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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 10/131,316 filed on Apr. 23, 2002, now U.S. Pat. No. 6,766,760, and is cross-referenced to and claims priority from U.S. patent application Ser. No. 10/131,316 filed on Apr. 23, 2002, U.S. Provisional Application 60/442,355 filed on Jan. 23, 2003 and PCT Application US03/02116 filed on Jan. 23, 2003, which are all hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates generally to traffic marker devices and safety cones that are used to alert or divert vehicles, watercrafts, aircrafts and pedestrians to pass safely around hazards, obstacles or other areas. More particularly, the present invention relates to a flexible safety marker device with a fast impulse response to direct (contact) and indirect (no-contact) perturbations and large flexibility.
BACKGROUND
Traffic or safety cones, are routinely used to direct motorists and pedestrians away from obstacles or dangerous area. These cones are usually brightly colored, hollow conical shaped devices made of a synthetic, rubber or other plastic (See for example U.S. Pat. No. 2,333,273 to Scanlon et al.). Traffic and safety cones are meant to minimize damage to persons or vehicles which may collide with the cones. However, safety cones are still of significant danger to the public. One reason is that, although the traffic cones are made out of a synthetic, rubber or other plastic, they are still relatively rigid and tend to fall over easily when the cones are subject to natural or traffic wind, perturbations by passing traffic or violence. Furthermore, safety cones that are, for instance, run over or hit by a vehicle, could become dangerous objects or obstacles by being airborne or simply laying on the road, in particular to following traffic or surrounding people.
A variety of different self-righting traffic cones have been proposed. For instance, U.S. Pat. No. 3,386,409 to Dietz Company describes to shape the base of the cone in such a manner that the cone is nestable or stackable self-righting in the manner of a self-righting top. The objective of U.S. Pat. No. 3,386,409 is to provide a nestable cone which, when it has been toppled over, will not roll away but will right itself and stand erect near to the position in which it was originally placed. This was accomplished by a hollow molded plastic traffic cone that has a base portion weighted to give a low center of gravity to the cone. The annular bottom of the base is gradually curved outward and upward to provide rockers so the cone is self-righting and is divided into six angularly spaced triangular legs to prevent rolling when the cone is knocked over.
U.S. Pat. No. 5,888,016 to Eui Sig Ahn et al. describes a traffic collar cone that has a delineator having a reflection sheet attached on its upper part. A plug is placed under the sheet having an air inlet and outlet extending upwardly and downwardly there-through. A conical body member is provided, having in its upper end wall an insertion hole in which the plug is mounted. A support panel is provided at the bottom of the body and cone collars are attached on the outer surface of the body member, with vertical spacing between them. The traffic collar cone is made of flexible material and designed to recover its original shape after being impacted, so that injury to collar cone is eliminated or minimized.
U.S. Pat. No. 5,993,105 to Chan describes a safety marker that includes a hollow frusto-conical body and a base having a bowl-shaped main portion and a resiliently flexible skirt for yieldably stabilizing the marker against tipping relative to a supportive surface.
So far the solutions have focused on self-righting of the traffic cone. However, these solutions are still not satisfactory from a safety standpoint since they still are either too rigid or can still relatively easy fall over. Accordingly, there is a need to develop a better traffic cone or marker device that further improves road and traffic safety.
SUMMARY OF THE INVENTION
The present invention provides a new marker device for increased safety due to a flexible design. The marker device of the present invention includes a base with an opening and a flexible means that is positioned over the base. The bottom part of the flexible means is attached to the base. The flexible means has a fast impulse response to direct (contact) and indirect (no-contact) perturbations. Due to the perturbations one or more parts of the flexible means might undergo different degrees of deflection from their original (vertical) position. In general, depending on the type of perturbation (direction of force applied and amount of force applied), one or more parts of the flexible means should be able to allow deflections ranging up to about 180 degrees which is defined from the original (vertical) position. In one example the range of deflection is from about 15 degrees up to about 180 degrees. In case the flexible means is a coil the design of the coil is restricted to the number of loops of the coil in such a manner that during these large deflections the loops maintain spaced from each other; i.e. the loops should for instance not be touching or locking into each other since this would risk that the coil could not restore from the perturbation back to its original position. In addition, touching or intertwined loops might increase the stiffness of the coil during deflections and work against the fast impulse response of the flexible means.
In one embodiment, one or more of the bottom loops of the coil should have a larger diameter than the diameter of the opening of the base. The reason for this is that these bottom loops could get stuck with the base which would jeopardize the restoration of the flexible means from a perturbation.
The marker device of the present invention includes a cover, preferably a mesh-cover, to cover the flexible means. The outside of the cover could include one or more bands of reflective material. In addition, the present invention could include one or more light sources to illuminate the marker device. The light source(s) could be placed inside and/or outside the cover and/or attached to the flexible means and/or the base.
The advantage of the present invention over previous devices is that the present marker device quickly responds and deflects, with one or more parts of the flexible means capable of deflecting up to about 180 degrees from their original position, to direct (contact) and indirect (no-contact) perturbations. The marker device increases the likelihood for the marker device to remain upright once the perturbations disappear, therewith increasing the likelihood for the marker device to remain serving as a marker device safely alerting traffic; i.e. its intended purpose.
BRIEF DESCRIPTION OF THE FIGURES
The objectives and advantages of the present invention will be understood by reading the following detailed description in conjunction with the drawings, in which:
FIG. 1 shows an exemplary embodiment of a marker device according to the present invention;
FIG. 2 shows an example of a top view of a marker device according to the present invention;
FIGS. 3–5 show exemplary embodiments of the flexibility and degree of bending/deflection of parts of the flexible means of a marker device due to a perturbation according to the present invention;
FIG. 6 shows an example of the degree of flexibility of the marker device when a marker device is hit and run over by a car according to the present invention;
FIG. 7 shows an example of a light source inside of a marker device according to the present invention;
FIG. 8 shows an example of a marker device with one rod as flexible means according to the present invention;
FIG. 9 shows an example of a position of the marker device shown in FIG. 8 due to a perturbation according to the present invention;
FIG. 10 shows an example of a marker device with three rods as flexible means according to the present invention;
FIG. 11 shows an example of a position of the marker device shown in FIG. 10 due to a perturbation according to the present invention;
FIG. 12 shows a cross section view of an exemplary marker device assembly according to the present invention;
FIG. 13 shows an example of a rod with a spring to enhance the flexibility of the rod, i.e. flexible means, according to the present invention; and
FIG. 14 shows an example of a marker device with two or more flexible means according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Although the following detailed description contains many specifics for the purposes of illustration, anyone of ordinary skill in the art will readily appreciate that many variations and alterations to the following exemplary details are within the scope of the invention. Accordingly, the following preferred embodiment of the invention is set forth without any loss of generality to, and without imposing limitations upon, the claimed invention.
The marker device of the present invention could be used to alert or divert vehicles, watercrafts, aircrafts and pedestrians to pass safely around hazards, obstacles or other areas. However, the marker device of the present invention is not limited to any particular use and could also be used for recreational or sporting events. Furthermore, the marker device is usually recognized as a cone and is therefore called safety cone. However, the marker device of the present invention is not limited to any particular shape and could also be straight, curved, circular, cylindrical, square, a hexagonal, a tubular marker, any three-dimensional shape type, or any type of shape that is needed or required to alert or divert someone, or mark-off a particular space or area. Therefore, the device of the present invention is referred to as a marker device. Furthermore, there is also no restriction to the size of the particular marker device or safety cone of the present invention.
FIGS. 1–2 show an exemplary embodiment of a marker device 100 according to the present invention. Marker device 100 includes a base 110 with an opening 200 and a cone 120 . Opening 200 is preferred to allow stacking of marker devices. The bottom part 142 of flexible means 140 is attached to base 110 , preferably centered over base 110 , and close to the edge 210 of opening 200 , either at the inside of opening 200 or at the top of base 110 . Base 100 provides the support of marker device 100 and keeps the marker device on the ground or surface. Base 110 is shown as a square with round edges 112 . However, base 110 could take any type of shape and could also be made out of any material as long as it provides the required support. The base of the marker device plays an important role in the stability of the marker device. The weight of the base should be significantly larger than the combined weight of all the components that are positioned above the base (see description infra). Furthermore, the dimensions of the base should be large enough to support, in a stable fashion, the entire marker device with or without perturbations. The measurement (length and width) of base 110 could be, but is not limited to, about 14″ by about 14″, which is the standard base size for conventional safety cones in the U.S.A. (e.g. 18″ and 28″ high cones). The materials that could be used for the base are, for instance, but not limited to, rubber, recyclable rubber, soft/hard plastic, PVC, any type of wood including bamboo or wood compositions, metal, or the like.
Cone 120 includes a flexible lightweight cover 130 that covers a flexible means 140 . Preferably, cover 130 is made out of a flexible material that allows cone 120 to easily flex, bend or fold. Cover 130 should not resist or minimal resist the movement of flexible means 140 . The top 132 and bottom 134 of cover 130 could be attached to flexible means 140 . Instead of attaching bottom 134 of cover 130 to flexible means 140 , bottom 134 could be attached to base 110 . The type of means for connecting cover 130 is, for instance, but not limited to, stitches, clamp(s), glue, Velcro, a ring (See FIG. 13 ) or the like. However, cover 130 could also fit tight over flexible means 140 and in this case there is no need for a connecting means to connect cover 130 .
In a preferred embodiment, the cover should have air-passing capabilities, e.g. by having a mesh cover, to make it less wind resistant. Examples of cover materials are for instance, but not limited to, a mesh-type material, vinyl, canvas, polyester, or the like. Furthermore, the outside of the cover could include all kinds of shapes and/or reflective material. Preferred shapes (reflective collar(s), stripes, or other types of regulatory shapes or signs) are the ones recommended by the Government (Federal, State/Province or Local; e.g. the U.S. Department of Transportation including the FAA and/or the Federal Highway Administration) and include common traffic control or warning signs. FIG. 1 shows an example of a cone 100 with a cover 130 . Cover 130 includes two bands of reflective material that are positioned at two distinct positions on cover 130 according to U.S. Government regulations. FIG. 1 shows the first reflective band (shaded) positioned at about 3″ (inches) from the top of cover 130 and this first band is about 6″ (inches) in height. FIG. 1 shows the second reflective band (shaded) positioned at about 2″ (inches) from the bottom of the first reflective band and this second band is about 4″ (inches) in height. Any other type of shape or sign can be included and is depended on the type of application. It is possible to use a reflective material that can be attached/assembled to the cover using heat, glue, tape, Velcro, sewing or the like. An example of a suitable reflective material is the 8710 reflective material (from 3M Worldwide Corp.; See U.S. Pat. No. 6,656,319 to Innovative Properties Company, which is hereby included by reference for all that it discloses) that also has the benefit of about 500 candlelight power. The present invention is not limited to 8710 reflective material or to a reflective material with about 500 candlelight power, since any type of reflective material could be used each with a different amount of reflective intensity (higher or lower), (see e.g. Reflecto-Lite Inc.).
Flexible means 140 is, for instance, a coil that is shaped as a cone when marker device 100 is meant to be a safety cone. Flexible means 140 provides for the flexibility of marker device 100 . The key idea of the present invention is that the base provides stable support on the ground or surface, and the flexible means is in either its original position or a deviated position from the original position caused by indirect (non-contact) or direct (contact) perturbations. Examples of indirect (non-contact) perturbations are, for example, but not limiting to, perturbations caused by natural wind, traffic wind, ground-shaking caused by earthquakes, falling or being dropped on the ground (see also description infra), or the like. Examples of direct (contact) perturbations are, for example, but not limiting to, perturbations from vehicles by hitting, running over or running into the marker device, violence, or the like.
The applied (direct and/or indirect) perturbation force (F) applied at the flexible means for a period of time is an impulse, which is the act of applying force suddenly (See e.g. Webster Dictionary). The mechanical definition of impulse is the action of a force during a very small time interval (See e.g. Webster Dictionary and Oxford Dictionary of Physics). To sustain, without the marker device permanently fallen over, direct and indirect perturbations, the material properties of the flexible means of the present invention require a fast impulse response to these direct and indirect perturbations; i.e. the flexible means needs to respond fast by flexing, bending and/or folding to any direction in response to the suddenly applied (indirect and/or direct) force as shown in FIGS. 3–6 and could, for instance, bend sideways, downward or even flex/extend upward. In other words, flexible means deviates from its original position (i.e. natural or neutral position in case flexible means is a coil or a spring). The direction and amount of deviation from the original position depends on the amount and direction of the perturbation force. Once the perturbation force is removed or disappears, flexible means restores from the deviated position to its original position.
As shown in FIG. 3–6 the degree of flexibility or deflection (α) from original (vertical) position of the flexible means is significant. Due to the perturbations different parts of the flexible means undergo different degrees of deflection from their original (vertical) position. For example, parts 310 , 320 , 330 as shown in FIG. 3 , show a deflection of about 11 degrees, about 31 degrees, about 100 degrees (indicated by lines 312 , 322 , 332 ), respectively. In another example, part 410 , 420 , 430 shown in FIG. 4 , show a deflection of about 21 degrees, about 90 degrees, about 170 degrees (indicated by lines 412 , 422 , 432 ), respectively. A deflection of up about 180 degrees for instance could require a perturbation whereby the top of the cone is brought downward to the direction of the ground or base.
FIG. 5 shows an example of marker device 500 now including a cover over the flexible means subject to a perturbation force 510 that makes flexible means to quickly flex, bend or fold away from its original (upright) position with deflections 530 , 540 , 550 , 560 of different parts of the cone (flexible means and cover). In this example part 530 , 540 , 550 , 560 have a deflection of about 2 degrees, about 12 degrees, about 26 degrees, about 52 degrees, respectively.
In general, depending on the type of perturbation (direction of force applied and amount of force applied), one or more parts of the flexible means should be able to allow deflections of up to about 180 degrees which is defined from the original (vertical) position. In one example the range of deflection is from about 15 degrees up to about 180 degrees. In case the flexible means is a coil the design of the coil is restricted to the number of loops of the coil in such a manner that during these large deflections the loops maintain spaced from each other; i.e. the loops should for instance not be touching or locking into each other since this would risk that the coil could not restore from the perturbation back to its original position. In addition, touching or intertwined loops might increase the stiffness of the coil during deflections and work against the fast impulse response. In general, depending on the height of the marker device between 2–10 loops could be used; i.e. the number of loops spaced between the base and the top of the cone leaving a large space 144 between the loops. Examples of a type of material for the flexible means are, for example, but not limited to, a metal (e.g. aluminum, steel, etc.), a carbon, a graphite, a wood (including bamboo), a fiberglass, a plastic, a rubber or the like.
In one embodiment, in particular for the case that the flexible means is a coil, it is also important that during the perturbations the coil does pop through opening 200 . For instance, if the largest diameter of the loops of the coil is the same as or less than the diameter of the opening, then during perturbations (e.g. bending of the coil or pressing the coil downwards) the coil could pop through the opening and one of the bottom loops could get stuck with or under the base. This would be a concern since the coil can then no longer properly restore from the perturbed position back to its original position. To prevent this from happening, the coil in this embodiment would then require that at least one of the bottom loops, e.g. loop 146 of coil 140 has a larger diameter than the diameter of the opening (see top view of FIG. 2 where different in diameter is shown). In one exemplary embodiment, opening could have a diameter of about 10″ and the diameter of at least one of the bottom loop(s) is about 12.5″. The present invention is not limited to the number of loops with larger diameters than opening or any particular dimensions. In an alternative embodiment a small recess at the edge of the opening (not shown) could be created, still leaving a large enough opening for stacking with another marker device, to provide support to the coil and prevent it from popping through.
FIG. 6 shows a situation where a moving car 600 runs into and over a marker device of the present invention, i.e. a direct (contact) perturbation force. When car 600 hits marker device 610 with bumper 620 (i.e. a high speed impact), base 630 remains on the ground and only the flexible means and cover bend as indicated by 640 . In the example of 640 , the impact of the car with the flexible means causes the original position of the flexible means (see e.g. FIG. 1 ) to quickly change to deviated position 640 with large deflections of different part of the cone (flexible means and cover). To sustain such an impact, the flexible means requires a fast impulse response. When marker device 650 is under the car, base 630 could rock but does not permanently tip over mainly due to its weight and the flexible means responding (see 660 ) to the impact and perturbation. The flexible means and therewith the cone also quickly re-positions itself to the original (upright) position when the car is no longer on top of the marker device as indicated by 670 . During the perturbation, the base of the marker device of the present invention might undergo some rocking motion(s), however, once the perturbation disappears the base of the marker device will return to its original and stable position.
Another example (not shown) is that the marker device of the present invention could be dropped down to the ground (which results in an indirect perturbation to the flexible means, through a direct impact to the base), for instance, but not limited to, from a car or a truck that is delivering several marker devices to an area to, for instance, block an obstacle. The impact of the landing of the marker device on the ground causes sudden and fast perturbations to the flexible means. After landing on the ground, the marker device of the present invention might initially rock but will come to their original and stable position once the rocking motions oscillate out.
The likelihood that the marker device of the present invention remains in that position is facilitated by a very low center of gravity (close to the ground or supporting surface) of the marker device. The low center of gravity is mainly due to a relatively heavier base compared to the combined weight of the flexible means and cover that over positioned over the base (flexible means and cover are preferably made of lightweight material(s)). The center of gravity of the marker device could virtually be close to the top of the base or somewhere in the base in case the difference between the weight of the base and combined weight of the flexible means and cover that are positioned over the base is large as a person of average skill would readily appreciate. Furthermore, the fact that the flexible means (and cover) bends at different spots, with the loops maintaining space between each other (i.e. without loops touching each other or locking into each other), significantly reduces the torque that the perturbed flexible means produces onto the base (this in contrast to existing traffic safety cones or marker devices which have a relatively stiff top/cone part or where coil loops are restricting even small deflections such as less than about 10 degrees). The reduced torque improves the stability of the base and therewith the stability of the marker device of the present invention.
The marker device of the present invention could include one or more light sources such as light source 710 shown in marker device 700 in FIG. 7 . Light source 710 could be positioned anywhere inside cover 720 to illuminate the inside of cover 720 . However, light source 710 could also be positioned to the base or flexible means. In case a light source is included inside cover 710 , it would be preferred that the material of the cover is transparent to light so that the marker device becomes visible in the dark or in situations of poor visibility. Light source 710 could be any type of light source and is not limited to a particular type or mechanism. Light source 710 is preferably lightweight and small. Light source 710 could be positioned by or near opening 200 of base 110 , but could also be positioned near the top 730 of the flexible means 740 . In general, the light source(s) could be placed at the base, flexible means or cover (inside or outside). The marker device of the present invention could also have a sensor to turn on the light source. The sensor could, for instance, be positioned at the bottom of the base. Once the marker device is placed on the ground or surface, the sensor turns on the light source and the marker device becomes lit. The sensor could, for instance, be a mechanical switch. However, the sensor is not limited to a mechanical switch since it could also be a light-sensitive sensor that turns on the light source depending on whether it is, for instance, daytime or nighttime. In addition, the sensitivity of the sensor can also be set so that it will be turned on when the visibility becomes less.
The present invention has now been described in accordance with several exemplary embodiments, which are intended to be illustrative in all aspects, rather than restrictive. Thus, the present invention is capable of many variations in detailed implementation, which may be derived from the description contained herein by a person of ordinary skill in the art. For instance, in order to meet the stated (explicit or implied) objectives and advantages of the present invention, the marker device and its components could be designed, manufactured and assembled in a variety of different ways with a variety of compatible different of materials and dimensions. The discussion infra provides some examples of the different materials, dimensions as well as possible assemblies and variations.
Generally speaking, the height of the marker device of the present invention is not restricted. However, the art as well as Government (Federal, State/Province or Local) regulations teach several specific dimensions/heights for safety traffic cones. Examples of such dimensions in the U.S.A. are, for instance, but not limited to, a 14-inch high cone, 18-inch high cone, 28-inch high cone or a 36-inch high cone. As a person of average skill in the art would readily appreciate, the height of the marker device is mostly dependent on the type of use or application as well as on any type of Government regulations or requirements (Federal, State/Province or Local), which (may) vary in different countries/parts around the World.
