic and the weft yarns 5 a , 5 b are hydrophobic, total projected area of hydrophilic yarn on the first side (A 1phi ) is calculated from the following formula:
A 1pho =d 2 S 1
[0088] The total projected area of hydrophobic yarn on the second side (A 2pho ) is calculated from:
A 2pho =d 1 S 2
[0089] As seen in FIG. 15 , experimental work on various fabric constructions has revealed a relationship to exist between A 1phi and A 2pho as a percentage of A tot which provides a fabric with good moisture wicking performance as measured by the one-way transfer index (using apparatus as described in the inventor's U.S. Pat. No. 6,499,338).
[0090] If A 2pho is between 40% and 70% of A tot , and A 1phi exceeds 50% of A tot , then a fabric according to the fabric design represented by the model is manufactured. Fabric manufacturing processes for achieving a given fabric design are well-known and are therefore not described. It will be apparent that the method of the invention could be readily implemented by computer, in particular the model may be created using computer-aided fabric design software. In this way a number of variations of the model can be readily determined, before one falling within the above ranges is selected.
[0091] In FIG. 14 a - 14 c , there is analogously illustrated a weave formed by large diameter warp yarns 4 a , 4 b etc alternating with warp yarns 10 a , 10 b etc of smaller diameter, by way of a further example of the application of the method of the invention. In the crossing scheme shown, the weft yarns 5 b , 5 c are interlaced alternately around the upper warp yarns 4 a , 4 b etc and the lower warp yarns 10 a , 10 b etc, whereas the weft yarns 5 a extend linearly between the upper and lower warps 4 a , 4 b etc and 10 a , 10 b etc. As the views are derived by orthographic projection, the dimension 11 selected in the model for the spacing between the planes of the centrelines of the warp yarns has no affect upon the relevant areas calculated from the views.
[0092] Assuming all the large diameter warp yarns 4 a , 4 b etc, the small diameter warp yarns 10 a , 10 b and the weft yarns 5 a , 5 b are made from three respective materials with respective moisture management properties (hydrophilicity, hydrophobicity) then the unit cell 3 has a rectangular border of dimension S 1 ×S 2 , more specifically the unit cell 3 is bounded by the longitudinal centre lines of the warp yarns 4 a , 10 a and the weft yarns 5 a , 5 b.
[0093] FIGS. 14 b and 14 c show views of the first side 8 and second side 9 of the unit cell 3 projected onto respective planes parallel to the plane of the fabric 7 . As there is no opening visible between the yarns the total projected area (A tot ) of the yarns is calculated from the following formula:
A tot =S 1 S 2
[0094] If the warp yarns 10 a , 10 b , 10 c etc are hydrophilic relative to at least one of the other yarns 4 a , 4 b , 5 a , 5 b etc, the total projected area of hydrophilic yarn on the first side (A 1 phi) is determined from FIG. 14 b and the projected area of the unit cell 3 for the warp yarn 10 a alone. It is determined from the geometry, and it will be clear that it is calculated from the following formula:
A 1 phi = d 3 2 ( S 2 - d 1 2 ) - S 2 [ ( d 2 + d 3 ) 2 - S 1 ]
[0095] If the warp yarns 4 a , 4 b are hydrophobic relative to the warp yarns 10 a , 10 b , 10 c the total projected area of hydrophobic yarn on the second side (A 2pho ) is calculated from FIG. 14 c and the projected area of the unit cell 3 for the warp yarn 4 b alone.
[0096] As described above, if A 1phi exceeds 50% of A tot and A 2pho is between 40% and 70% of A tot , then a fabric according to the fabric design represented by the model is manufactured.
[0097] Likewise the total projected area of hydrophilic yarn on the second side (A 2phi ) may be determined from FIG. 2 c and the total projected area of hydrophobic yarn on the first side (A 1pho ) may be calculated from FIG. 14 b . If A 1pho is between 40% and 70% of A tot , and A 2phi exceeds 50% of A tot , then a fabric according to the fabric design represented by the model is manufactured. Otherwise at least one of the properties defining the model (the quantities of hydrophilic and hydrophobic yarns, yarn crossing scheme, yarn cross section for each yarn and yarn spacing) are varied and the calculations performed until a result having a pair of opposing sides within these two ranges is obtained. While these examples and the FIG. 15 refer to conventional clothing fabrics this technology also has application to fabrics manufactures in the nano-scale for medical applications, and the like.
[0098] Embodiments of the invention have been described, however it is understood that variations, improvements or modifications can take place without departure from the spirit of the invention or scope of the appended claims. | A technique allowing manufacturers to produce woven moisture management fabrics with good moisture transfer properties is based upon a model of the fabric construction, thereby avoiding a manufacturing trial-and-error process. An initial woven fabric design including hydrophilic and hydrophobic yarns is modelled, the warp and weft yarns generally lying in a plane of the fabric. By orthographic projection onto respective planes substantially parallel to the plane of the fabric, a first view and an opposing second d view of a unit cell of the model is produced. If the total projected area of hydrophobic yarn on one of the first and second views is between 40% and 70% of the total projected area, and total projected area of hydrophilic yarn on the other of the first and second views exceeds 50% of the total projected area, then a fabric according to the fabric design will have near optimum moisture wicking properties and is manufactured to the design. Otherwise, in an iterative process, one of the factors in the model is varied and the design steps repeated. | 3 |
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