The flexible means could also include one or more rods as long as the physical characteristics of the rod(s) meet the objectives and advantages of the present invention as they are discussed supra; i.e. the rods have a fast impulse response to direct and indirect perturbations. This includes the need to allow for large deflections of one or more parts of the rod(s) as described supra. FIG. 8 shows an example of a safety cone 800 in which the flexible means is based on one rod 810 that is positioned over base 820 . Rod 810 could, for example, be attached with its bottom end to base 820 and with its top end to the top of cover 830 (e.g. a ring). The cone shape of exemplary safety cones as it is discussed supra, is defined and determined predominantly by the flexible means. However, in case of marker device 800 , the cone shape has to be determined by cover 830 that is placed over rod 810 . FIG. 9 shows safety cone 800 subject to a perturbation 900 , whereby rod 810 is bend due to perturbation 900 . FIG. 10 shows examples of a safety cone 1000 in which the flexible means is based on three rods 1010 , 1020 , and 1030 that are positioned over base 1040 . Rods 1010 , 1020 , and 1030 could, for example, be attached with their bottom ends to base 1040 and with their top ends to the top of cover 1050 (e.g. a ring). FIG. 11 shows safety cone 1000 subject to a perturbation 1100 , whereby rods 1010 , 1020 , and 1030 are bend due to perturbation 1100 .
FIG. 12 shows an example of a marker device assembly 1200 with a base 1210 , a spiral 1220 , a cover 1230 and a ring 1240 using a cross sectional view of marker device assembly 1200 . Ring 1240 is used as a sort of quick-connector to assemble the modular components (i.e. base 1210 , spiral 1220 and cover 1230 ) of the marker device. Note that for clarity purposes in the inset figure, only part of the bottom ring of spiral 1220 is shown and spiral 1220 should in fact extend upward as shown by 1200 . The key idea of ring 1240 is to position spiral 1220 and cover 1230 against the inner edge 1215 of base 1210 . Ring 1240 could be made out of any type of material (e.g. a plastic, rubber or polyester) as long as it has enough strength to hold together base 1210 , spiral 1220 and cover 1230 as well as enough flexibility to assemble (de-assemble) these three parts together (apart).
FIG. 13 shows an example of how base 1310 and flexible means could be connected in case the flexible means includes one or more rods 1320 and 1330 each with a fast impulse response to direct and indirect perturbations. For example, rod 1320 includes an end part 1322 that could be positioned more or less parallel to the bottom 1315 of base 1310 . Rod 1320 could include a spring 1324 as an integral part of rod 1320 to ensure the necessary flexibility of the flexible means. However, the question whether spring 1324 is necessary depends on the physical characteristics (e.g. flexibility) of rod 1320 .
The present invention is also not limited to a marker device with one flexible means since it could also include two or more flexible means each with a fast impulse response to direct and indirect perturbations. This includes the need to allow for large deflections of one or more parts of each of the flexible means as described supra. FIG. 14 shows an exemplary embodiment of a marker device 1400 in the form of a barricade that includes two or more flexible means 1420 and 1430 that are positioned over base 1410 . In case of a barricade, base 1410 typically has a rectangular shape. Base 1410 could have opening that could be advantageous for stacking purpose, however, this is not necessary. The two or more flexible means 1420 and 1430 could be positioned to base 1410 is a similar manner as discussed supra for a single flexible means. Marker device 1400 could also include: (1) a cover 1440 that covers the two or more flexible means, (2) one or more shapes and/or reflective materials 1450 and 1452 , and/or (3) one or more light sources placed on the outside (e.g. 1460 and 1462 ) of cover 1440 or at the inside of cover 1440 (not shown in FIG. 14 , but discussed supra). It should be clear to a person of average skill in the art that the teachings for a marker device with one flexible means, as discussed supra, also apply to a marker device with two or more flexible means. Furthermore, it should be clear to a person of average skill in the art that a marker with two or more flexible means is not limited to a barricade, since such a marker device could also be a fence-like structure as long as all these variations include the advantages and objective as stated and discussed supra in terms of safety, flexibility when subject to direct or indirect perturbations. A fence-like marker device according to the present invention could be small but also significantly wide, for instance to fence-off a yard, a street part etc. Imagine that a car runs into such a wide fence, then the part of the fence where the car runs into flexes, bends etc. according to the teaching supra and restores to its natural original position when the car (read perturbation) has disappeared.
All such variations are considered to be within the scope and spirit of the present invention as defined by the following claims and their legal equivalents. | A marker device for increased road safety due to a flexible design is provided. The marker device includes a base with an opening and a flexible means that is positioned over the base. The flexible means has a fast impulse response to direct (contact) and indirect (no-contact) perturbations with one or more parts of the flexible means capable of deflecting up to about 180 degrees from their original position. In one example the deflection ranges from about 15 degrees to about 180 degrees. The marker device increases the likelihood for the marker device to remain upright once the perturbations disappear, therewith increasing the likelihood for the marker device to remain serving as a marker device safely alerting traffic; i.e. its intended purpose. | 4 |
This is a continuation of co-pending application Ser. No. 07/205,162 filed on June 10, 1988, now abandon.
TECHNICAL FIELD OF INVENTION
The present invention concerns a novel composition used as an additive to improve the characteristics of hydrocarbon fuels exhibiting a boiling range of gasoline being suitable for use in spark ignition-type engines. Hydrocarbon fuels of this type are those comprising hydrocarbonaceous gasoline fuels, oxygenated gasoline fuel compositions such as gasohol and alcogas and blends of various hydrocarbon components exhibiting boiling points in the range of 65°-430° F. Such additives can also be employed with ethanol, methanol and other oxygenates when blended into hydrocarbons boiling in the gasoline range suitable for use as fuels without adversely affecting the storage stability, oiliness, water shedding properties or corrosion, characteristics of the fuels or their distillation, combustion curve and vapor pressure.
BACKGROUND OF THE INVENTION
Historically, gasoline manufacturers have employed tetraethyl lead as an anti-knock additive for use in hydrocarbon based gasoline fuels. However, as mandated by the environmental protection agency, the maximum amount of lead allowable in gasoline as of Jan. 1, 1986 was but a mere 0.1 grams per gallon. Total removal of lead from gasoline is under consideration. Due to the practice of banking lead credits, many refineries in the United States continue to produce gasoline with more than the 0.1 gram per gallon limit. However, the lead credit process terminated at the end of 1987 thereby increasing the need to find tetraethyl lead alternatives.
There is obvious concern over the need to maintain octane while dropping lead levels in gasoline based fuels. Many industry observers believe that there is a limit to how much extra octane can be squeezed out of such fuels during the refining process and the general belief remains that prices for high octane gasolines at the 92 octane level will soar as demand outstrips supply for such products. The problem has become particularly acute in large part due to the trend of automobile manufacturers to increase horsepower by increasing compression ratios of their internal combustion engines. This necessitates higher octane gasolines to avoid knocking.
It has been known for some time that the octane of motor fuels could be enhanced by varying the thermal and catalytic processes used in the distillation of the hydrocarbon fuels. Octane could also be enhanced by addition of, as previously noted, tetraethyl lead, as well as cyclopentadiene manganese compounds or by blending hydrocarbon fuels with large volumes of aromatics. However, benzene is a known carcinogen and a growing public awareness for the need to create cleaner air will obviously limit the availability of such alternatives.
The virtual elimination of tetraethyl lead as a hydrocarbon fuel additive results in yet another concern and that is the observation that the elimination of tetraethyl lead results in severe engine exhaust valve seat recession. Tetraethyl lead acts as a lubricant for exhaust valve seats for it was noted that without significant quantities of tetraethyl lead in hydrocarbon fuels, wear rates above 0.015 inches per hundred hours of engine operation were observed resulting in a loss of engine compression and ultimate engine failure, sometimes occurring in less than 1,000 hours of engine operation.
In contemplating various additives to improve octane and anti-knock properties of hydrocarbon fuels, care must be taken to avoid deposits which have been found to accumulate on the carburetor throttle plate and intake valves--basically all components from carburation to combustion. Such deposits can cause rough idling, loss of power and even valve burning. Such deposits can account for a substantial increase in the octane requirements of an engine and can require a gasoline octane improvement of 5 to 25 numbers in order to prevent engine knocking.
It is thus an object of the present invention to provide a chemical composition which could be employed to increase the octane of hydrocarbon fuels exhibiting a boiling range of gasoline being suitable for use in spark ignition-type engines while avoiding the shortcomings of the prior art.
It is yet another object of the present invention to provide improved anti-knocking and lubrication characteristics of hydrocarbon fuels exhibiting a boiling range of gasoline being suitable for use in spark ignition-type engines which is environmentally safer than prior alternatives and yet do not result in destructive engine deposits.
These and other objects will be more readily appreciated when considering the following disclosure of the present invention.
SUMMARY OF THE INVENTION
The present invention deals with a composition for the improvement of hydrocarbon fuels exhibiting a boiling range of gasoline being suitable for use in spark ignition-type engines. The composition comprises firstly, an amine comprising a member selected from the group consisting of aliphatic amines, aromatic amines and mixtures thereof. The composition further comprises a polyaminated detergent and, optionally, an alkyl or phenol and/or alkylphenol phenylenediamine inhibited aromatic monomer stabilized by a polymeric substrate. A catalyst should be included comprising a colloidal suspension or amine salt of transition/alkali/alkaline earth metal organic coordinations having at least one metal oxidehydroxide linked to an alkyl chain via a carboxyl group. The composition also includes a solvent comprising an alkanol-aliphatic ether oxygenated hydrocarbon and, optionally, a promoter comprising a member selected from the group consisting of an organic oxide, alone or azeotroped with carbon disulfide with one or more alkanes and, optionally, a co-promoter comprising an organic ester.
As will be more readily apparent in considering the remaining disclosure particularly the various examples, the combination of components comprising the present composition provide, as a group, the enhancement of hydrocarbon fuels far superior to any single component or group of prior components, taken alone.
DETAILED DESCRIPTION OF THE INVENTION
As previously noted, the present invention is directed to a composition for the improvement of hydrocarbon fuels exhibiting a boiling range of gasoline. Such fuels include, but are not limited to, straight-chain and branched-chain, alkanes, olefins, aromatics and napthenes prepared by well-known catalytic processes. It is obviously necessary that the composition of the present invention be soluble as well as stably dispersable in any such hydrocarbon fuel to which it is added.
The composition of the present invention firstly contains an amine and a polyamine also characterized as a polyaminated detergent. These ingredients can comprise preferably between 5 and 85%, and preferably at least 40%, by weight of the entire composition. Further, it is contemplated that the range of amine to polyaminated detergent be, on the one extreme, from 99 parts by weight amine to one part by weight polyaminated detergent to, on the other extreme, two parts by weight polyaminated detergent to one part by weight amine.
It is contemplated that the amine component comprise one or more members selected from the group consisting of aromatic amines; methyl-, trimethyl- and tetramethyl alkylated forms of ethylene diamines; primary alkyl fatty amines; alkylether propylamines; ether diamines; alkylpropylene diamines; methyl-, dimethyl-, trimethyl-, methoxy-, ethyl-, butyl-, propyl-, isobutyl-, fluoro-, chloro-, bromo-, iodo-, difluoro-, dichloro- and diiodo-phenylamines, and mixtures thereof.
It is proposed that the polyamine or polyaminated detergent comprise one or more members selected from the group consisting of polypropylene and polyisobutene succinic polyalkene amines; substituted benzylpolyamines; acylated polyalkene amine-polyolefins; hydrocarbon polyether-substituted succinamic acid compounds; reaction products of polyethers and maleic anhydride; the reaction products of polyethers and asparagine; primary aliphatic hydrocarbon aminoalkene substituted asparagines; ω-N-disubstituted amino alkanoic acid; N'-amides; alkyl and hydroxy-substituted benzylpolyamines and mixtures thereof.
Multicomponent polyaminated detergents for use in the present invention are available from the Lubrizol Corporation as multifunctional dispersant type additives for gasoline available under Lubrizol Component Nos. 8101, 8107, 8150 and 8157A, etc. Various amine-polyamine ashless polymeric dispersants are obtainable from Mobil Corporation, Chevron Chemicals and E. I. duPont deNemours & Co., among others.
The composition next can also include a phenylenediamine, or a phenol, alkyl-phenol phenylenediamine inhibited polymeric substrate. The phenylenediamine, or phenol, alkyl-phenol phenylenediamine acts as an antioxidant and metal deactivator while the polymeric substrate is employed to stabilize the composition against known destabilizing components such as excess maleic anhydride which may be present upon the copolymerization neutralization of the polyamine component. This component is to be incorporated within this composition in an amount between approximately 0 to 1.0% (by weight) and, preferably between approximately 100 ppm to 1000 ppm.
The polymeric substrate comprises one or more polymers prepared from monomers selected from the group consisting of styrene, α-methyl styrene and C 1-4 alkyl and alkoxy ring substituted styrenes. These include para-methyl styrene, para-sec butyl styrene and para-methoxy styrene.
It is preferred that the polymeric substrate be prepared by combining approximately 60% of a styrene monomer with approximately 15% of partially polymerized styrene monomer in the presence of ethyl benzene preferably pre-blended in either xylene or a coal tar distillate. The alkyl and phenol phenylenediamine components are readily available as anti-oxidants. Typical examples of suitable materials include N,N-di-secondary butyl P-phenylene diamine available from E. I. duPont deNemours & Co., Ethyl Corporation and Monsanto, among others.
The composition of the present invention is next to include a catalyst comprising a colloidal suspension or amine salt of transition/alkali/alkaline earth metal coordinations having at least one metal oxide-hydroxide linked to an alkyl chain via a carboxyl group. The hydrocarbon structure of the catalyst is selected in order to generate a high resistance coefficient to the nitrated components as well as to the active oxidizers found in the composition. It is suggested that sodium and potassium are the preferred alkali metals to be used herein although lithium, rubidium, cesium and francium can also be employed. The catalyst is to be included within the entire composition in an amount between approximately 250 ppm to 30% (by weight) or more, and preferably between approximately 500 ppm to 15% (by weight).
Transition metals which may be employed in the catalyst component are mainly those from the first two series of the Periodic Table including, but not limited to, titanium, chromium, manganese, nickel, copper and molybdenum. However, it is possible to also use elements derived from other groups in the periodic table, namely, zinc, boron and aluminum.
The applicable alkaline earth metals for use in the catalyst component include magnesium, calcium and barium, although it was found that elements of the carbon group such as tin and lead and minor amounts of sulfur could also be incorporated within the catalyst component.
It is preferred that the amine salt component of the catalyst comprise the reaction product of one or more of the above-recited alkaline metals or boron group elements with one or more members selected from the group consisting of methyl-, trimethyl- and tetramethyl ethylene diamines.
When the catalyst composition is a colloidal suspension, it is preferred that the colloidal suspension be derived from the reaction of a monocarboxylic acid having 1 to 30 carbon atoms with a member selected from the group consisting of transition metals, zinc, alkaline earth metals, tin, lead and sulfur. The preferred monocarboxylic acids include those containing 1 to 30 carbon atoms with the more preferred range being from 5 to 18 carbon atoms while the most preferred range, 5 to 9 carbon atoms. Saturated and unsaturated fatty acids can be employed as well as synthetic organic acids. Included within this group are monocarboxylic acids in the C 3 -C 4 , C 9 , C 18 , range as well as tall oil acid, versatic acid, 2-ethylhexoic, 3,5,5-trimethylhexoic acid and mixtures thereof.
The solvent component of the composition comprises a hydrocarbon or hydrocarbons containing oxygen such as alkanol-aliphatic ethers. It is to be employed within the composition in an amount between approximately 5.0 to 65.0% (by weight) and preferably between approximately 5.0 to 30% (by weight).
It is believed that the nature of, for example, the hydrocarbon used as a solvent is not critical. It may be paraffin, naphtene, an olefin, an aromatic or mixtures of all of these components. The solvent may be quite volatile which is the case when a material such as pentane is employed or may be a high boiling fraction of a lubricating oil. Mixtures of hydrocarbons such as gasoline fractions are often preferred or oxygenated blends using a catalyst as a peptizing agent.
As previously noted, the present composition is also intended to include a promoter which comprises a member selected from the group consisting of an organic oxide and optionally a co-promoter comprising an organic oxide azeotroped with one or more alkanes. When an azeotrope is formed, it is preferable that the organic oxide be azeotroped with carbon disulfide dispersed in a hydrocarbon stream wherein said hydrocarbon stream comprises one or more members selected from the group consisting of n-alkanes and cycloparaffins. The organic oxide is intended to include, but not be limited to, methyl-, ethyl-, butyl- and propyl- alkyl groups and mixtures of these alkyl groups including, but not limited to, methyl-ethyl, methyl-butyl, etc., either taken alone or combined with a polyether. Preferably, the promoter comprises an organic oxide having ethyl or propyl alkyl groups thereon. It is preferred that when an azeotrope is formed with carbon disulfide that it be dispersed in a hydrocarbon stream chiefly comprising an n-alkane and/or cycloparaffin having 2 to 9 carbon atoms and preferably 5 to 8 carbon atoms.
It is also optionally advantageous to employ an alternative promoter comprising an organic ester. Organic esters for use herein include, but are not limited to, butyl acetate and a member selected from the group consisting of methanol, ethanol and butanol. When used, the promoter, co-promoter and alternative promoter can be employed in the present invention in an amount between approximately 0.1 to 10.0% (by weight) and preferably between approximately 2.0 to 5.0% (by weight).
EXAMPLE 1
A mixed polyamine, namely, Lubrizol 8150, was dispersed into N-methyl-phenylamine at weight ratio of 1 part polyamine to 24 parts phenylamine.
Approximately 19 parts by weight of the polyamine-phenylamine mixture was combined with approximately 1 part by weight of the appropriate polymeric substrate. This substrate comprised approximately 60.0 percent (wt.) of styrene monomer, approximately 25.0 percent (wt.) ethylbenzene and approximately 15.0 percent (wt.) of partially polymerized styrene monomer dispersed in equal parts by weight of a solvent. The solvent comprised naphtha containing approximately 14.62 percent (wt.) xylene with an ortho to para weight ratio of approximately 3:1, the meta to para weight ratio being approximately 3.65:1. It was noted that the solvent boiled at approximately 160° IBP having an EP of approximately 180° C. Approximately 5.0 percent (wt.) of the polymeric substrate was comprised of a mixture of hindered phenols and the phenylene diamine component comprised approximately 70.0 percent (wt.) N,N-di-secondary butyl para-phenylene diamine in 30.0 percent (wt.) Lubrizol 817 which is a hindered phenol-type product.
EXAMPLE 2
Approximately 80.0 percent (wt.) of the composition of Example 1 was added to approximately 5.0 percent (wt.) of a catalyst. The catalyst component which was used is one which is commercially available from DG Chemie of Wuppertal, Germany, sold under its trade designation DG-247-C, which is a low aminated barium-sulphur, sodium alkanol naphtenic solute with low acid to neutral pH. To this was added approximately 15.0 percent (wt.) of a common alkanol, namely, methanol.
The catalyst was added to the composition as a "catalyst concentrate." The catalyst concentrate was prepared by mixing approximately 7.0 percent (wt.) of the component referred to previously as being available from DG Chemie of Wuppertal, Germany with approximately 28 percent (wt.) of a naphthenic straight mineral oil available from Exxon Co. and sold under the trade name Coray 15. To this was added approximately 35.0 percent (wt.) n-hexane, approximately 10.0 percent (wt.) n-butanol and approximately 20.0 percent (wt.) of a petroleum ether boiling at approximately 30° IBP and having an EP of approximately 60° C.
EXAMPLE 3
The same polyamine and phenylamine employed in Example 1 were now combined whereby approximately 60.0 percent (wt.) of the polyamine was added to approximately 40.0 percent (wt.) of the phenylamine. The same polymeric substrate of Example 1 was used employing the same hindered phenols and phenylamine diamine components. However, in this example, approximately 70.0 percent (wt.) of the hindered phenol component, namely, Lubrizol 817 was used with approximately 30.0 percent (wt.) of N,N-di-secondary butyl para-phenylene diamine.
EXAMPLE 4
The composition of Example 3 was combined, at a weight ratio of approximately 1:1 with a solvent comprising approximately 30 percent (wt.) of a mixed alkanol solution comprising isobutanol and isopropanol mixed at a ratio of approximately 2 parts isobutanol to one part isopropanol with approximately 60 percent (wt.) propylene oxide.
Approximately 10.0 percent (wt.) of the solvent comprised the "catalyst component" which was formulated from approximately 27.0 percent (wt.) DG-217-C solution combined as a ratio of one part of such solution to 2 parts by weight of a premium gasoline obtained from Texaco-Belgium (Antwerp). Approximately 70.0 percent (wt.) of the "catalyst component" comprised the combination of 15.0 percent (wt.) methanol and 85 percent (wt.) of 99+ percent 2-propanone forming an azeotropic combination and approximately 3.0 percent (wt.) of the combination of 1 part Lubrizol 8150 (polyamine) with 2 parts by weight isobutanol.
EXAMPLE 5
A mixed polyamine, namely Lubrizol 8150, was dispersed into N-methyl-phenylamine at a weight ratio of 1 part polyamine to 24 parts phenylamine. Four parts of this mixture was then added to 1 part by weight of the promoter/solvent methyl tertiarybutyl ether. To this solution was added the "catalyst component" comprising 15.0 percent (wt.) of DG Chemie's DG-218-C which itself includes 63.5 percent (wt.) of the catalyst DG-217-C and approximately 37.5 percent (wt.) of the naphthenic solvent Coray 15. The "catalyst component" also includes approximately 15 percent (wt.) of Lubrizol 8164, which is a detergent inhibited valve seat lubricant containing apart from its hydrocarbon elements, the elements sodium and sulfur, approximately 20.0 percent (wt.) n-heptane, approximately 40.0 percent (wt.) of petroleum ether boiling at approximately 30° IBP having an EP of approximately 60° C. with approximately 10.0 percent (wt.) n-butanol.
EXAMPLE 6
The composition of Example 5 was altered by substituting the previously employed promoter MTBE with a carbon disulfide azeotroped organic oxide. More specifically, the alternative promoter comprised approximately 5.0 percent (wt.) based upon the total weight of the composition of carbon disulfide azeotroped with ethyl oxide and the alkane, dry pentane. The MTBE promoter of Example 5 was replaced in equal weight amounts by the alternative promoter which contained one part of the carbon disulfide azeotroped ethyl oxide to 1.5 parts by weight of the dry pentane.
EXAMPLE 7
The composition of Example 5 was again prepared. However, now, the promoter which previously comprised MTBE was replaced with a co-promoter, namely, the organic ester, t-butyl acetate. The co-promoter was employed in an amount approximately 5.0 percent (wt.) calculated on a total weight basis of the composition.
EXAMPLE 8
The composition of Example 6 was duplicated whereby a co-promoter, an organic ester, was employed in addition to the promoter of Example 6. As in the previous example, the organic ester employed was t-butyl acetate. The amount of promoter and co-promoter remained constant with respect to the amount of catalyst employed. | A composition for the improvement of hydrocarbon fuel as exhibiting a boiling range of gasoline. The composition comprises an amine, a polyaminated detergent, a phenylamine diamine inhibited aromatic monomer stabilized by a polymeric substrate, a catalyst, a solvent, a promotor, alternative promoter and co-promoter. When used collectively, the recited composition has been found to significantly increase the octane of such hydrocarbon fuels while enhancing their anti-knock, anti-icing, anti-oxidency, anti-corrosion, detergency, and combustion properties and providing a lubrication quality to spark ignition-type engines used to burn the hydrocarbon fuels. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for improving the picture quality of television signals given activity-controlled DPCM coding, wherein an estimated value for the determination of the DPCM signal of a value is calculated from the surrounding video signal values of the current sample and from the video values of the preceding television field surrounding this sample, wherein an activity criterion is identified from the video signal values of the same television field surrounding the current sample and from the video signal values of the preceding television field surrounding the current sample by calculating the amplitude differences, and wherein the estimated value from the video signal values and of the preceding television field is employed given an activity criterion below the first threshold. The invention also relates to a circuit arrangement for realizing the method of the invention.
2. Description of the Prior Art
The picture quality achieved with known DPCM methods is not always satisfactory at low transmission rates of, for example, 34 Mbit/s given two-dimensional calculation of the estimated value. An improvement can be achieved given standing images by the addition of video signal values of the preceding television field (interfield DPCM).
The coding dependent on the activity, i.e. on the contrast between mutually-corresponding picture points of chronologically-successive television signals was investigated in a CCIR document 11/CMTT of the CCIR Study Groups, in the period 1978-1982, Study Program 25A/11 (Mod I), "Getrennte Codierung von Farbfernsehsignalen mit 34 Mbit/s".
This proposed method requires a substantial expense for computation.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a simply-realizable method for the improvement of picture quality given DPCM-coded television signals.
Proceeding from the initially mentioned art, the above object is achieved in that the estimated value from the video signal values of the current television field is employed given transgression of a second threshold by the amount of the activity criterion; in that, given an amount of the activity criterion between the two thresholds, the estimated value is calculated from the surrounding video signal values of the current television field and of the preceding television field; and in that the video signal values are multiplied by factors for the calculation of the activity criterion.
Given this method, a determination is first made as to whether successive television fields of a cutout under consideration differ from one another. When only small differences exist, then the determination of the estimated value, also referred to as a prediction value, occurs solely from the preceding television field. Given greater differences of intensity (amplitude differences) of neighboring video signal values of the current television field and of the preceding television field, the calculation of the estimated value occurs both from the preceding and the current television field. Given extremely high differences in intensity between successive television fields, the calculation of the estimated value occurs only from the current television field. The intensity differences are also referred to as activity.
It is thereby advantageous that a prediction value x o from the preceding television field and a second prediction value x 1 from the current television field are simultaneously calculated. Switching is undertaken between the two estimated values or a combination of both estimated values occur depending on the size of an activity criterion determined from successive television sub-fields.
The activity criterion can be determined by comparison of the spatially-adjacent video signal values, these corresponding to picture points, of the current television field and of the preceding television field, being determined by differential formation.
It is advantageous that the video signal values be multiplied by the factors 1/2 n for the calculation of the estimated value.
The calculation of the activity criterion becomes particularly simple when the respective signal value need only be divided by 2,4,8. This respectively means only the bitwise shift of the respective video signal value towards the right or, respectively, a corresponding type of connection.
It is advantageous that
AK=|(1/4B+1/2C+1/4D)-1/2(1/4H+1/2I+1/4J+1/4K+1/2L+1/4M)|
is employed as the activity criterion.
The calculation of the activity criterion supplies sufficiently accurate results for the evaluation of the intensity differences of successive television fields. The use of the most recently-identified video signal value A has been omitted since there is only a short computation time available. The incorporation of the most recently-identified video signal value is, possible, however, when all arithmetic operations in which the video signal values, beginning with B participate are executed first and the most-recently identified image signal value is separately considered.
Given a prescribed value set of video signal values, it is advantageous that the first threshold value lies at 1/8 and the second threshold value lies at 1/4 of the value set.
The thresholds of 32 and 64 are easy to determine digitally. Given the prescribed value set of 256, these thresholds supply favorable results for the control of the coding.
It is advantageous that a sum P=1/4B+1/2C+1/4D is respectively calculated from the current video signal values, that this sum is stored for nearly the duration of a field and is additionally stored by twice a television line, and the activity criterion and estimated value are calculated from the stored sums by multiplication of the factors 1/4 and 1/2.
A simple circuit structure is achieved as a result. Due to the delay, all required video signal values (A, B, C, D: E, F, G, H, . . . ) combined to form a sum are already present for the calculation of the activity criterion and of the estimated value.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the invention, its organization, construction and mode operation will be best understood from the following detailed description, taken in conjunction with the accompanying drawings, on which:
FIG. 1 is a schematic representation of a basic circuit diagram for the implementation of the method of the invention;
FIG. 2 is a representation of an excerpt or cut out from a television picture;
FIG. 3 is a graphic illustration of a characteristic for sliding coding;
FIG. 4 is a schematic representation of a circuit arrangement for practicing the invention; and
FIG. 5 is a schematic representation of a digital filter employed as an arithmetic circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a coding loop for three-dimensional coding, i.e. for a spatial and chronological coding. It comprises a subtractor 1 having an input 1 1 by way of which the digitized samples x are supplied to the coding loop. The output of the subtractor 1 is connected to the input of a quantizer 2 whose output 2 2 is connected to a first input 3 1 of a first adder 3. Its output 3 3 is connected to the input of a planar coder 4 and of an interfield coder 8. The output of the planar coder 4 is connected via a first multiplier 5 to a first input 6 1 of a second adder 6. The output of the interfield coder 8 is connected via a second multiplier to the second input 6 2 of the second adder 6. The output 6 3 of the second adder 6 is connected to a second input 3 2 of the first adder 3 and to a subtraction input 1 2 of the subtractor 1. The first multiplier 5 works with a fixed factor (1-λ). The second multiplier 7 multiplies the data output by the interfield coder 8 by the factor λ.
Up to this point, the coding loop exhibits no special characteristics. The samples x are compared to the calculated estimated value x and the differences of these two values Δx is supplied to the quantizer 2 which emits the quantized DPCM signal Δx q at its output.
The estimated value x of the prediction value
x.sub.1 =αA+βB+γD+δD
and the prediction value
x.sub.0 =eE+fF+gG+hH+iI+jJ+kK+lL+mM
calculated by the interfield coder.
FIG. 2 illustrates a cutout from a television picture. The picture points which correspond to individual signal values of the current television field have been illustrated by thick strokes and fat letters. The corresponding picture points of the preceding television field have been marked by thin strokes and lean letters. In order for the decoder to make the same prediction as the coder, this may not calculate with the original samples but with the video signal values A, B, C . . . from the so-called local output 3 3 of the first adder. The corresponding video signal values A, B, C, D and E through M are therefore entered in FIG. 2 instead of the preceding samples.
The coding loop according to FIG. 1 also comprises a coder control 9 which is operatively connected to the output 3 3 of the adder 3. The factors λ and 1-λ are determined via its outputs 9 2 and 9 3 . The activity criterion
AK=|1/4B+1/2C+1/4D)-1/2(1/4H+1/2I+1/4J+1/4K+1/2L+1/4M)|
is first identified in the coder control 9. For reasons of calculating speed, this occurs by way of a hardware circuit known per se. The multiplications by the factors 1/2, 1/4 and 1/8 are realized by corresponding connections. Of course, it is not necessary to again store the video signal values in the coder control since this is already required in the planar coder and in the interfield coder. The coder control also contains a threshold circuit having two thresholds S 1 and S 2 . When the identified activity criterion AK remains below the first threshold S 1 , then the factor λ=1 applies. This means nothing more than that the prediction value x 0 is employed as an estimated value x. When an activity criterion between the two thresholds occurs, then λ=1/2 is selected. This means that both prediction values x 0 and x 1 equally contribute to the estimated value x. When, however, the second threshold S 2 is transgressed by the activity criterion, then the factor λ=0 is selected and, therefore, only the prediction value x 1 output by the planar coder is utilized for the calculation of the DPCM signal.
An interesting modification enables the sliding transition between the two types of coding as a function of the activity criterion. A corresponding characteristic is illustrated in FIG. 3. λ=1 is illustrated before the first threshold; above the threshold, λ decreases steadily up to the second threshold S 2 in order to remain at 0 after the transgression of the second threshold. The characteristic according to FIG. 3 can be approximated by way of a stepped function. The computational or, respectively, circuit expense becomes lower as a result. This modification produces another, slight improvement in the picture quality.
FIG. 4 illustrates a realizable circuit arrangement for λ=0, 1/2 and 1. Corresponding to FIG. 1, this circuit arrangement again contains the subtractor 1, the quantizer 2 and the first adder 3. The output of the adder 3 is connected by way of a first register 10 to a further line register 11 by way of which the video signal values are delayed by nearly one television line. The output of the line register 11 is connected to a digital filter 12 whose output is connected to a field memory 13, to the coder control 9 and to a third multiplier 21. Two further line registers 14 and 15, by way of which the adjacent signals are likewise delayed by a television line, are connected in series to the output of the field memory 13. The output of the field memory 13 and the output of the second line register 14 are combined by way of a third adder 17 whose output is connected to the subtraction input 1 2 of the subtractor 1 via a second multiplier 20, a fourth adder 22 and a fifth adder 23. The output of the third multiplier 21 is connected to the second input of the fourth adder 22. A fourth multiplier 16 is connected between the output of the first register 10 and the second input of the fifth adder 23 whose output is also connected to the second input of the first adder 3. The output of the second line register 14 and the output of the third line register 15 are combined via a sixth adder 18 whose output is connected via a first multiplier 19 to a second input of the coder control 9. The control outputs of the coder control 9 act on the second multiplier 20, the third multiplier 21 and the fourth multiplier 16. As factors, 0, 1/4 and 1/2 may be set, respectively independently of one another. The fourth multiplier 16 is connected between the first register 10 and the second input of the adder 23. A product
P=1/4B+1/2C+1/4D
is calculated by the digital filter 12. This moment is illustrated in FIG. 5. Due to the delay according to FIG. 4,
Q=1/4E+1/2F+1/4G
then lies at the output of the field memory 13,
R=1/4H+1/2I+I/4J
lies at the output of the second line register 14, and
S=1/4K+1/2L+1/4M
lies at the output of the third line register 15. These products are therefore respectively derived from a line of FIG. 2. The activity criterion is first determined in the coder control 9. Dependent thereon, the three multipliers 20, 21 and 16 are controlled such that the desired estimated value is respectively calculated, depending on the size of the activity criterion. When the activity criterion lies below the first threshold S 1 , then the determination of the estimated value x=x 0 occurs exclusively from the video signal value E--J of the most-recent television field. The multiplication factor of the fourth multiplier 16 and of the third multiplier 21 therefore become equal to zero, whereas the second multiplier multiplies its input values by 1/2. The prediction value a 0 is thereby calculated as the estimated value.
When the first threshold S 1 is transgressed, then the multipliers 20, 21 and 16 multiply all input values by the factor 1/4; when the second threshold is also transgressed, then the estimated value is calculated only from the video signal values of the current television field; the second multiplier 20 then multiplies its input values by the factor 0.
The multiplication by the factor 1/2 only means a bit shift at the corresponding code word towards the right; a further shift by yet another bit occurs given the factor 1/4. The multipliers are therefore realizable by way of simple switchovers. Given the factor 0, the outputs of the multipliers are placed at zero or a switch over to a prescribed potential occurs. The factor 1/2 at the first multiplier 19 is already achieved by a corresponding bit-shifted connection at the adder 18; this multiplier is not required in the real structure of a circuit. The formation of the activity criterion AK likewise presents no difficulties. The value 1/2(R+S) is subtracted from the value P and, if necessary given a negative operational sign, the amount is formed (inverted).
The digital filter 12 illustrated in FIG. 5 comprises two further registers 24 and 25 connected in series which respectively effect a delay by one video signal value. The input 24 1 of the first further register 24 and the output of the second further register 25 are combined via a seventh adder 26 followed by a multiplier 27. The output of the multiplier 27 and the output of the first further register 24 are combined via an eighth adder 28 whose output is connected to a following multiplier 29 whose output, in turn, forms the output 24 2 of the digital filter. Both multipliers 27 and 29 multiplied by the factor 1/2. Given one realization, these multipliers are superfluous since the factor 1/2 can be achieved by the corresponding connection at the further adders 26 and 28 which is respectively offset by one bit.
When one considers a point in time which corresponds to the point in time illustrated in FIG. 4, then is precisely the video signal values B, C and D that are processed by the digital filter. As one can easily see from this circuit, the value
P=1/4B+1/2C+1/4D
occurs at the output.
The circuit expense remains low in that the same value P as already described with respect to FIG. 4 is further employed and is only evaluated with simple factors.
Although I have described my invention by reference to particular illustrative embodiments, many changes and modifications of the invention may become apparent to those skilled in the art without departing from the spirit and scope of the invention. I therefore intend to include within the patent warranted hereon all such changes and modifications as may reasonably and properly be included within the scope of my contribution to the art. | A method for improving picture quality given DPCM coded television signals provides for the determination of an activity criterion from the video values of the same television field which surround a current sample and the video signal values of the preceding television field by calculation of the intensity differences between the video signal values. The estimated value is determined from the video signal values of the most recent television field, from the video signal values of the most recent and current television fields, or only from the video signal values of the current television fields, as a function of two thresholds. | 7 |
RELATED APPLICATIONS
[0001] The present patent application is a continuation of co-pending U.S. patent application Ser. No. 11/901,196 filed Sep. 14, 2007, which is a continuation of U.S. patent application Ser. No. 11/483,128 filed Jul. 7, 2006, which is a continuation-in-part of U.S. application Ser. No. 11/032,699 filed on Jan. 10, 2005, which claims priority to U.S. Provisional Patent Application Ser. No. 60/583,782 filed Jun. 29, 2004, the entire contents of each of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] Residential and commercial construction projects require several organizations to communicate with one another in order to distribute payments. A conventional construction payment management process begins with a verbal notification that a draw from the construction loan or the property owner's account will take place. The general contractor (GC) of the construction project notifies subcontractors (or any other person, firm, or corporation engaged by the GC, such as material suppliers) of the draw by telephone, fax, or at a meeting. The subcontractors prepare invoices and send them to the GC by mail, fax, hand delivery, or at a meeting with the GC. The GC and the subcontractors often must negotiate the final invoice dollar amount by telephone or at meetings. The GC confirms the invoices, enters the details into a GC project accounting system, and prepares its own invoice.
[0003] Once the invoices are complete, the GC also manually prepares a sworn statement. In the sworn statement, the GC confirms that the subcontractors engaged by the GC have performed particular services in the construction or repair of the property. In the sworn statement, the GC also confirms the dollar amount entitled to each subcontractor.
[0004] The GC forwards the executed sworn statement to the title company and the construction loan lender and/or the property owner. The lender, the property owner, or the title company notifies an inspector that an inspection of the property must be performed and sends the sworn statement to the inspector. The inspector assembles the previous inspection reports for the property. The inspector performs the new inspection and manually prepares an inspection report. The inspector distributes the inspection report to the lender, the property owner, and/or the title company by fax, mail, or hand delivery.
[0005] The lender, the property owner, and/or the title company receives the sworn statement and the inspection report by mail, fax, hand delivery, or at a meeting with the GC and/or the inspector. The lender, the property owner, and/or the title company must retrieve the previous draw and project documentation. The lender, the property owner, and/or the title company often must negotiate the payment amounts and project details with the GC by telephone, fax, or at a meeting. The lender, the property owner, and/or the title company approves the sworn statement and communicates the approval by telephone, fax, or at a meeting. The lender or the property owner then approves the disbursement of the dollar amount specified in the sworn statement.
[0006] The construction loan lender or the property owner's bank generally transfers the funds necessary to pay all of the subcontractors to an escrow account. Often the title company then disburses the funds from the escrow account to the GC. The GC and/or the title company prepares checks for the subcontractors. At this time, the subcontractors generally complete lien waivers for the previous draw of funds from the construction loan or for the work completed during the previous month. As a result, the lien waivers for the current draw or the current month are not actually released until a subsequent draw is made from the construction loan or until the next month. In addition, subcontractors may have their own subcontractors that they must pay after receiving payment from the GC.
[0007] The conventional construction payment process can take 90 days or longer from the date of the verbal draw notification to the date the subcontractors actually receive payment. The conventional construction payment process generally involves unreliable verbal notification of events upon which movement of the process is contingent. For example, if one subcontractor is unavailable to prepare an invoice or submit a lien waiver, the payment process for all of the other subcontractors can be delayed.
[0008] The conventional construction payment process also involves enormous amounts of data entry. For example, for a single large construction project, a GC often must enter hundreds of invoices into its accounting system each month. Also, a GC must gather hundreds of lien waivers each month. In addition, a GC must prepare, approve, sign, and distribute hundreds of checks to subcontractors each month. Further, a GC must store all of the paper documents collected during each draw process. The timing of the draw notifications, the approvals, and the exchanges of lien waivers for payment requires hundreds of faxes, phone calls, and meetings each month.
SUMMARY OF THE INVENTION
[0009] Embodiments of the invention provide a system and method for managing a construction payment process. One method embodying the invention can include generating a budget for a construction project, receiving an invoice amount from at least one participant in the construction project, generating at least one of an automated invoice and an automated sworn statement based on the invoice amount and the budget, generating at least one automated lien waiver based on at least one of the automated invoice and the automated sworn statement, and electronically executing at least one of the automated invoice, the automated sworn statement, and the at least one automated lien waiver to create at least one of a legally-binding invoice, a legally-binding sworn statement, and a legally-binding lien waiver.
[0010] One construction payment management system embodying the invention can include an electronic signature service and an application server that stores a budget module and a draw module. The budget module generates a budget for a construction project. The draw module receives an invoice amount from a participant of the construction project, generates at least one of an automated invoice and an automated sworn statement based on the invoice amount and the budget, and generates at least one automated lien waiver based on at least one of the automated invoice and the automated sworn statement. The electronic signature service electronically executes at least one of the automated invoice, the automated sworn statement, and the at least one automated lien waiver to create at least one of a legally-binding invoice, legally-binding sworn statement, and legally-binding lien waiver.
[0011] Additional embodiments of the invention provide a method of managing a construction payment process. The method includes electronically receiving a lien waiver from a participant in a construction project, electronically transmitting payment to the participant in response to receipt of the lien waiver, and releasing the lien waiver in response to the payment.
[0012] Further embodiments provide a construction payment management system including an application server that stores an electronic holding bin and a draw module. The electronic holding bin receives a lien waiver from a participant in a construction project and the draw module transmits payment to the participant in response to receipt of the lien waiver and releases the lien waiver in response to the payment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a schematic illustration of a construction payment management system according to one embodiment of the invention.
[0014] FIG. 2 is a schematic illustration of construction payment management processes that can be performed using the system of FIG. 1 .
[0015] FIG. 3 is a schematic illustration of a manage project process.
[0016] FIG. 4 is a schematic illustration of a manage organization process.
[0017] FIG. 5 is a schematic illustration of a manage draw process.
[0018] FIG. 6 is a schematic illustration of a manage change order process.
[0019] FIG. 7 is a schematic illustration of manage system environment tasks.
[0020] FIG. 8 is a schematic illustration of a create organization process.
[0021] FIG. 9 is an illustration of a create organization form.
[0022] FIG. 10 is an illustration of an update user system notification.
[0023] FIG. 11 is an illustration of a system notification.
[0024] FIG. 12 is an illustration of an edit organization form.
[0025] FIG. 13 is an illustration of an activate organization notification.
[0026] FIG. 14 is an illustration of an activate organization form.
[0027] FIG. 15 is an illustration of an organization activated notification.
[0028] FIG. 16 is an illustration of an organization deactivation notification.
[0029] FIG. 17 is a schematic illustration of a maintain organization process.
[0030] FIG. 18 is an illustration of a view organization screen.
[0031] FIG. 19 is an illustration of a browse organization screen.
[0032] FIG. 20 is an illustration of an edit organization form.
[0033] FIG. 21 is an illustration of an organization profile updated notification.
[0034] FIG. 22 is a schematic illustration of a create user process.
[0035] FIG. 23 is an illustration of a create user form.
[0036] FIG. 24 is an illustration of an update user profile notification.
[0037] FIG. 25 is a schematic illustration of a maintain user process.
[0038] FIG. 26 is an illustration of a view user screen.
[0039] FIG. 27 is an illustration of a browse users screen.
[0040] FIG. 28 is an illustration of an edit user form.
[0041] FIG. 29 is an illustration of a user profile updated notification.
[0042] FIG. 30 is a schematic illustration of a create project process.
[0043] FIGS. 31 and 32 are illustrations of a create project form.
[0044] FIG. 33 is an illustration of a project created notification.
[0045] FIG. 34 is an illustration of a project user access screen.
[0046] FIG. 35 is an illustration of a project responsibilities notification.
[0047] FIG. 36 is a schematic illustration of a maintain budget process.
[0048] FIG. 37 is an illustration of an enter top level budget form.
[0049] FIG. 38 is an illustration of an enter draw dates form.
[0050] FIG. 39 is an illustration of an invoice code setup form.
[0051] FIG. 40 is an illustration of an assign invoice codes form.
[0052] FIG. 41 is an illustration of an accept project notification.
[0053] FIG. 42 is an illustration of an accept project form.
[0054] FIG. 43 is an illustration of a project declined notification.
[0055] FIG. 44 is an illustration of a project accepted notification.
[0056] FIG. 45 is an illustration of a project home page.
[0057] FIG. 46 is an illustration of an add users notification.
[0058] FIG. 47 is an illustration of a project user access form.
[0059] FIG. 48 is an illustration of a project responsibilities notification.
[0060] FIG. 49 is an illustration of a project budget view screen.
[0061] FIG. 50 is an illustration of an enter budget form.
[0062] FIG. 51 is a schematic illustration of a terminate budget item process.
[0063] FIG. 52 is an illustration of an enter top level budget form.
[0064] FIG. 53 is an illustration of a terminate budget screen.
[0065] FIG. 54 is a schematic illustration of a draw process.
[0066] FIG. 55 is an illustration of a create scheduled draw notification.
[0067] FIG. 56 is an illustration of an initiate draw form.
[0068] FIG. 57 is an illustration of an enter invoice notification.
[0069] FIG. 58 is an illustration of an enter invoice form.
[0070] FIG. 59 is an illustration of a sign invoice notification.
[0071] FIG. 60 is an illustration of a sign invoice form.
[0072] FIG. 61 is an illustration of an invoice details updated notification.
[0073] FIG. 62 is an illustration of a view pending draw request screen.
[0074] FIG. 63 is an illustration of an invoice details rejected notification.
[0075] FIG. 64 is an illustration of an invoice not included in the draw notification.
[0076] FIG. 65 is an illustration of an automatically-generated invoice form.
[0077] FIG. 66 is an illustration of a sworn statement form.
[0078] FIG. 67 is an illustration of a make funds available notification.
[0079] FIG. 68 is an illustration of a view draw request screen.
[0080] FIG. 69 is an illustration of a sign lien waiver notification.
[0081] FIG. 70 is an illustration of a lien waiver form.
[0082] FIG. 71 is an illustration of a lien waiver signed notification.
[0083] FIG. 72 is an illustration of a view draw request screen.
[0084] FIG. 73 is an illustration of an all lien waivers signed notification.
[0085] FIG. 74 is an illustration of a view draw request form.
[0086] FIG. 75 is an illustration of a payment disbursed notification.
[0087] FIG. 76 is a schematic illustration of maintain system screens tasks.
[0088] FIG. 77 is an illustration of a maintain phase codes form.
[0089] FIG. 78 is an illustration of an administration user login screen.
[0090] FIG. 79 is an illustration of an add/edit picklist form.
[0091] FIG. 80 is an illustration of an add/edit organization role form.
[0092] FIG. 81 is an illustration of a default/configure settings form.
[0093] FIG. 82 is an illustration of an edit notification form.
[0094] FIG. 83 is an illustration of a default/configure process form.
[0095] FIG. 84 is an illustration of an add/edit user role form.
[0096] FIG. 85 is a schematic illustration of perform inspections processes and related tasks.
[0097] FIG. 86 is an illustration of a prepare to conduct inspection notification.
[0098] FIG. 87 is an illustration of an inspection required notification.
[0099] FIG. 88 is an illustration of an inspection required screen.
[0100] FIG. 89 is an illustration of an enter inspection report notification.
[0101] FIG. 90 is an illustration of an enter inspection report form.
[0102] FIG. 91 is an illustration of an inspection report form screen.
[0103] FIG. 92 is an illustration of an inspection report failed notification.
[0104] FIG. 93 is an illustration of a view previous inspections screen.
[0105] FIG. 94 is a schematic illustration of an approve draw request process.
[0106] FIG. 95 is an illustration of an Authorize Draw Request One form.
[0107] FIG. 96 is an illustration of an Authorize Draw Request One declined notification.
[0108] FIG. 97 is an illustration of an inspection confirmed notification.
[0109] FIG. 98 is an illustration of a payment details modified notification.
[0110] FIG. 99 is an illustration of an inspection authorized notification.
[0111] FIG. 100 is an illustration of an Authorize Draw Request Two notification.
[0112] FIG. 101 is an illustration of an Authorize Draw Request Two form.
[0113] FIG. 102 is an illustration of an Authorize Draw Request Two declined notification.
[0114] FIG. 103 is an illustration of an Authorize Draw Request Two approved notification.
[0115] FIG. 104 is an illustration of an issue lien waiver notification.
[0116] FIG. 105 is a schematic illustration of a change request process.
[0117] FIG. 106 is an illustration of a change request form.
[0118] FIG. 107 is an illustration of a change request issued notification.
[0119] FIG. 108 is an illustration of an authorize change request notification.
[0120] FIG. 109 is a schematic illustration of a process change request process.
[0121] FIG. 110 is an illustration of a view pending change request screen.
[0122] FIG. 111 is an illustration of an authorize change request form.
[0123] FIG. 112 is an illustration of a change request declined notification.
[0124] FIG. 113 is an illustration of a change request approved notification.
[0125] FIG. 114 is a schematic illustration of a change project participant process.
[0126] FIG. 115 is an illustration of a change participant screen.
[0127] FIG. 116 is an illustration of a check participant delete screen.
[0128] FIG. 117 is an illustration of a change affidavit screen.
[0129] FIG. 118 is a schematic illustration of maintain project screen tasks.
[0130] FIG. 119 is an illustration of a project profile form.
[0131] FIG. 120 is an illustration of a project contact information screen.
[0132] FIG. 121 is an illustration of a project information screen.
[0133] FIG. 122 is an illustration of a close project screen.
[0134] FIG. 123 is a schematic illustration of manage access screen tasks.
[0135] FIG. 124 is an illustration of a log in screen.
[0136] FIG. 125 is an illustration of a log out screen.
[0137] FIG. 126 is an illustration of a project home page screen.
[0138] FIG. 127 is an illustration of a reset password screen.
[0139] FIG. 128 is an illustration of a main screen for a particular user.
[0140] FIG. 129 is an illustration of a browse projects screen.
[0141] FIG. 130 is an illustration of a forgot password screen.
[0142] FIG. 131 is an illustration of a your password notification.
[0143] FIG. 132 is a schematic illustration of a manage message screens process.
[0144] FIG. 133 is an illustration of a view messages screen.
[0145] FIG. 134 is an illustration of a specific message being viewed by a user.
[0146] FIG. 135 is an illustration of a create/send messages screen.
[0147] FIG. 136 is an illustration of a status message screen.
[0148] FIGS. 137-153 are flow charts illustrating a method of managing a construction payment process according to another embodiment of the invention.
[0149] FIGS. 154-179 are input/output diagrams illustrating a method of managing a construction payment process according to still another embodiment of the invention.
DETAILED DESCRIPTION
[0150] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limited. The use of “including,” “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “mounted,” “connected” and “coupled” are used broadly and encompass both direct and indirect mounting, connecting and coupling. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings, and can include electrical connections or couplings, whether direct or indirect. Also, electronic communications and notifications may be performed using any known means including direct connections, wireless connections, etc.
[0151] It should be noted that a plurality of hardware and software based devices, as well as a plurality of different structural components may be utilized to implement the invention. Furthermore, and as described in subsequent paragraphs, the specific configurations illustrated in the drawings are intended to exemplify embodiments of the invention and that other alternative configurations are possible.
[0152] FIG. 1 illustrates a construction payment management system (CPMS) 10 according to one embodiment of the invention. The CPMS 10 can include an application server 12 , a database server 14 , an application logic module 16 , a web server 18 , a network 20 (such as the Internet or other networks individually or in combination with the Internet), a verification service 22 , participating organizations or individuals 24 (hereinafter “participant” or “organization”), and a payment system 26 . The payment system 26 can include an automated clearing house (ACH) system, a wire transfer system, a debit card system, a credit card system, or any other suitable electronic funds transfer (EFT) system.
[0153] The application server 12 can store and provide access to a project module 28 , a form-handling module 30 , a permissions and authorizations engine 32 , a database management system 34 , a budget module 36 , an access manager 38 , a notifications manager 40 , an organization module 42 , a draw module 44 , a contracting module 46 , a change order module 48 , a user module 50 , a system environment manager 52 , and an electronic holding bin/escrow 54 . The draw module 44 can include a core module 56 , an inspection module 58 , and a draw approval module 60 . The system environment manager 52 can include a report generator 62 , a help module 64 , and a system maintenance module 66 . The electronic holding bin/escrow 54 can store one or more lien waivers 68 . It should be understood that the components of the application server 12 could be combined in a different manner than as shown and described with respect to FIG. 1 . The software used to code the various modules, managers, and engines of the application server 12 can be combined or separated in any suitable manner and can be stored and accessed in any suitable manner.
[0154] The application server 12 can be connected to the database server 14 , the application logic module 16 , and the verification service 22 . However, in some embodiments, the verification service 22 may only be connected to the network 20 . The application logic module 16 can be connected to the web server 18 or, in some embodiments, directly to the network 20 . The web server 18 can be connected to the network 20 .
[0155] The participants 24 can include a property owner 70 (and/or the owner's representative 72 ), a general contractor (GC) 74 , an inspector 76 , one or more subcontractors (Subcontractor A 78 , Subcontractor B 80 , etc.), one or more material suppliers 82 , one or more lenders 84 (and/or one or more loan officers 86 ), one or more title companies 86 , and one or more architects 88 . The participants 24 can also include one or more interior designers (and/or furniture manufacturers) and one or more real estate owners (i.e., the land owner who sells the construction site to the property owner 70 ). The participants 24 can include organizations and/or individuals that are either considered “above the line” (i.e., higher in the construction process than the GC) or “below the line” (i.e., employed by the GC). Participants 24 above the line can include lenders, architects, interior designers, property owners, property owners' representatives, title companies, and real estate owners. Participants 24 below the line can include subcontractors and material suppliers. The CPMS 10 can be used to facilitate the construction payment process between any of these types of participants 24 , whether above or below the line of the GC. The CPMS 10 is often described herein as being used to facilitate payment between a GC and subcontractors. However, it should be understood that the CPMS 10 can be used to facilitate payment between any type of participant, not only between a GC and subcontractors.
[0156] In addition to classifying participants as being above or below the line of the GC, costs associated with the construction process can be classified as “soft” costs or “hard” costs. Soft costs can include inspector fees, architect fees, interior design fees, title company fees, permit fees, utility bills for the property during the construction process, furniture costs, audio/visual equipment, computers, etc. Hard costs can include all the costs incurred by the organizations or individuals employed by the GC, including all costs for subcontractors and material suppliers employed by the GC. Each construction project can include an overall budget (from the owner's perspective) that includes all of the soft and hard costs. Each construction project can also include a GC budget. The CPMS 10 can be used to facilitate all the payments made within the overall budget and the GC budget. However, in some embodiments of the invention, the CPMS 10 can be used only to facilitate payment of the hard costs managed by the GC (i.e., only the GC budget). It should be understood by one of ordinary skill in the art that the CPMS 10 can be used to facilitate payment for only hard costs by the GC, only soft costs by participants above the line of the GC, or a combination of hard and soft costs by participants above and below the line of the GC. The CPMS 10 is often described herein with respect to hard costs, but can also be used for soft costs or a combination of hard and soft costs.
[0157] Each one of the participants 24 can be connected to the payment system 26 ; however, some of the participants 24 may not be connected to the payment system 26 in some embodiments of the invention. In some embodiments, the payment system 26 can include an ACH system with one or more originating depository financial institutions (ODFI) and one or more receiving depository financial institutions (RDFI).
[0158] The participants 24 can access the application server 12 in order to use the various modules, managers, and engines to perform construction payment management methods according to several embodiments of the invention.
[0159] In some embodiments, the CPMS 10 can connect all project participants to a substantially uniform, web-based, real-time system; can organize the budgeting for the construction project; can facilitate the electronic submission and approval of invoices; and can automate and streamline the payment and lien waiver release process through the use of electronic payments and production of the matching electronic lien waiver releases.
[0160] While there can be variations in details (for instance, in a publicly financed project, initiation and oversight of the project might be done by a surety bond issuer, rather than a bank), one embodiment of the CPMS 10 can be used as follows. A loan officer can sign on to the Internet and enter the CPMS web site. After a security clearance, the loan officer can enter the lender's portfolio and access a series of screens to create a new project by entering all of the project details. The project details can include details of the participants for each project, for example, the owner, architect, general contractor and title insurance company. Each participant can receive email notification of their involvement in the project and can verify their profile details. The GC can add subcontractors and material suppliers. The subcontractors and material suppliers can receive notification that they have been added to the project and can go through the security and verification process. The GC can select the number of draws and the draw dates for the project. The CPMS 10 can notify participants of a pending draw date in real-time. Each participant can complete their draw request form by entering their material and labor invoice details. The GC can review the draw requests and authorize them, and the CPMS 10 can generate the sworn statement. A series of project site inspections, approvals, completion of lien waivers, generation of statements, etc. can follow, all of which can be prompted by the CPMS 10 through email notifications in real-time. Once all forms have been completed and verified, the CPMS 10 can facilitate payments. The payments can be deposited directly into a participant's banking account via an electronic payment system. This process can be repeated for all draws. The project budget can be kept in balance through the completion of pay outs, collection of lien waivers, and approved inspections. Project progress can be tracked through the CPMS 10 via graphical progress indicators.
[0161] The CPMS 10 can include the following features: one-time registration of participating organizations into the CPMS 10 ; real-time notification of a draw; automated invoice generation; automated sworn statement generation; automated lien waiver generation; coordinated payment/lien waiver release; and direct distribution of funds to participating organizations.
[0162] The one-time registration of participating organizations into the CPMS 10 can lower the cost of participating in the service because a participant has to register only once. The one-time registration also lowers the number of potential errors because the entry of registration information only has to be done once. This makes it more likely that potential participants will in fact participate and, when participants do participate, that they will have a good (error free) outcome. The one-time registration helps ensure that a party wishing to be a participant in the process and the online community using the process, only needs to register once to be able to participate in any of the projects whose payments are executed through the CPMS 10 . The CPMS 10 can improve the efficiency of the registration of participating organizations into the construction payment process by creating a durable community that facilitates the process of participating on multiple projects over time by capturing organization and individual information once. The method allows organizations to be registered as a potential participant in any project that is being initiated by a member of the community of businesses using the CPMS 10 . In addition to its value in participating in multiple projects, the one-time registration is also valuable for participants to access information regarding multiple GC's, owners, lenders, subcontractors, etc. For example, the one-time registration gives owners, lender, and GC's the opportunity to learn about new subcontractors through the CPMS 10 . Also, an owner that has several projects pending each with different GC's can access information about each individual GC.
[0163] The real-time notification of the draw helps ensure that all participants in a draw are: 1) notified in a timely and uniform way; and 2) provided with a template to provide the information necessary to be paid. The CPMS 10 helps to eliminate the errors (not getting notified or mistaking which project the request is coming from) that delay the payment process. The CPMS 10 improves the efficiency of the real-time notification of the draw process by giving the GC the option of maintaining the schedule of draws on the CPMS 10 , by reducing the effort of notifying the participants in the draw, by automating the process of building the list of participants for a draw, by automatically notifying draw participants of the draw once it has been declared, and by providing readily accessible links so that subcontractors can access the CPMS 10 to submit the documentation that is required by the draw.
[0164] The CPMS 10 can be used by an owner, owner's representative, lender, GC, or title company to create and maintain a project budget. As noted above, the project budget can include soft costs above the line of the GC, hard costs below the line of the GC, or a combination of hard and soft costs. Some embodiments of the CPMS 10 can also be used to create and manage change orders in which the budget is modified (generally by expanding the budget) and the modified budget is approved by the appropriate participants. The budget can include a total cost for the construction project, along with line item costs for each phase or job that must performed to complete the construction project. The CPMS 10 can structure the budget to facilitate the payment of subcontractors, to allow efficient progress tracking, and to allow automated invoicing.
[0165] The CPMS 10 can create automated invoices that correspond precisely to the overall project budget and that also correspond precisely to the lien waivers and sworn statements. The CPMS 10 creates automated invoices that are a snap-shot in time of the activity that has already occurred against the overall project budget. The CPMS 10 can be used to create automated invoices that correspond precisely to the line items in the overall budget. This results in invoices and reports that are consistent with the way in which the construction project is broken down for financial purposes, tracking purposes, etc. Using the CPMS 10 , an invoice screen can be used to capture information necessary to create the invoice; however, not all of the information necessary to create the invoice must be re-entered, because the information can be gathered by referring to the overall project budget. This also guarantees that the invoices (and the G702/703 documents) will be consistent with the overall project budget and will be consistent between draws or between any other time periods (unless a participant such as the owner wants the invoices to change). The CPMS 10 can also be used to customize the automated invoices (or the G702/703 documents) according to the requirements of the lender, the owner, the owner's representative, the GC, etc.
[0166] The budget and the automated invoices can be used to uniformly collect and continually reference information that will be used throughout the construction payment management process. The information collected does not have to be re-entered again in the payment process helping to ensure that errors (either key-stroke or due to a misinterpretation of the data) are not introduced. In general, participants have visibility into the payment process conducted using the CPMS 10 . This helps to lower the effort necessary to determine the project status and to understand what work each participant must to do to facilitate the payment process. It also helps to highlight organizations or individuals who may habitually cause delays or errors in the process, making it easier to correct the behavior or eliminate the participant. Accurate invoicing minimizes invoice review and issue resolution effort, promotes complete and accurate sworn statements, minimizes discrepancies between sworn statements and inspections, and enables timely payment. The CPMS 10 can improve the efficiency of several activities later in the construction payment process by capturing complete and consistent invoice information in a timely manner.
[0167] The CPMS 10 can be used to generate automated sworn statements and automated lien waivers. Using the CPMS 10 , the GC knows who was notified of the draw and who has responded by providing an invoice. Once the invoices are approved by the GC (and any other participant above the line of the GC, such as the owner, the owner's representative, the lender, the title company, etc., that must approve the invoices), the CPMS 10 can use the approved invoices to automatically generate the sworn statement and the lien waivers, and other documents by other names that provide the same functionality (e.g., statutory declarations). The CPMS 10 can automatically generate the sworn statement and the lien waivers from the invoices submitted by subcontractors and material suppliers, helping to ensure that no typographical errors will be introduced and that the sworn statement and lien waivers will only include line items that have been submitted by the subcontractors and material suppliers. The CPMS 10 can help reduce the risk of inaccuracies in the sworn statement and the lien waivers by drawing on the invoice details already stored in the system to automatically create the content of the sworn statement and the lien waivers. This processing helps eliminate errors that are possible due to nonstandard, inconsistent, and untimely invoices and typographical errors that can occur during transcription. Overall, this lowers the risk profile of the construction payment process by increasing the accuracy and timeliness of critical construction project information. The CPMS 10 can create the automated lien waivers according to the legal standards of the state in which the construction site is located.
[0168] The CPMS 10 can generate sworn statements that correspond precisely to the invoices. Invoices are often broken down by the type of work being performed (e.g., electrical, plumbing, etc.), while sworn statements are often broken down by the participant performing the work (e.g., GC, subcontractors, and material suppliers). The CPMS 10 can be used to ensure that the sum of the invoice amounts equals the total amount on the sworn statement. Also, the CPMS 10 can also be used to ensure that the amounts on the lien waivers equal the amounts on the invoices, because the information for the automated lien waivers is gathered from the approved invoices that have been stored in the CPMS 10 . In addition, the lien waivers will be consistent with the sworn statement because the sworn statement was also generated by the CPMS 10 using the information from the approved invoices. This is particularly valuable when GC's and subcontractors (or owners, lender, and GC's) have disputed the invoice amount and have negotiated a final amount over a period of time. The final amount will be reflected in the automated and approved invoice that is stored in the CPMS 10 and used to generate the lien waivers and sworn statement. The CPMS 10 assures that only the approved invoice amount will be reflected in the lien waiver and sworn statement documents. By also using the stored budget as a framework for all automated documents, the CPMS 10 further assures that the invoices, lien waivers, and sworn statements will be precise and consistent. The CPMS 10 can also be used to customize the sworn statements and lien waivers based on the requirements of the lender, the owner, the owner's representative, the GC, etc.
[0169] The CPMS 10 also helps improve the efficiency of generating sworn statements and lien waivers by migrating storage of the invoice, sworn statement, and lien waiver documents to an electronic medium, reducing the time and effort necessary to store and access them. This improves the overall efficiency of the construction payment process by making these documents available to authorized parties needing them to carry out their responsibilities. The database of the CPMS 10 can store a library of electronically signed invoices, sworn statements, and lien waivers. If necessary, participants can use the CPMS 10 to generate hard copies of any of the electronically signed documents.
[0170] In one embodiment, the CPMS 10 can create the automated invoices, sworn statement, and lien waivers once all information has been entered and all issues have been resolved. In other embodiments, the CPMS 10 can create the automated invoices first, ensure the invoices are approved, create the automated sworn statement second, ensure the sworn statement is signed, and create the automated lien waivers third.
[0171] Once all of the information (invoices, inspection reports, banking information, etc.) has been entered and all issues have been resolved, the owner, the owner's representative, the lender, the title company, or the GC can pay the participants in the draw. The sub-contractors, material suppliers, or any other participants can provide their lien waivers in exchange for payment. The CPMS 10 can organize this process and can automatically execute the exchange without risk that either party will do their part without the other doing theirs. The CPMS 10 also helps eliminate the need for expensive and time consuming in-person meetings to affect the exchange of lien waivers for payment. The CPMS 10 (which rigorously tracks the documents) also helps to ensure that all of the lien waivers are collected. This reduces the risk that bad record keeping will result in lien waivers that have not been released at the conclusion of the construction project. The CPMS 10 can improve the efficiency of the payment/lien waiver release process by implementing the method in a network-enabled computer system. This allows all parties to securely prepare both payment and lien waiver release in a trusted environment. The CPMS 10 facilitates an efficient exchange of payment for lien waiver, because the CPMS 10 allows both the payment and lien waiver to be staged in preparation for an automated exchange thereby reducing the risk associated with the project. The GC can be assured that it will receive the appropriate lien waivers coincident with payment, and the subcontractors do not bear the risk associated with lengthy delays in payment.
[0172] The CPMS 10 can facilitate an exchange of lien waivers and payment instructions. In some embodiments, the CPMS 10 can release the lien waiver(s) substantially simultaneously with an acknowledgement from the payment system 26 that the participant(s) have received payment. The term “substantially simultaneously” as used herein and in the appended claims includes any time period less than the time necessary to request, process, and transfer funds with an automated clearing house (ACH) payment (which can take up to about 72 hours). For example, the “substantially simultaneously” release of lien waivers can include an immediate release of lien waivers, a release of a batch of lien waivers at the end of a business day, or a release of lien waivers after the typical time period that it takes to transfer funds via an ACH system. In one embodiment, the CPMS 10 can receive and store the lien waivers in the electronic holding bin/escrow 54 until all lien waivers from the participants in the draw have been received. Once all the lien waivers have been received, the CPMS 10 can send instructions for the payment system 26 to transfer funds to each participant in the draw. For example, once all the subcontractors electronically sign and submit their lien waivers to the CPMS 10 , the CPMS 10 can instruct the payment system 26 to pay each subcontractor. The CPMS 10 can release the lien waivers either when the payment instruction is transmitted to the payment system 26 or only after receiving an acknowledgement that the participants have actually received funds.
[0173] If the payment system 26 includes an ACH system, the payment instructions are generally processed in batches so that the participants will not receive the funds immediately. In an ACH system, the payment instruction can generally be returned by the RDFI during a 48 hour period. During this 48 hour period, the RDFI can notify the CPMS 10 and the ODFI that the funds cannot be transferred (e.g., due to insufficient funds, an invalid account number, etc.). After this 48 hour period, the CPMS 10 can assume that the RDFI has processed the payment instruction if the CPMS 10 has not been notified otherwise. The ODFI generally has a 24 hour front window to collect the payment instructions from the RDFI and to release payment to the accounts of the participants in the draw. As a result, it can take about 72 hours from the time the CPMS 10 transmits the payment instructions until the ODFI transfers funds into the accounts of the participants.
[0174] In some embodiments, the CPMS 10 can hold the lien waivers even after receiving an acknowledgement from the payment system 26 that the participant(s) have received payment. For example, the CPMS 10 can hold the lien waivers up to 31 days or until the next draw is initiated.
[0175] In some embodiments, the CPMS 10 can flag certain participants to remove those participants from the batch processing of the ACH system and can pay those participants separately by another method, such as by a direct wire transfer of funds or another immediate type of electronic funds transfer. In other embodiments, most participants can be paid by an immediate type of electronic funds transfer (such as a direct wire transfer), but some participants can be combined for one or more ACH batch transfers. In still other embodiments, the CPMS 10 can transmit each payment instruction to the payment system 26 as the CPMS 10 receives each lien waiver from each participant and funds can be transferred immediately to the participant from which the lien waiver was received. In general, the CPMS 10 can group the payment instructions in any suitable manner and can use any suitable type of payment method.
[0176] In each embodiment of the invention, the CPMS 10 can establish a connection between the current lien waiver and the current payment corresponding to the current draw, rather than exchanging the previous lien waiver for the current payment of the current draw. For example, the CPMS 10 can release the lien waiver for the current month for the current draw, rather than releasing the lien waiver for the previous month for the current draw. In this manner, the subcontractor is not exposed to liability if the CPMS 10 releases its lien waiver before payment is made, and the owner (or GC, title company, lender, etc.) is not exposed to liability if the CPMS 10 makes payment before the lien waivers are released.
[0177] Rather than paying the GC who pays its subcontractors who then pay their subcontractors, participants in the CPMS 10 can be paid directly using an electronic distribution of funds (e.g., any suitable type of EFT, ACH, or wire transfer of funds). This speeds up the payment process (lowering costs) and reduces the risk that parties (in the hierarchy) will not be paid. The direct distribution of funds is made possible by the CPMS 10 being used to collect all of the information that is necessary to make payments. The information collected using the CPMS 10 can be trusted, because of the rigor with which the methods can be implemented with software. As a result, the direct distribution of funds can be efficient (no reworking or reentry of information necessary) and error free. The CPMS 10 can improve the efficiency of the subcontractor/material supplier payment process by reducing the elapsed time necessary to complete the payment process. The CPMS 10 can reduce transaction costs by replacing a hierarchical payment process with direct payments, while improving fiscal and management control. The CPMS 10 can replace the use of checks by an electronic transfer of funds, reducing communications costs and improving visibility into the status of payments and reducing the risk of untimely or incomplete payment to all parties involved in the construction process (especially those lower on the supply chain).
[0178] FIGS. 2-7 illustrate an overview of the construction payment management processes that can be performed by the participants 24 using the various modules, managers, and engines stored in the application server 12 . FIG. 2 illustrates a manage project process 94 (which can be performed by the project module 28 and/or the budget module 36 ), a manage draw process 96 (which can be performed by the draw module 44 ), a manage change order process 98 (which can be performed by the manage change order module 48 ), a manage organization process 100 (which can be performed by the organization module 42 and/or the user module 50 ), and a manage system environment process 102 (which can be performed by the access manager 38 , the notifications manager 40 , and/or the system environment manager 52 ).
[0179] FIG. 3 illustrates the manage project process 94 , which can include a create project task 104 , a maintain project task 106 , and a create budget task 108 . FIG. 4 illustrates the manage organization process 100 , which can include a create organization task 112 , a maintain organization task 114 , a create user task 116 , and a maintain user task 118 . FIG. 5 illustrates the manage draw process 96 , which can include an initiate draw task 120 , a create draw request task 122 , a disburse funds task 124 , a perform inspection task 126 , and an approve draw request task 128 . FIG. 6 illustrates the manage change order process 98 , which can include a create change request task 130 , a process change request task 132 , and a change participant task 134 . FIG. 7 illustrates manage system environment tasks 102 , which can include a manage access task 136 , a manage messages task 138 , a create reports task 140 , a provide help task 142 , and a maintain system task 144 . The create reports task 140 can be performed by any participant above or below the line of the GC in order to create customized reports regarding the progress of the construction project, including the ability to monitor portions of the construction project, particular participants, the overall project, etc.
[0180] FIGS. 8-136 illustrate construction payment management methods according to several embodiments of the invention. FIG. 8 illustrates a create organization process 146 , which can be included in the manage organization process 100 . The create organization process 146 can be performed by any of the participants 24 using the organization module 42 . The create organization process 146 can include a create organization task 148 , an update organization profile task 150 , an edit organization task 152 , an activate organization notification task 154 , an activate organization task 156 , and either an organization declined task 158 or an organization activated task 160 . An update user profile task 162 can also be performed, as further described with respect to FIG. 22 .
[0181] FIG. 9 illustrates a create organization form that can be associated with the create organization task 148 . Each participant 24 can access the create organization form through the organization module 42 . The participant 24 can enter the requested information, such as business information, primary contact information, tax information, and banking information. In some embodiments, the first user of the participating organization 24 that enters his or her information as the primary contact information can be deemed an administrator for that participant 24 and can be given more access to the information for the participant than subsequent users. The CPMS 10 can use comprehensive role-based security so that project participants only see information tailored to their specific needs in the project. Once an organization is registered in the CPMS 10 , the organization can receive payments for any projects managed by the CPMS 10 .
[0182] FIG. 10 illustrates a notification that can be transmitted during the update user profile task 162 . The terms “system notification,” “notification,” or “system message” as used herein and in the appended claims refer to any form of communication with a participant 24 , such as an email message, a screen notice, a text message, a voice message, etc. The system notification of FIG. 10 can include a username and a temporary password for the first user of the participant 24 .
[0183] FIG. 11 illustrates a notification that can be transmitted during the update organization profile task 150 . The notification of FIG. 11 can be sent to the administrator for the participant 24 . The notification can include a statement requesting the recipient to update the organization profile, add users before participating in a project, and provide bank details.
[0184] FIG. 12 illustrates an edit organization form that can be associated with the edit organization task 152 . Each participant 24 can access the edit organization form through the organization module 42 . The participant 24 can modify the existing information, such as business information, primary contact information, tax information, and banking information. In some embodiments, the first user of the participating organization 24 that entered his or her information as the primary contact information is the only user given access to the edit organization form.
[0185] FIG. 13 illustrates an activate organization notification that can be transmitted during the activate organization notification task 156 . The notification of FIG. 13 can include a statement that the details of the organization have been updated and a request that the organization be validated and activated.
[0186] FIG. 14 illustrates an activate organization form that can be associated with the activate organization task 156 . The form of FIG. 14 can include a listing of participants 24 (e.g., including the organization name, its role in the construction process, the ability to select participants 24 , and the ability to view information for the participants 24 ). The form of FIG. 14 can also include a “Find” feature, the ability to specify the type of participant 24 , and the ability to decline/deactivate selected organizations and to provide a reason for the decline/deactivation.
[0187] FIG. 15 illustrates an organization activated notification that can be transmitted during the organization activated task 160 . Similarly, FIG. 16 illustrates an organization declined notification that can be transmitted during the organization declined task 158 .
[0188] FIG. 17 illustrates a maintain organization process 162 , which can be included in the manage organization process 100 . The maintain organization process 162 can be used by the organizations themselves or by other participants to maintain the accuracy of the contact information, bank account information, or any other type of information necessary for the construction payment process. The maintain organization process 162 can be performed by any of the participants using the organization module 42 . The maintain organization process 162 can include a browse organization task 164 , an edit organization task 166 , an organization updated task 168 , and a view organization task 170 .
[0189] FIG. 18 illustrates a view organization screen that can be associated with the view organization task 170 . The view organization screen can include business information and primary contact information for an organization.
[0190] FIG. 19 illustrates a browse organization screen that can be associated with the browse organization task 164 . The browse organization screen can include a list of participants, including the organization name, the organization role in the construction process, the primary contact, and the phone number. The browse organization screen can include a “Find” feature and links for viewing additional information about each participant. In one embodiment, the browse organization screen can be used by a GC to view its preferred subcontractors or material suppliers.
[0191] FIG. 20 illustrates an edit organization form that can be associated with the edit organization task 166 . The participant can edit the existing information, such as business information, primary contact information, tax information, and banking information. In some embodiments, the first user of the organization that entered his or her information as the primary contact information is the only user given access to the edit organization form.
[0192] FIG. 21 illustrates an organization profile updated notification that can be transmitted during the organization updated task 168 . The notification of FIG. 21 can include information regarding the updated profile for the participant along with a name of the primary user or administrator for the participant.
[0193] FIG. 22 illustrates a create user process 172 , which can be included in the manage organization process 100 . The create user process 172 can be used each time a new user at an existing organization is created in order to give the new user the appropriate access to the CPMS 10 (e.g., the appropriate security levels with a user identification and password). The create user process 172 can also be used to update user profiles. The create user process 172 can be performed by any of the participants 24 using the organization module 42 . The create user process 172 can include a create user task 174 and an update user profile task 176 .
[0194] FIG. 23 illustrates a create user form that can be associated with the create user task 174 . In some embodiments, the create user form can be used to add users after the primary user or administrator has already been created for the participant. The new user can enter personal information, security information (e.g., user name and password), email notification preferences, and security clearance levels (e.g., whether the user can manage projects and/or sign documents).
[0195] FIG. 24 illustrates an update user profile notification that can be transmitted during the update user profile task 176 . The notification of FIG. 24 can include a statement that the user has been added as a member of the organization, along with the user's security information (e.g., user name and a temporary password).
[0196] FIG. 25 illustrates a maintain user process 178 , which can be included in the manage organization process 100 and can continue from FIG. 22 . The maintain user process 178 can be used to browse the users in each organization and to view, edit, and update the users in each organization. The maintain user process 178 can be performed by any of the participants using the organization module 42 . The maintain user process 178 can include a browse users task 180 , and edit user task 182 , a user profile updated task 184 , and a view user task 186 .
[0197] FIG. 26 illustrates a view user screen that can be associated with the view user task 186 . The view user screen of FIG. 26 can include the user's personal information, email notification preference, and security clearance level.
[0198] FIG. 27 illustrates a browse users screen that can be associated with the browse users task 180 . The browse users screen of FIG. 27 can include a list of one or more users for each participant, and can include the users' names, email addresses, and phone numbers. The browse users screen can also include links to edit the information for each user.
[0199] FIG. 28 illustrates an edit user form that can be associated with the edit user task 182 . A user can provide personal information, email notification preferences, and security clearance levels.
[0200] FIG. 29 illustrates a user profile updated notification that can be transmitted during the user profile updated task 184 .
[0201] FIG. 30 illustrates a create project process 188 , which can be included in the manage project process 94 . The create project process 188 can be performed by a GC, a lender, an owner, or an owner's representative using the project module 28 to initiate a new project in the CPMS 10 . The create project process 188 can include a create project task 190 , a project creation task 192 , a project user access task 194 , and a project responsibilities task 196 .
[0202] FIGS. 31 and 32 illustrate a create project form that can be associated with the create project task 190 . A GC, a lender, an owner, or an owner's representative can provide project identification information, project funding information, project owner information, project architect information, and site information.
[0203] FIG. 33 illustrates a project created notification that can be transmitted during the project creation task 192 . The notification of FIG. 33 can include a statement that the GC, lender, owner, or owner's representative has created a new project, along with a link to a screen that allows users from the participants to be assigned to the project.
[0204] FIG. 34 illustrates a project user access screen that can be associated with the project user access task 194 . The project user access screen can include the project name, the project number, the GC name, and a list of users for a particular project and/or a particular organization. The users can be identified by name and username, and can be deemed a project manager or a signer.
[0205] FIG. 35 illustrates a project responsibilities notification that can be transmitted during the project responsibilities task 196 . The notification of FIG. 35 can include a statement that a user's responsibilities with respect to a project have been modified.
[0206] FIG. 36 illustrates a maintain budget process 198 , which can be included in the manage project process 94 . The maintain budget process 198 can be used to create and view a top level budget for the construction project, to assign line items to participants, and to assign responsibilities to participants. Using the budget module 36 , the maintain budget process 198 can be performed by a GC for subcontractors or by a subcontractor for a second-level subcontractor or a material supplier. The maintain budget process 198 can include an enter top level budget task 200 , an accept project task 202 , an accept project form task 204 , a project declined task 206 , an add users task 208 , a project accepted task 210 , a project home page task 211 , a project user access task 212 , a project responsibilities task 214 , and a project budget view task 216 . If the project is declined, the maintain budget process 198 can include an enter budget task 218 and can return to the accept project task 202 . After the enter top level budget task 200 , the maintain budget process 198 can include an invoice code setup task 220 , an enter draw dates task 222 , and an assign invoice code task 224 .
[0207] FIG. 37 illustrates an enter top level budget form that can be associated with the enter top level budget task 200 . The enter top level budget form can include the project name, the project number, and the contract value. A GC or a subcontractor can provide a retention percentage value, phase codes, phase code descriptions, organization names, budget amounts, and account codes. A GC or subcontractor can specify whether the organization is only providing materials. The enter top level budget form can also include links to setup draw dates and setup invoice code screens/forms. The phase codes and phase code descriptions can be used to define the contracting requirements of each particular job that must be completed in order to complete the project. The phase codes and phase descriptions can be provided, for example, by the American Institute of Architects (AIA), by the Construction Specifications Institute (CSI), or by customizing the AIA or CSI phase codes and phase descriptions. In some embodiments, the phase codes and phase descriptions can be completely customized by the participants. The top level budget can also be referred to as the schedule of values, the committed costs (after the GC has received bids from subcontractors), or the project estimate. In some embodiments, the phase codes included in the top level budget provide the basis for the draw requests, in that each draw request includes specific line items associated with specific phase codes. In some embodiments, the GC can use an external software program to generate a budget and the budget module 36 can interface with the external software program to import the budget into the application server 12 or the database server 14 .
[0208] FIG. 38 illustrates an enter draw dates form that can be associated with the enter draw dates task 222 . A GC or subcontractor can enter the day of the month on which draws are to take place, along with the specific dates for the draws (e.g., each month on a particular day). The enter draw dates form can also include a Calculate Draw Dates button for automatic calculation of the draw dates and/or an Add Draw Date button for manual entering of the draw dates.
[0209] FIG. 39 illustrates an invoice code setup form that can be associated with the invoice code setup task 220 . A GC or subcontractor can select an invoice code (e.g., codes by building—Building 1, 2, or 3), enter a new invoice code, create an invoice code, enter a preference for the display of budget lines (e.g., by phase code), and enter a preference for printing options. The invoice code setup form can facilitate the automated generation of invoices and sworn statements by the CPMS 10 . The invoice codes can be used for customized reports or for interfacing with other types of existing software. The invoice codes can allow participants to sort budget line items based on the requirements of the architect, the owner, etc. The CPMS 10 can also use account codes in the budget to interface with existing accounting systems. The account codes can be used to maintain the budget, to record results of the draw, and to facilitate invoicing and payment.
[0210] FIG. 40 illustrates an assign invoice codes form that can be associated with the assign invoice code task 224 . A GC or subcontractor can provide the invoice code (e.g., Building 1 , 2 , or 3 ) and can use links to access sub-budgets for each phase code. The assign invoice codes form can include the project name, the project address, the phase codes, the phase code descriptions, the organization to which the job is contracted to, and the budget amount. The assign invoice codes form can also facilitate the automated generation of invoices and sworn statements by the CPMS 10 .
[0211] FIG. 41 illustrates an accept project notification that can be associated with the accept project task 202 . The notification of FIG. 41 can include a statement that the subcontractor or material supplier has been added as a participant on a project, a project description, and the subcontractor's or material supplier's participation details. The subcontractor or material supplier can use a link to access an accept project form as shown in FIG. 42 to accept or decline the project.
[0212] FIG. 42 illustrates an accept project form that can be associated with the accept project form task 204 . The accept project form can include the GC project number, the system project number, the GC name, the project name, the project address, and a budget line item. The accept project form can provide the subcontractor or the material supplier with project information and a budget line item. The subcontractor or the material supplier can use the Accept or Decline buttons to accept or decline the project associated with the budget line item. The subcontractor or the material supplier can also provide a reason for declining the project. The line items from the accept project forms can also be used to facilitate automated generation of invoices and sworn statements by the CPMS 10 .
[0213] FIG. 43 illustrates a project declined notification that can be transmitted during the project declined task 206 . The notification of FIG. 43 can include the name of the subcontractor or material supplier that has declined the project, the budget item declined, and the reason for the decline. The notification of FIG. 43 can provide the ability to assign the organizational role to another participant.
[0214] FIG. 44 illustrates a project accepted notification that can be transmitted during the project accepted task 210 . The notification of FIG. 44 can include the name of the subcontractor or material supplier that has accepted the project and the budget item accepted. The notification of FIG. 43 can provide the ability to access the project details.
[0215] FIG. 45 illustrates a project home page that can be associated with the project home page task 211 . The project home page can include the project name, completed draws information, and pending draws information. The project home page can include a project overview with a project schedule progress bar, a funds disbursed progress bar, and a percent complete progress bar. The project home page can include one or more links to particular actions that can be performed with respect to the project (e.g., project profile, project budget, view project participants, setup invoice codes, manage project users, initiate unscheduled draws, etc.).
[0216] FIG. 46 illustrates an add users notification that can be transmitted during the add users task 208 . The notification of FIG. 46 can include a statement confirming that the subcontractor or material supplier has joined the project. The notification of FIG. 46 can include a request for the subcontractor or material supplier to add users (e.g., members of the organization) to the system.
[0217] FIG. 47 illustrates a project user access form that can be associated with the project user access task 212 . The subcontractor or material supplier can select each user's security clearance (e.g., a project manager or a signer). The project user access form can include the project name, the GC name, and a list of users at the subcontractor or material supplier organization.
[0218] FIG. 48 illustrates a project responsibilities notification that can be associated with the project responsibilities task 214 . The notification of FIG. 48 can include a statement that the user's responsibilities have been modified, along with the new security clearances. The notification of FIG. 48 can include a link to access the project budget.
[0219] FIG. 49 illustrates a project budget view screen that can be associated with the project budget view task 216 . A GC or subcontractor can access the project budget view screen through the budget module 36 . The project budget view screen can include the project name, the GC name, the project address, and a list of the budget items. The list of budget items can include the phase codes, the phase code descriptions, the subcontractor or material supplier to which the budget item is contracted, the budget amount, the payments, the retention, the balance, and a link to any sub-budgets.
[0220] FIG. 50 illustrates an enter budget form that can be associated with the enter budget task 218 . A GC or subcontractor can access the enter budget form through the budget module 36 . The GC or subcontractor can enter the requested information, such as the phase codes, the phase code descriptions, and the budget amount. The GC or subcontractor can change the organization associated with a particular budget line item. The GC or subcontractor can select whether the organization is providing materials only.
[0221] FIG. 51 illustrates a terminate budget item process 226 , which can be included in the manage project process 94 . The terminate budget item process 226 can be performed by a GC or subcontractor. The terminate budget item process 226 can include an enter top level budget task 228 and a terminate budget task 230 .
[0222] FIG. 52 illustrates an enter top level budget form that can be associated with the enter top level budget task 228 . A GC or subcontractor can access the enter top level budget form through the budget module 36 . The enter top level budget form can include the project name, the project number, the contract value, and a list of organizations. The GC or subcontractor can enter the requested information, such as a retention percentage, phase codes, phase code descriptions, an account code, and whether the organization is only supplying materials. The GC or subcontractor can also choose to add new line items or to terminate a particular line item. The enter top level budget form can include links to a setup draw dates form and/or a setup invoice codes form.
[0223] FIG. 53 illustrates a terminate budget screen that can be associated with the terminate budget task 226 . After a GC or subcontractor selects a line item to terminate, the terminate budget screen provides a confirmation and a statement that any un-paid balance can be made available for re-assignment.
[0224] FIG. 54 illustrates a draw process 232 , which can be included in the manage draw process 96 . The draw process 232 can be used to create a schedule for the project's draws; to initiate each draw; to enter and sign invoices; to view pending draws; to generate invoices, sworn statements, and lien waivers; to determine if funds are available; and to disburse funds. The draw process 232 can be performed by several of the participants using the draw module 44 . The draw process 232 can include a create draw schedule task 234 , an initiate draw task 236 , an enter invoice task 238 , an enter invoice form task 240 , a sign invoice task 242 , an invoice details updated task 244 , a view pending draw requests task 246 , a generate invoice task 248 , a sworn statement form task 250 , a funds available task 252 , a view draw request task 254 , a sign lien waiver task 256 , a lien waiver form task 258 , an all lien waivers signed task 260 , a view draw request with disburse funds button task 262 , a payments disbursed task 264 , a lien waiver signed task 266 , and a view draw request task 268 . The draw process 232 can also include a payments details accepted task 270 , an invoice not included in draw task 272 , and a payment details not accepted task 274 . The draw process 232 can be performed so that the lien waivers will be released for the current draw, not for the previous draw.
[0225] FIG. 55 illustrates a create scheduled draw notification that can be transmitted during the create draw schedule task 234 . The notification of FIG. 55 can be transmitted in real-time to all draw participants and can include a statement that a scheduled draw is pending and that participants for the draw have not yet been selected.
[0226] FIG. 56 illustrates an initiate draw form that can be associated with the initiate draw task 236 . A GC can access the initiate draw form through the draw module 44 . The initiate draw form can include the project name, the project number, the project address, the draw number, the draw date, and a list of the potential participants for the draw. The list of potential participants can include the phase codes, the phase code descriptions, the organization name, the budget amount, the payment amount, the holdback accrued, and the remaining balance. The GC can select each of the participants for the draw.
[0227] FIG. 57 illustrates an enter invoice notification that can be transmitted during the enter invoice task 238 . The notification of FIG. 57 can include a statement that a draw has been scheduled for a project and that the subcontractor or material supplier can enter the details of the payments due. The notification can also include the organization role and the particular budget item for the subcontractor or material supplier. The notification can be transmitted in real-time to all draw participants.
[0228] FIG. 58 illustrates an enter invoice form that can be associated with the enter invoice form task 240 . The subcontractor or material supplier can use the enter invoice form to provide the invoice amount for the draw. The enter invoice form can also include the project name, the project number, the project address, the draw number, the draw date, and the particular line item for that subcontractor or material supplier.
[0229] FIG. 59 illustrates a sign invoice notification that can be transmitted to the GC during the sign invoice task 242 . The notification of FIG. 59 can include a statement that the subcontractor or material supplier has approved the invoice for a particular draw and that a sworn statement must be signed. The CPMS 10 can be used to assign security/authority roles to each user, such as management, accounting, or authorized to sign. The CPMS 10 can notify a user with the authority to sign the sworn statement so that an officer of the organization signs the sworn statement, if necessary. The CPMS 10 can be used to change the security/authority roles that are necessary to sign a sworn statement (e.g., a lender can require that an officer signs the sworn statement, rather than an administrator for the organization).
[0230] FIG. 60 illustrates a sign invoice form that can be associated with the sign invoice task 242 . The GC can access the sign invoice form through the draw module 44 . The GC can review the details of the invoice, such as the particular organization, the request amount, the budget amount, the payment amount, the holdback accrued, and the remaining balance. The GC can then choose to sign the invoice statement. The sign invoice form can include a link to an automated sworn statement form.
[0231] FIG. 61 illustrates an invoice details updated notification that can be transmitted to the GC during the invoice details updated task 244 . The notification of FIG. 61 can include a statement that a subcontractor or material supplier has updated the payment details for a draw on a particular date for a particular project. The notification can provide a link in order to view the invoice details.
[0232] FIG. 62 illustrates a view pending draw request screen that can be associated with the view pending draw request task 246 . A GC can access the view pending draw request screen through the draw module 44 . The GC can select each participant to include in the draw, confirm the draw, and send a notification in real-time to the signer of each organization. However, the GC can also reject the pending draw request, notify selected participants to re-enter an invoice, and provide a reason for rejecting the draw request. The view pending draw request screen can include the project name, the project number, the project address, the draw number, the draw date, a list of participants who have submitted invoices, and a list of participants who have not submitted invoices. The participants can be organized by phase codes. For each phase code, the view pending draw requests screen can include the requested amount, the budget amount, the payment amount, the holdback accrued, and the remaining balance.
[0233] FIG. 63 illustrates an invoice details rejected notification that can be transmitted during the payment details not accepted task 274 . The notification of FIG. 63 can include a statement that the payment and invoice details entered by a particular user for a draw to be conducted on a date for a particular project have not been accepted and the reasons for the rejection. The notification can include a request for the subcontractor or the material supplier to re-enter the payment details before the draw closes.
[0234] FIG. 64 illustrates an invoice not included in the draw notification that can be transmitted during the invoice not included in draw task 272 . The notification of FIG. 64 can include a statement that the participant did not submit an approved sworn statement for a draw for a project and that the participant and all of their subcontractors will not be included in the draw. The notification can state that all sworn statements and invoices that were submitted have been destroyed.
[0235] FIG. 65 illustrates an automatically-generated invoice form (e.g., a form that is consistent with industry practices, such as a G702/703 form) that can be associated with the generate invoice task 248 (labeled G702/703 in FIG. 54 ). A GC, subcontractors, and material suppliers can access the invoice forms through the draw module 44 . The subcontractors, material suppliers, and/or architect can sign the invoice form electronically (e.g., using an electronic signature software provider, such as AlphaTrust Corporation).
[0236] FIG. 66 illustrates an automatically-generated sworn statement form that can be associated with the sworn statement form task 250 . A GC can access the sworn statement form through the draw module 44 . The GC can sign the sworn statement form electronically (e.g., using an electronic signature software provider, such as AlphaTrust Corporation).
[0237] FIG. 67 illustrates a make funds available notification that can be transmitted during the funds available task 252 . The notification of FIG. 67 can include instructions to follow a link to request lien waivers and release funds when funds are available to be released for a draw on a project.
[0238] FIG. 68 illustrates a view draw request screen that can be associated with the view draw request task 254 . A GC can access the view draw request screen through the draw module 44 . The GC can review the details of the draw, authorize funds, and request lien waivers. The view draw request screen can include the project name, the project number, the project address, the draw number, the draw date, and a list of participants in the draw. The list of participants can include the participant name, phase code, whether a lien waiver has been received, the requested amount, the budget amount, the payment amount, the holdback accrued, and the remaining balance. The list of participants can also include any subcontractor and their lien waivers.
[0239] FIG. 69 illustrates a sign lien waiver notification that can be transmitted during the sign lien waiver task 256 . The notification of FIG. 69 can be transmitted in real-time to all draw participants and can include a statement that the draw scheduled for a project has been authorized and that the subcontractor or material supplier is requested to sign its lien waiver to receive payments for the draw.
[0240] FIG. 70 illustrates an automatically-generated lien waiver form that can be associated with the lien waiver form task 258 . Subcontractors and material suppliers can access the lien waiver form through the draw module 44 . The lien waiver form can be automatically generated based on the budget, including the line items for each subcontractor or material supplier. The subcontractors and material suppliers can sign the lien waiver forms electronically (e.g., using the AlphaTrust Corporation electronic signature products). Once signed, the lien waivers 68 can be stored in the electronic holding bin/escrow 54 .
[0241] FIG. 71 illustrates a lien waiver signed notification that can be transmitted during the lien waiver signed task 266 . The notification of FIG. 71 can include a statement that a subcontractor or material supplier has signed their lien waiver for a draw for a project. The notification can include access to details of the draw and the lien waivers received so far.
[0242] FIG. 72 illustrates a view draw request screen that can be associated with the view draw request task 268 . A GC, subcontractor, or material supplier can access the view draw request screen through the draw module 44 . The view draw request screen can include the project name, the project number, the project address, the draw number, the draw date, and a list of participants in the draw. The list of participants can include the participant name, phase code, whether a lien waiver has been received, the requested amount, the budget amount, the payment amount, the holdback accrued, and the remaining balance. The list of participants can also include any subcontractor and their lien waivers.
[0243] FIG. 73 illustrates an all lien waivers signed notification that can be transmitted during the all lien waivers signed 260 . The notification of FIG. 73 can include a statement that all the lien waivers for the draw for a project have been signed. The notification can include a link to view the details of the draw and to disburse funds.
[0244] FIG. 74 illustrates a view draw request form that can be associated with the view draw request with disburse funds button task 262 . A GC (or architect, owner, owner's representative, lender, or title company) can access the view draw request form and approve the draw through the draw module 44 and/or the draw approval module 60 . The view draw request screen can include the project name, the project number, the project address, the draw number, the draw date, and a list of participants in the draw. The list of participants can include the participant name, phase code, whether a lien waiver has been received, the requested amount, the budget amount, the payment amount, the holdback accrued, and the remaining balance. The list of participants can also include any subcontractor and their lien waivers. When the GC disburses the funds, the lien waivers are substantially simultaneously released and the payment instruction is sent to the ACH system 26 .
[0245] FIG. 75 illustrates a payment disbursed notification that can be transmitted during the payments disbursed task 264 . The notification of FIG. 75 can be transmitted in real-time to all draw participants and can include a statement that the payments have been disbursed for the draw scheduled on a particular date on the project.
[0246] FIG. 76 illustrates maintain system screens tasks 276 , which can be included in the manage system environment process 102 . The maintain system screens tasks 276 can be used by each user or each organization to customize the software environment according to particular needs. For example, an organization can customize phase codes for their projects. The maintain system screens tasks 276 can be performed by any of the participants using the system environment manager 52 . The maintain system screens tasks 276 can include a maintain phase codes task 278 , an administrator user login task 280 , an add/edit picklist task 282 , an add/edit organization role task 284 , a default settings task 286 , an edit notifications task 288 , a default configuration task 290 , and an add/edit user role task 292 .
[0247] FIG. 77 illustrates a maintain phase codes form that can be associated with the maintain phase codes task 278 . Each participant can access the maintain phase codes form through the system environment manager 52 . The participant can add new or delete selected budget items.
[0248] FIG. 78 illustrates an administration user login screen that can be associated with the administrator user login task 280 . Each participant can access the administrator user login screen through the system environment manager 52 . The user at the organization can enter a user name and use the screen to log onto the system as any user in the system.
[0249] FIG. 79 illustrates an add/edit picklist form that can be associated with the add/edit picklist task 282 . An administrator of the CPMS 10 can add new or delete selected picklist entries (e.g., lists of states, types of projects, etc.) for various drop-down menus provided by the CPMS 10 .
[0250] FIG. 80 illustrates an add/edit organization role form that can be associated with the add/edit organization role task 284 . A GC can access the add/edit organization role form through the system environment manager 52 . The GC can select the security clearance for each type of organization (e.g., bank, title company, GC, subcontractor, or architect).
[0251] FIG. 81 illustrates a default/configure settings form that can be associated with the default settings task 286 . A GC can access the default/configure settings form through the system environment manager 52 . The GC can enter its preferred settings, such as the draw close reminder days, the draw start reminder days, the draw request minimum lead time, the security identification, whether the inspector is to be paid via the ACH system, whether to wait for all lien waivers, and who pays the inspector (e.g., the bank, the title company, the owner, the owner's representative, or the GC).
[0252] FIG. 82 illustrates an edit notification form that can be associated with the edit notifications task 288 . A GC can access the edit notification form through the system environment manager 52 . The GC can modify the notifications that are transmitted during the various processes. The GC can select a particular notification and edit the default notification as necessary. The GC can also specify whether particular authorizations are necessary, such as an authorization by the bank to change the notification.
[0253] FIG. 83 illustrates a default/configure process form that can be associated with the default configurations task 290 . A GC, owner, owner's representative, lender, etc. can access the default/configure process form through the system environment manager 52 in order to customize portions of the construction payment process or to change the rules for portions of the construction payment process. For example, a GC can define and store its own phase codes. The GC, owner, owner's representative, lender, etc. can choose whether to activate particular tasks in each process and can access a link to edit each one of the notifications associated with the tasks.
[0254] FIG. 84 illustrates an add/edit user role form that can be associated with the add/edit user role task 292 . A GC can access the add/edit user role form through the system environment manager 52 . The GC can select roles for a particular user, such as a system administrator, a system helpdesk user, a local administrator, a regular user, and view only access. The GC can add new roles or delete selected roles.
[0255] FIG. 85 illustrates perform inspections tasks 294 , which can be included in the manage draw process 96 . The perform inspection tasks 294 can be used to schedule and facilitate inspections of the construction project, if necessary before each draw. The perform inspections tasks 294 can be performed by the GC and the inspector using the inspection module 58 of the draw module 94 . The perform inspections tasks 294 can include an inspection required task 296 , an inspection required form task 298 , a prepare to conduct inspection task 300 , a view previous inspections task 302 , an enter inspection task 304 , an enter inspection report task 306 , an inspection report form task 308 , and an inspection report failed task 310 .
[0256] FIG. 86 illustrates a prepare to conduct inspection notification that can be transmitted during the prepare to conduct inspection notification task 300 . The notification of FIG. 86 can include a statement that a draw has been scheduled for a project on a date and that the inspector is requested to prepare to conduct an inspection for the draw. The notification can state that the inspection should be conducted only after receiving confirmation.
[0257] FIG. 87 illustrates an inspection required notification that can be transmitted during the inspection required notification task 296 . The notification of FIG. 87 can include a statement a scheduled draw is pending for a project and a link to specify if an inspection is required for the draw.
[0258] FIG. 88 illustrates an inspection required screen that can be associated with the inspection required task 298 . A GC (or owner, owner's representative, lender, or title company) can access the inspection required screen through the inspection module 58 of the draw module 44 . The inspection required screen can include the project name, the project number, the draw number, the owner name, the draw date, the project address, and a list of participants. The list of participants can include the request amount, the organization name, the organization role, the budget item, the budget amount, the payment amount, the holdback accrued, and the remaining balance. The inspection required screen can also include general comments, comments to the inspector, and whether an inspection should be scheduled.
[0259] FIG. 89 illustrates an enter inspection report notification that can be transmitted during the enter inspection task 304 . The notification of FIG. 89 can include a statement that the draw schedule on a date for a project has been authorized and that the recipient should proceed with the inspection. The notification can include a link to view the details of the project and to generate an inspection checklist FIG. 90 illustrates an enter inspection report form that can be associated with the enter inspection report task 306 . The inspector can enter the details of the inspection on the inspection report form. The inspection report form can include the project name, the project number, the draw number, the draw date, the owner name, the project address, the inspection date, and general inspection comments.
[0260] FIG. 91 illustrates an inspection report form screen that can be associated with the inspection report form task 308 . A GC, owner, owner's representative, title company, or inspector can access the inspection report form screen through the inspection module 58 of the draw module 44 .
[0261] FIG. 92 illustrates an inspection report failed notification that can be transmitted during the inspection report failed task 310 . The notification of FIG. 92 can include a statement that there is a high concern level for the project following the inspection conducted on a particular date. The notification can include a link to access the inspection report form.
[0262] FIG. 93 illustrates a view previous inspections screen that can be associated with the view previous inspections task 302 . A GC, owner, owner's representative, title company, or inspector can access the view previous inspections screen through the inspection module 58 of the draw module 44 and can select an inspection performed on a particular date.
[0263] FIG. 94 illustrates an approve draw request process 312 , which can be included in the manage draw process 96 . The approve draw request process 312 can be used to confirm that the necessary inspections have been performed, to approve each draw in the construction payment process, and to issue lien waivers. The approve draw request process 312 can be performed by a GC and/or any participant above the line of the GC (such as the owner, the owner's representative, the title company, the architect, etc.) using the draw approval module 60 of the draw module 44 . Once the project has been initiated, the CPMS 10 can be used to approve any type of payment associated with the construction process. The CPMS 10 can facilitate parallel approvals (e.g., both the GC and the owner must approve the draw) or a sequence of approvals (e.g., the architect must approve the draw, then the owner, then the lender). The CPMS 10 can be used to configure the approval process for each project. The CPMS 10 can be used to approve change orders for the budget or particular amounts contracted between parties. For example, the CPMS 10 can be used to obtain approval from a GC and/or any participant above the line of the GC for a change order that exceeds a certain amount or to approve all change orders after a limit has been exceeded. The approve draw request process 312 can include an Authorize Draw Request One task 314 , an Authorize Draw Request One—declined task 316 , an inspections confirmed task 318 , an inspection authorized task 320 , a payment details modified task 322 , an Authorize Draw Request Two—notification task 324 , an Authorize Draw Request Two task 326 , an Authorize Draw Request Two declined task 328 , an Authorize Draw Request Two approved task 330 , and an issue lien waiver task 332 .
[0264] FIG. 95 illustrates an Authorize Draw Request One form or authorize sworn statement form that can be associated with the Authorize Draw Request One task 314 . A GC, owner, owner's representative, or title company can access the Authorize Draw Request One form through the draw module 44 . The Authorize Draw Request One form can include the project name, the project number, the owner, the project address, the draw number, and the draw date. The Authorize Draw Request One form can include any entry for each organization including the request amount, the organization name, the organization role, the budget item, the budget amount, the payment amount, the holdback accrued, and the remaining balance. The Authorize Draw Request One form can include the authorizations received, the authorizations outstanding, whether an inspection is required, the ability to enter a password for authorization, and the ability to deny authorization and specify a reason.
[0265] FIG. 96 illustrates an authorize first draw declined notification that can be transmitted during the Authorize Draw Request One—declined task 316 . The notification of FIG. 96 can include a statement that the draw for a project has been denied authorization and a link to view and/or modify the draw details.
[0266] FIG. 97 illustrates an inspection confirmed notification that can be transmitted during the inspections confirmed task 318 . The notification of FIG. 97 can include a statement that the draw scheduled for a project has been authorized and instructions to proceed with inspection of the site, along with a link to view the details of the project and to generate an inspection checklist.
[0267] FIG. 98 illustrates a payment details modified notification that can be transmitted during the payment details modified task 322 . The notification of FIG. 98 can include a statement that the payment details for a project for a draw have not been accepted. The notification can list details of project participation and payments due for the draw, organization role, budget item, and payment amount.
[0268] FIG. 99 illustrates an inspection authorized notification that can be transmitted during the inspection authorized task 320 . The notification of FIG. 99 can include a statement that an on-site inspection for a project has been authorized.
[0269] FIG. 100 illustrates an Authorize Draw Request Two notification that can be transmitted during the Authorize Draw Request Two—notification task 324 . The notification of FIG. 100 can include a statement that the recipient is requested to check the inspection report entered for a project, that the recipient's authorization is required before the draw can proceed to the next phase (e.g., asking draw recipients for lien waivers), and a link to view the inspection report and to grant or deny authorization for the draw.
[0270] FIG. 101 illustrates an Authorize Draw Request Two form that can be associated with the Authorize Draw Request Two task 326 . A GC, owner, owner's representative, or title company can access the Authorize Draw Request Two form through the draw approval module 60 of the draw module 44 . The Authorize Draw Request Two form can include the project name, the project number, the owner, the project address, the draw number, and the draw date. The Authorize Draw Request Two form can include any entry for each organization including the request amount, the organization name, the organization role, the budget item, the budget amount, the payment amount, the holdback accrued, and the remaining balance. The Authorize Draw Request Two form can include the authorizations received, the authorizations outstanding, whether an inspection is required, the ability to enter a password for authorization, and the ability to deny authorization and specify a reason.
[0271] FIG. 102 illustrates an Authorize Draw Request Two declined notification that can be transmitted during the Authorize Draw Request Two declined task 328 . The notification of FIG. 102 can include a statement that the draw scheduled for a project has been denied authorization by a participant and that the draw cannot proceed without this authorization.
[0272] FIG. 103 illustrates an Authorize Draw Request Two approved notification that can be transmitted during the Authorize Draw Request Two task 330 . The notification of FIG. 103 can include a statement that a draw for a project has been authorized by a participant.
[0273] FIG. 104 illustrates an issue lien waiver notification that can be transmitted during the issue lien waiver task 332 . The notification of FIG. 104 can include a statement that a draw scheduled for a project has been authorized by a participant and that the recipient is requested to issue a lien waiver to receive payments for the draw, along with a link allowing the recipient to issue a lien waiver.
[0274] FIG. 105 illustrates a change request process 334 , which can be included in the manage change order process 98 . The change request process 334 can be used to modify the overall project budget (generally to expand the budget) by adding new line items, by changing existing line items, or by terminating subcontractors and making the remaining funds available to other participants. The change request process 334 can be performed by a GC, architect, owner, owner's representative, lender, or subcontractor using the change order module 48 . The change request process 334 can include a change request task 336 , a change request issued task 338 , and an authorize change request task 340 .
[0275] FIG. 106 illustrates a change request form that can be associated with the change request task 336 . A GC or subcontractor can access the change request form through the change order module 48 . The change request form can include the project name, the project number, the project address, the owner name, and a list of the amounts to change. The list of amounts to change can include the change amount, the organization name, the organization role, the budget item, the budget amount, the payment amount, and the remaining balance. The change request form can include a change description field. The change request form can include whether the payment form is loan or owner payment, and whether the payment method is loan, owner check, or credit card. The change request form can include the currently estimated completion date and a new estimated completion date.
[0276] FIG. 107 illustrates a change request issued notification that can be transmitted during the change request issued task 338 . The notification of FIG. 107 can include a statement that a change request has been issued on a project and is pending authorization. The notification can include the details of the change request, the organization name, the budget item, the current budget amount, and the change amount.
[0277] FIG. 108 illustrates an authorize change request notification that can be transmitted during the authorize change request task 340 . The notification of FIG. 108 can include a statement that a change request has been issued on a project and that the recipient's approval is required for the change request. The notification can include a link to view the details of the change request, as well as to approve or decline the change request.
[0278] FIG. 109 illustrates a process change request process 342 , which can be included in the manage change order process 98 . The process change request process 342 can be used to ensure that changes being made to the budget are authorized by the appropriate participant, such as the architect, the lender, the title company, the owner, the owner's representative, or the GC. The process change request process 342 can be performed by a GC, architect, owner, owner's representative, lender, or subcontractor using the change order module 48 . The process change request process 342 can include a view pending change requests task 344 , an authorize change request task 346 , a change request declined task 348 , and a change request approved task 350 .
[0279] FIG. 110 illustrates a view pending change request screen that can be associated with the view pending change requests task 344 . A GC, subcontractor, owner, owner's representative, lender, or architect can access the view pending change request screen through the change order module 48 . The view pending change request screen can include the project name, the project number, the project address, the owner name, and a list of the amounts to change. The list of amounts to change can include the change amount, the organization name, the organization role, the budget item, the budget amount, the payment amount, and the remaining balance. The view pending change request screen can include a change description field. The view pending change request screen can include whether the payment method is loan, owner check, or credit card. The view pending change request screen can include the new estimated completion date, the authorizations received, and the authorizations outstanding.
[0280] FIG. 111 illustrates an authorize change request form that can be associated with the authorize change request task 346 . A GC, subcontractor, owner, owner's representative, lender, or architect can access the authorize change request form through the change order module 48 . The authorize change request form can include the project name, the project number, the project address, the owner name, and a list of the amounts to change. The list of amounts to change can include the change amount, the organization name, the organization role, the budget item, the budget amount, the payment amount, and the remaining balance. The authorize change request form can include a change description field. The authorize change request form can include whether the payment method is loan, owner check, or credit card. The authorize change request form can include the new estimated completion date, the authorizations received, and the authorizations outstanding. The authorize change request form can include the ability to enter a password and to authorize the change request, and the ability to refuse the change request and enter a reason for the refusal.
[0281] FIG. 112 illustrates a change request declined notification that can be transmitted during the change request declined task 348 . The notification of FIG. 112 can include a statement that a change request issued on a date for a project has been declined by a participant.
[0282] FIG. 113 illustrates a change request approved notification that can be transmitted during the change request approval task 350 . The notification of FIG. 113 can include a statement that a change request issued on a date for a project has been approved by a participant (e.g., a lender). Only a change request can be used to modify the overall project budget (generally to expand the budget) by adding new line items, by changing existing line items, or by terminating subcontractors and making the remaining funds available to other participants. The CPMS 10 can be used to ensure that changes being made to the budget are authorized by the appropriate participant, such as the architect, the lender, the title company, the owner, the owner's representative, or the GC. The notification of FIG. 113 can be transmitted when the appropriate participant has approved the change request.
[0283] FIG. 114 illustrates a change project participant process 352 , which can be included in the manage change order process 98 . The change project participant process 352 can be used, for example, to terminate one subcontractor and to make the remaining funds available to another participant (such as a replacement subcontractor). The change project participant process 352 can be performed by a GC or a subcontractor using the change order module 48 . The change project participant process 352 can include a change participant task 354 , a check participant delete task 356 , and a change affidavit task 358 .
[0284] FIG. 115 illustrates a change participant screen that can be associated with the change participant task 354 . A GC or subcontractor can access the change participant screen through the change order module 48 . The change participant screen can include the project name, the project number, the owner name, the project address, and the current status of the project. The change participant screen can include a list of the organizations that can be changed. The list of organizations can include organization name, organization role, budget item, budget amount, payment amount, holdback accrued, remaining balance, and a link to delete each participant.
[0285] FIG. 116 illustrates a check participant delete screen that can be associated with the check participant delete task 356 . A GC or subcontractor can access the check participant delete screen through the change order module 48 . The check participant delete screen can include the project name, the project number, the owner name, the project address, and information about the participant to be deleted (e.g., organization name, organization role, budget item, budget amount, payment amount, holdback accrued, and remaining balance). The check participant delete screen can include the ability to specify whether the participant has materially participated in the project.
[0286] FIG. 117 illustrates a change affidavit screen that can be associated with the change affidavit task 358 . A GC or subcontractor can access the change affidavit screen through the change order module 48 . The change affidavit screen can include the project name, the project number, the owner name, the project address, the current status of the project, the budget amount, the previously paid to date amount, the hold back to date amount, and the remaining budget. The change affidavit screen can include a field to enter comments and the ability to enter a password and authorize the change in the affidavit.
[0287] FIG. 118 illustrates maintain project screens tasks 360 , which can be included in the manage project process 94 . The maintain project screens tasks 360 can be used to edit the project's profile, the contact information, and to close out a project. The maintain project screens tasks 360 can be performed by a GC, lender, owner, or owner's representative using the project module 28 . The maintain project screens tasks 360 can include a project profile task 362 , a project contact information task 364 , a project information task 366 , and a close project task 368 .
[0288] FIG. 119 illustrates a project profile form that can be associated with the project profile task 362 . A GC, lender, owner, or owner's representative can access the project profile form through the project module 28 . The GC, lender, owner, or owner's representative can enter the requested information, such as project information, project funding information, project owner information, site information, and GC information.
[0289] FIG. 120 illustrates a project contact information screen that can be associated with the project contact information task 364 . A GC, lender, owner, or owner's representative can access the project contact information screen through the project module 28 . The project contact information screen can include the project name, the project identification, the project address, and a list of contact information for the participants in the project. The list of contact information can include participant identification number, organization name, organization role, project manager name, contact email address, and contact phone number.
[0290] FIG. 121 illustrates a project information screen that can be associated with the create project information task 366 . A GC, lender, owner, or owner's representative can access the project information screen through the project module 28 . The project information screen can include project information, site information, project owner information, and GC information.
[0291] FIG. 122 illustrates a close project screen that can be associated with the close project task 368 . A GC, lender, owner, or owner's representative can access the close project screen through the project module 28 . The close project screen can include the project name, the loan account number, the owner name, and the ability to close the project.
[0292] FIG. 123 illustrates manage access screens tasks 370 , which can be included in the manage system environment process 102 . The manage access screens tasks 370 can be used to customize the various screens displayed to particular users or organizations during the construction payment process. For example, the manage access screens tasks 370 can be used to include an organization's trademark or logo on one or more of the screens displayed during the construction payment process (e.g., a lender's trademark can be included in the upper right corner of each screen). In addition, the manage access screens tasks 370 can be used to change the layout of particular forms or screens according to the preferences or requirements of particular users or organizations. The manage access screens tasks 370 can be performed by any of the participants using the system environment manager 52 . The manage access screens tasks 370 can include a log in task 372 , a log out task 374 , a project home page task 376 , a reset password task 378 , a main screen task 380 , a browse projects task 382 , a forgot password task 384 , and a your password task 386 .
[0293] FIG. 124 illustrates a log in screen that can be associated with the log in task 372 . Each participant can access the log in screen through the access manager 38 . The participant can enter a user name and password to log in. The log in screen can provide a link if a user forgets his or her password.
[0294] FIG. 125 illustrates a log out screen that can be associated with the log out task 374 . Each participant can access the log out screen through the access manager 38 . The log out screen can confirm that the user has been logged out.
[0295] FIG. 126 illustrates a project home page screen that can be associated with the project home page task 376 . Each participant can access the project home page screen through the access manager 38 . The project home page screen can include the project name, the number of new messages, and a link to read the new messages. The project home page can include project overview information (including a project schedule progress bar and a funds disbursed progress bar), completed draws information (including draw number, draw date, and links to draw information), pending draw information (including draw number and started date). The project home page can include links to several actions, forms, or screens (e.g., project profile, project budget, view project participants, setup invoice codes, manage project users, title company approval tracking, initiate unscheduled draw, etc.).
[0296] FIG. 127 illustrates a reset password screen that can be associated with the reset password task 378 . Each participant can access the reset password screen through the access manager 38 . The participant can enter the new password twice in order to change the password associated with a particular user name.
[0297] FIG. 128 illustrates a main screen for a particular user that can be associated with the main screen task 380 . Each participant can access the main screen through the access manager 38 . The main screen can list the projects that the participant is involved with, along with the number of new messages associated with each project and a link to read the new messages.
[0298] FIG. 129 illustrates a browse projects screen that can be associated with the browse projects task 382 . Each participant can access the browse projects screen through the access manager 38 . The browse projects screen can include a project search feature and a list of projects. The list of projects can include the project name, the GC name, a link to edit the project, and the ability to select one or more projects to browse.
[0299] FIG. 130 illustrates a forgot password screen that can be associated with the forgot password task 384 . Each participant can access the forgot password screen through the access manager 38 . A user can enter his or her user name and email address, and the system can email the password to the user.
[0300] FIG. 131 illustrates a your password notification that can be transmitted during the your password task 386 . The notification of FIG. 131 can include a statement that you requested your password be emailed to you, the password, and a request to use the password the next time you log in.
[0301] FIG. 132 illustrates a manage message screens process 388 , which can be included in the manage system environment process 102 . The manage message screens process 388 can be used to view messages, to create messages, or to view a system status message. The manage message screens process 388 can be performed by any of the participants using the system environment manager 52 . The manager message screens process 388 can include a view message task 390 , a view specific message task 392 , a create message task 394 , and a status message task 396 .
[0302] FIG. 133 illustrates a view messages screen that can be associated with the view message task 390 . Each participant can access the view message task 390 through the system environment manager 52 . The view message screen can include the user's name, the ability to specify the type of messages that are displayed (e.g., unread, recent, all, sent messages, or archived), and a list of the type of messages specified. The list of messages can include the ability to select particular messages, the message date, the project name, the message subject, and whether an action is required. The view message screen can also provide the ability to archive selected messages and move to another screen of messages.
[0303] FIG. 134 illustrates a specific message being viewed by a user. The specific message can include any one of the notifications shown and described herein.
[0304] FIG. 135 illustrates a create/send messages screen that can be associated with the create message task 394 . Each participant can access the create/send message screen through the system environment manager 52 . A user can enter a project name, whether to send the message to an organization or a user, the organization names, the user names, a message subject, and a message.
[0305] FIG. 136 illustrates a status message screen that can be associated with the status message task 396 . Each participant can access the status message screen through the system environment manager 52 . The status message screen can post messages, such as a statement that a draw has been initiated for a project and that all participants have been notified. The status message screen can include a link to an organization or user home page.
[0306] FIGS. 137-153 illustrate a method of managing a construction payment process according to another embodiment of the invention. Aspects of the method of FIGS. 137-153 can be used in conjunction with the embodiment of the invention shown and described with respect to FIGS. 1-136 and FIGS. 154-179 .
[0307] FIGS. 154-179 are input/output diagrams for a method of managing a construction payment process according to still another embodiment of the invention. Aspects of the method of FIGS. 154-179 can be used in conjunction with the embodiments of the invention shown and described with respect to FIGS. 1-136 and FIGS. 137-153 .
[0308] FIG. 155 includes an open project task, a create draw schedule task, and an identify and assign project roles task, each of which can be performed by a GC. An enter budget task can be performed by an owner, owner's representative, GC, lender, or title company. An update details task can be performed by a GC for subcontractors and/or material suppliers or by an owner, lender, or title company for any type of participant. A close project task can be performed by a title company, GC, or lender.
[0309] FIG. 156 includes an enter project details task in which the system can assume that the project has full approval from all necessary agencies and participating organizations before opening a project. FIG. 156 includes an enter loan details in which the lender may choose to input only select information for legal or business reasons. If there is no loan for the project, no information is entered.
[0310] FIG. 157 includes a review proposed draw schedule task in which the system can generate a proposed draw schedule by equally spacing the number of draws across the estimated project schedule. FIG. 157 includes an accept or reject proposed draw schedule task in which a GC can manually declare draws according to a schedule established by the owner, the owner's representative, the lender, or the GC. An automated schedule can be rejected and the schedule can be manually maintained.
[0311] FIG. 159 includes an enter project budget for a participating organization in which a hierarchical process can be used. At each level, the participating organization can perform the process for the organizations that they use to support them.
[0312] FIG. 160 includes an authorize change order task in which an issue resolution process may require rejection of an initial change order and creation of a second change order that is mutually agreeable to all parties. Only a final change order in the resolution process must be approved.
[0313] FIG. 162 includes an add organization task in which an organization must be added before it can participate in a project. The system, the title company, the lender, or the GC can add organizations to the system. While organizations can be added during the identify and assign project roles task of the maintain project payment plan process, organizations can be added independently of that process. FIG. 162 includes an enter organization details task in which the initial contact at an organization can be responsible for entering their organization's details and additional contact information. Each organization can identify an internal system administrator who can be responsible for updating their organization details and contact information. FIG. 162 includes a maintain organization details task in which security can be particularly stringent due to sensitive financial information.
[0314] FIG. 164 includes a verify organization task which can be provided by a third party based on the requirements of the participants. The system can facilitate the verification of organizations and charge a service fee.
[0315] FIG. 166 includes a declare draw task that can be performed by a GC. The draw is the mechanism by which project participants can submit invoices, the owner (generally through the GC) can pay for work completed, and participating parties receive payment and release their associated lien waivers. FIG. 166 includes a generate sworn statement task in which the GC can review the submissions on-line (referring to backup paper documentation when necessary) and once the submission is correct, the system can generate a sworn statement based on the information that has been electronically submitted by the parties participating in the draw. The GC can reject submissions and they can be revised and resubmitted for approval. This mechanism can be used to resolve any issues with the invoice. FIG. 166 includes a request inspection task that can generally be performed by the lender or the title company. FIG. 166 includes an authorize draw task that can generally be performed by the lender, but may require involvement of the owner, the owner's representative, or another designated project participant. A configurable authorization mechanism can include any project participant in the authorization process. FIG. 166 includes an enter and stage lien waivers task which can be required to complete the draw. Funds are not transmitted to the invoicing parties until their lien waivers are entered and staged. This requirement ensures the substantially simultaneous execution of payment and lien waiver release. FIG. 166 includes an execute simultaneous payment/lien waiver release task in which the substantially simultaneous exchange of lien waiver for payment is automated. This automated exchange can eliminate the need for meetings and can eliminate time lags between payment and lien waiver release. This automated exchange can reduce the change that a lien waiver will be lost and can speed payment to all draw participants by eliminating intermediate organizations from the payment process.
[0316] FIG. 167 includes an announce draw task in which an electronic message can be sent substantially simultaneously to all participating and/or interested organizations.
[0317] FIG. 168 includes an enter invoice details task which can be executed by any party wishing to be paid through the draw process. The electronic submission can be followed by paperwork that supports the submission. A service can be provided that allows the parties to submit the supporting information via scanning.
[0318] FIG. 169 includes an authorize invoice task in which an issue resolution process may require rejection of the initial invoice and creation of a second invoice that is mutually agreeable to all parties. Only the final invoice in the resolution process will be approved.
[0319] FIG. 170 includes a select inspector task in which there may be more than one inspector associated with a project. In this case, the correct inspector must be selected to perform the inspection.
[0320] FIG. 171 includes a confirm scope of inspection task in which the organization requesting the inspection can define the scope of the inspection, either for the entire sworn statement or for a subset of the sworn statement. FIG. 171 includes an enter inspection results task in which supporting documentation may be necessary depending upon the scope and nature of the inspection. FIG. 171 includes a forward supporting documentation task in which the system can allow files with digital photographs or other electronic material to be attached to the electronic inspection reports.
[0321] FIG. 173 includes a stage lien waiver task in which the electronic signed lien waiver can be staged in the system, secured from any alterations. In one embodiment of the invention, the lien waiver is not released to the title company until the substantially simultaneous exchange of payments and lien waivers occurs.
[0322] FIG. 174 includes a confirm draw authorization and staged lien waivers task which can include a review of all lien waivers to ensure they are complete and correct.
[0323] FIG. 178 includes a provide customer support task that can include support for adding or modifying organizations or projects, fixing password problems, fixing projects and transactions. FIG. 178 includes a system administration task that can include security administration, financial auditing, and contingency support. FIG. 178 includes a maintain activity history for system participants task that can include a vendor directory with history about the vendors and/or ratings of vendors.
[0324] It should be understood by one of ordinary skill in the art that embodiments of the invention can be implemented using various computer devices, such as personal computers, servers, and other devices that have processors or that are capable of executing programs or sets of instructions. In general, the invention can be implemented using existing hardware or hardware that could be readily created by those of ordinary skill in the art. Thus, the architecture of exemplary devices has not always been explained in detail, except to note that the devices will generally have a processor, memory (of some kind), and input and output applications. The processor can be a microprocessor, a programmable logic control, an application specific integrated circuit, or a computing device configured to fetch and execute instructions. In some cases, the devices can also have operating systems and application programs that are managed by the operating systems. It should also be noted that although components of the CPMS 10 are shown connected in a network, no specific network configuration is implied. One or more networks or communication systems, such as the Internet, telephone systems, wireless networks, satellite networks, cable TV networks, and various other private and public networks, could be used in various combinations to provide the communication links desired or needed to create embodiments or implementations of the invention, as would be apparent to one of ordinary skill in the art. Thus, the invention is not limited to any specific network or combinations of networks.
[0325] Various features and advantages of the invention are set forth in the following claims. | A system and method for managing a construction payment process including establishing electronic communication between a payee device and a construction project management server and transmitting a lien waiver document to the payee through the payee device with a request for a signature. A signed lien waiver document is received from the payee and stored to a computer-readable memory. The payor is temporarily prevented from accessing the signed lien waiver document. A payment is transmitted to the payee from the payor after receiving the signed lien waiver document, but before transmitting the signed lien waiver document to the payor. Only after the payment has been transmitted is the signed lien waiver document transmitted to the payor. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to a loading vehicle operated by electric battery power, wherein a chassis is associated with a loading means at the front end thereof, an electric traction motor, a battery box and a battery lifting device are carried on said chassis, and said battery box is supported by said chassis and removable therefrom by actuation of said lifting device. The invention also relates to a free standing supporting pallet arranged to be used in connection with such a vehicle.
Up to now, loading vehicles operated by electric battery power have been used in coal mines for relatively ligh work and, according to general belief, they have not been considered suitable for heavy duty applications, for example in metal mines.
It is an object of this invention to provide an electric battery driven loading vehicle which is not limited for use in coal mines but can be given a design and size so as to enable heavy duty applications for example in metal mines. Another object of the invention is to provide such a vehicle with improved means to facilitate the removal, carrying, and replacement of the battery.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a loading vehicle according to the invention looking towards the front end of the vehicle.
FIG. 2 is a side view of the vehicle where the battery box is shown in its normal position in full lines and in its elevated position in chain dotted lines. Correspondingly the bucket is shown in full lines when it is arranged for load hauling and in chain dotted lines when it is in the position for discharging its contents.
FIG. 3 is a plan view of the vehicle in the position according to the full lines in FIG. 2.
FIG. 4 is a side view of a part of the vehicle showing the mechanical and electrical connections between the vehicle and the battery box in a disconnected position.
FIG. 5 shows the same vehicle part as FIG. 4 but with closed connections.
FIG. 6 shows in perspective view looking at the back of the vehicle how the vehicle showing is arranged when it is reversed to a battery pallet and FIGS. 7 and 8 show how the battery box is lowered to a position on the pallet.
FIG. 9 is a perspective view of the vehicle during elevation of the battery pallet and the battery box in the bucket.
FIG. 10 is a schematic circuit diagram off the switching equipment for driving either with the main battery or with a smaller extra battery.
DETAILED DESCRIPTION
The loading vehicle illustrated in FIGS. 1-3 comprises a front section 10 and a rear section 11 which are pivotally connected to each other. The front section 10 is provided with a chassis frame carrying a loading means 12 and a traction motor system 13 and is supported on a front wheel axle 14 with wheels 15, while the rear section is provided with a driver's compartment 16, a battery box 17 and a rear wheel axle 18 with wheels 19.
The loading means 12 comprises a bucket 20 which is connected to a boom 21. The boom 21 is verticaly swingable aout a swing-axis 22 by means of two hydraulic lifting cylinders 23 and 24. In the lowest position of the boom it rests on a not shown stop device in the chassis frame which device unloads the mountings 22 from the big loading pressure which appears during the scooping movement.
A fork means 25 is bolted to the front end of the boom 21 and the bucket is turnably journalled in bearings 26 in said fork means 25. The turning movement is actuated by two hydraulic cylinders 27 and 28 coupled between the bucket 20 and the chassis frame. The mutual positions of the bearing points for the bucket 20, the boom 21 and the hydraulic cylinders 27 and 28 are placed in such a way as to give the bucket 20 a parallel holding during the lifting movement; in other words, the angularity of the bucket in relation to the vehicle will remain constant during the lifting movement.
The traction motor system 13 comprises a series-wound direct current motor 29 which is connected to the front wheel axle 14 and to the rear wheel axle 18 by a reduction gear 30 and a front 31 and a rear 32 drive shaft. The front wheel axle 14 contains a differential gearing 33 including an automatic differential brake in order to have the maximum tractive force when the friction coefficient of the load is different for the two wheels 15. Planetary gearings are encased in the wheel centres 34.
The connection between the front 10 and the rear 11 section comprises an upper 35 and a lower 36 bearing which permit the sections 10 and 11 to be swingable in the horizontal plane. In order to reduce the bearing forces, the two bearings are arranged at a long distance from each other. The vehicle is steered by pivoting the sections 10 and 11 in relation to each other by means of two hydraulic cylinders 37 and 38.
The rear section 11 is also provided with a chassis frame in whose rear part a hydraulic pumping unit 39 is arranged which has two hydraulic pumps 40 and a driving motor 41 for the pumps 40. The motor 41 is a shunt-wound direct current motor. The pumps 40 supply the loading and the controlling systems of the vehicle with hydraulic oil. A hydraulic oil tank 42 is placed in the front part of the chassis frame and a control box 43 is attached to the front right side of the frame. The box contains the main part of the electrical equipment for controlling the traction motor 13 and the pump motor 41 and for charging a low voltage extra or auxiliary battery 44 placed in a box-like bracket 45 which is attached to the forward left side of the frame. The rear wheel axle 18 with the wheels 19 is swingably suspended under the rear part of the frame whereby the axle 18 can be swingable in order to simplify driving over rough ground. Besides the swingable mounting, the rear wheel axle 18 is of the same construction as the front wheel axle 14. A disc brake 46 is mounted on the rear drive shaft 32, which brake is intended to be a parking brake or an emergency brake. The normal travelling braking is obtained by switching the traction motor to be a generator, so-called regenerative braking, which also enables charging of the battery.
A lifting frame 47 is swingably connected to the chassis frame of the rear section 11 which frame 47 is provided for carrying the battery box 17. The frame 47 contains two bars 48 and 49 which, by means of two bearings 50 and 51, are mounted to the chassis. The bearings 50 and 51 are disposed in front of the rear wheel axis so that the bars 48 and 49 can be long enough for giving the battery box 17 a suitable pivoting movement. The bars are welded to a base plate 52 which forms a seat for said battery box 17. The rear part 53 of the plate is slightly wedge-shaped in order to be better guided into a correspondingly shaped part 54 in a battery pallet 55 (see FIG. 6) which shall be further described later on. The lifting frame 47 is pivotable by means of two hydraulic cylinders 56 coupled between each bar 48 and 49 and the frame. The battery box 17 comprises an outer case 58 which contains six batteries 59 connected in series, each having an electric voltage of 60 volts. The case 58 forms the outer limit of the vehicle which means that battery equipment of different types and sizes can be used without changing the other parts of the vehicle.
Two latches 60 and 61 mounted on the lifting frame 47 lock the battery box 17 automatically to the lifting frame 47 when it is lowered to its normal position and unlock the battery box 17 when the frame 47 is lifted. As will be seen in FIGS. 4 and 5, each latch has a locking bar 62 guided in holes in two flanges 63 and 64 which are mounted on the lifting frame 47. When locking, the locking bar 62 is adapted to be inserted through a tie 65 mounted on the battery box 17. The locking motion is caused by the lifting frame which brings one end 66 of the locking bar 62 into contact with an actuating means 67 on the chassis frame, when the lifting frame 47 is lowered, and the unlocking motion is achieved by a return spring 68 arranged between the locking bar 62 and one of the flanges 64. A plug socket 69 is located in a contact box 70 mounted on the battery case 58 and a plug 71, shaped to fit in the socket 69, is arranged on the lifting frame 47. Said plug 71 and socket 69 connect automatically the battery box 17 to the electrical system of the vehicle when the box 17 is elevated from the pallet 55 and disconnect the battery box 17 when it is replaced on the pallet 55.
A projecting stop lug 57 is mounted on each side of the lifting frame 47, which lugs 57 are adapted to make the lifting frame 47 rest on the chassis frame when said lifting frame 47 is in its low position (FIG. 5).
By available battery technique the accumulated battery charge will last for about four hours operation time. Then the battery must be exchanged by a charged battery. During the intervals of the changing procedure, when the battery box is disconnected, the extra auxiliary low tension voltage battery 44 is used to drive and operate the vehicle. The electrical between the two batteries is shown in FIG. 10. The high voltage battery in the battery box 17 is connectable to the driving and operating system 72 over a controller 73 by means of a contactor 74. In the same way the low tension voltage battery 44 is connectable to the driving and operating system 72 by another contactor 75. The switch-over is operated by a rotary switch 76 in the driver's compartment 16. In the position A of the switch 76 the contactor 75 will be closed and the low voltage battery 44 will be connected. In the position B the contactor 74 will be closed and instead the high voltage battery will be connected. The position O is a neutral position. The contactors 74 and 75 are equipped with cooperating contacts 77 and 78, respectively which will break the operating circuit for one contactor when the other one is closed. These switching means 74-78 prevent from connecting both batteries at the same time, even if one of the contactors should get stuck in a closed position. The normally required electrical equipment 79 of the vehicle, as for example the light, is always connected to the low voltage battery 44.
As will be seen from FIG. 6, a free standing battery pallet 55 is arranged to carry the unloaded battery box 17. The upper part 80 of the pallet 55 comprises an opening 54 through which the lifting frame 47 can be passed when the battery box is to be elevated from or lowered on to the pallet 55. The pallet has also a bottom plate 81 intended to be placed on the ground and an open space 82 between the upper part 80 and said bottom plate 81, in which space 82 the bucket 20 can be inserted to enable transport of the battery pallet 55 and of the battery box 17 as one unit, as shown in FIG. 9. The equipment for charging the batteries is associated with the pallet 55.
The battery changing is as follows, see FIGS. 6-8.
(a) The vehicle is moved backwards to a free battery pallet 55 and the battery box 17 is elevated with the lifting frame 47. During the lifting movement the latches 60 and 61 will be disconnected. The lifting frame 47 will then be guided into the opening 54 in the upper part 80 of the pallet 55 holding the battery box 17 somewhat above the pallet 55.
(b) The vehicle is arranged to be operated by the low voltage battery 44 and the battery box 17 is lowered on to the pallet 55 while the frame 47 passes through the opening 54. Thereby the plug 71 and the socket 69 will be automatically disconnected.
(c) The charging equipment is connected to the unloaded battery and is disconnected from another charged battery placed on a pallet at an adjoining location.
(d) The vehicle is driven by the low voltage battery 44 to the other battery pallet 55 with the charged battery and is moved backwards to the pallet.
(e) The battery is elevated by the lifting frame 47 whereby the plug 71 and the socket 69 will be connected automatically.
(f) The vehicle is arranged to be driven by the high voltage battery and is moved forwards while the frame 47 is lowered and the battery box 17 is locked up with the latches 60 and 61.
This completes the changing procedure and the vehicle is ready for continued operation. It is to be noted that the removal and the replacement of the battery is accomplished by the operation of the vehicle itself and that no extra person would be needed to help the operator.
Obviously various changes can be made in the details and arrangements of parts without diverging from the invention as defined by the following claims. | A loading vehicle operated by electric battery power includes a chassis, a loading bucket mounted at the front end of the chassis. The chassis also carries an electric traction motor, a battery box and a battery lifting device pivotally mounted to the rear of the chassis and movable relative to the chassis by power. The battery box is supported by the chasis and is removable therefrom by power actuation of the battery lifting device. The battery lifting device has a lifting frame forming a part thereof which projects rearwardly from the chassis so as to provide a seat for the battery box, the lifting frame being pivotally movable relative to the chassis by application of the power to lift the battery box relative to the chassis. The battery box is then placed on a pallet and a fresh battery box is arranged on the battery lifting device and moved in place on the chassis. | 1 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application is a U.S. national stage application of International App. No. PCT/FI2007/050039, filed Jan. 25, 2007, the disclosure of which is incorporated by reference herein, and claims priority on Finnish App. No. 20065060, filed Jan. 30, 2006.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] The invention relates to a method in a dryer section of a fiber-web machine and to a device in a dryer section of a fiber-web machine.
[0004] As known from the prior art, drying groups of dryer sections based on cylinder drying in fiber-web machines, such as paper or board machines, employ twin-wire draw and/or single-wire draw. In twin-wire draw, each group of drying cylinders comprises two wires, which press the web, one from above and the other one from below, against heated cylinder surfaces. In single-wire draw, each group of drying cylinders comprises only one drying wire on whose support the web runs through the entire group so that the drying wire presses the web against the heated cylinder surfaces of the drying cylinders and the web remains at the side of the outside curve of the reversing cylinders or rolls situated between the drying cylinders. Thus, in single-wire draw, the drying cylinders are arranged outside the wire loop, and the reversing cylinders or rolls are arranged inside the loop. In the following description, by the term ‘reversing cylinder’ is also meant a reversing roll alternatively placed in a corresponding position, and the terms ‘reversing cylinder’ and ‘reversing roll’ are used synonymously in this description. In the single-wire draw groups of dryer sections based on cylinder drying in fiber-web machines, a pocket space defined by a wire is formed between two adjacent drying cylinders and a reversing cylinder situated between them in a lower row. In connection with the pocket space, we speak of ‘opening’ and ‘closing nips’, i.e. ‘opening’ and ‘closing gaps’, by which opening nip, or opening gap, is meant an area where the drying wire separates from the drying cylinder and, correspondingly, a closing nip, or a closing gap, is formed on the side of the pocket space when the wire runs to the reversing cylinder. In a similar manner, when the wire leaves the reversing cylinder, an opening nip, i.e. an opening gap, is formed on the outgoing side of the pocket space and, correspondingly, when the wire runs to the next drying cylinder, a closing nip, i.e. a closing gap, is formed between the drying wire and the drying cylinder. Although in this description the invention is mainly described in connection with paper machines, the invention also encompasses embodiments associated with other fiber-web machines, such as, for example, board machines.
[0005] During the process of manufacturing a paper web, a shrinkage profile in the cross direction of the web is typically created in the web in paper machines known from the prior art, which shrinkage profile is not straight but, typically, shrinkage is greater in the edge areas of the web than in the middle. The shrinkage in the edge areas is generally 6-10% and the shrinkage in the middle areas is about 1.5%. The shrinkage of the web also affects other properties of paper, such as roughness, thickness and curl. For these reasons, in the design and manufacture of paper and board machines it has been necessary to take into account the cross-direction non-straight shrinkage profile of the web, for example, it has been necessary to supply less stock from the headbox to the edges, which increases the costs of design and manufacture.
[0006] As known from the prior art, attempts have been made to solve the problems discussed above by increasing the negative pressure in suction rolls used as reversing rolls. In that case, however, the difference in shrinkage between the edge and middle areas may even increase. In addition, suction rolls provided with a device arrangement at both ends of the roll for producing a higher negative pressure in the end area than in the middle area of the roll have been used as reversing rolls. With respect to the prior art relating to this, reference can be made to U.S. Pat. No. 5,135,614.
[0007] U.S. Pat. No. 5,388,347 in turn discloses an arrangement in which, among other things, for the purpose of reducing cross-direction shrinkage, the drying cylinders in connection with transfers over gaps between the groups in a dryer section of a paper machine are arranged close to each other.
[0008] With respect to the prior art, reference can also be made to U.S. Pat. No. 5,279,049, which discloses a method for restrained drying of a paper web, wherein the web is carried on support of a fabric around a dryer of a dryer section and, after that, the web is wrapped around a portion of a guide device placed immediately downstream relative to the dryer so that shrinkage in the edge area of the web is minimized.
[0009] It is also known from the prior art to arrange runnability components in pocket spaces of dryer sections, for example, blow boxes, blow-suction boxes and suction boxes, which are commonly used for providing negative pressure areas in connection with the pocket space to enhance runnability and to affect the run of the web and the wire from a drying cylinder to a reversing roll and, similarly, from the reversing roll to the next drying cylinder. Some arrangements of this kind are described below.
[0010] On the other hand, with respect to the prior art, reference can also be made to U.S. Pat. No. 5,163,236 disclosing an arrangement for a dryer section of a paper or coating machine, wherein pocket spaces between drying cylinders are arranged to be enclosed pocket chambers, the spaces between the cylinders being closed by a wall which is provided at both edges with sealing parts, preferably adjustable sealing parts, placed at a small distance from a wire.
[0011] With respect to the prior art, reference is further made to U.S. Pat. No. 4,905,380, in which ejection blows are arranged by means of a blow box placed in a pocket space of a drying group in order to produce a negative pressure field in gap spaces between the blow box and a wire on the run of the wire from a drying cylinder to a reversing roll and, correspondingly, from the reversing roll to a drying cylinder.
[0012] In addition, with respect to the prior art, reference is made to U.S. Pat. No. 4,876,803 disclosing a seal arrangement for reducing flows of air into a pocket space between two adjacent dryers in a dryer section, and a blow box arranged in the pocket space, and in which connection a reversing roll provided with an internal negative pressure source is used.
SUMMARY OF THE INVENTION
[0013] An object of the invention is to provide a method and a device in a dryer section of a fiber-web machine, such as a paper or board machine, in which attempts have been made to at least partly eliminate and/or minimize the problems described above in connection with the prior art, in particular in connection with cross-direction shrinkage of a web.
[0014] In accordance with the invention, means for controlling the cross-direction shrinkage of a web are arranged in connection with a pocket space of a dryer section applying single-wire draw in a fiber-web machine, such as a paper or board machine. In accordance with the invention, the web that is being dried is held in contact with a drying fabric, such as a drying wire, so that the pressure difference over the web is sufficiently high from the viewpoint of the cylinder/reversing roll dimensioning used and their position with respect to one another as well as from the viewpoint of the tension of the wire. A pressure difference over the web is produced by arranging a high negative pressure of 500-5000 Pa, most appropriately 1000-2500 Pa, in the pocket space, which negative pressure is also affected by the stock used, the dry solids and basis weight of the web, and running speed, so that a high speed, low dry solids at the beginning of drying or, in particular, a high basis weight of board require the highest negative pressure, as high as 5000 Pa. The inventors have realized the possibility of applying runnability components known in themselves in a new manner as negative pressure components used in connection with a pocket space in a dryer section for the purpose of controlling the cross-direction shrinkage of the web. In accordance with the invention, to control the cross-direction shrinkage of the web, a pressure difference is arranged over the web for holding the web in contact with a drying fabric, whereby its cross-direction shrinkage can be controlled. The pressure difference is produced by providing the pocket space with a negative pressure using a negative pressure component, and by sealing the pocket space between adjacent drying cylinders in the upper part of the pocket space by arranging members in connection with the upper sealing of the pocket space for sealing the gaps between it and the adjacent drying cylinders, and by arranging the transfer of the web from the drying cylinder to the reversing cylinder to be short. In addition, the tension of the wire is maintained at a level that is at least 3 kN/m, advantageously at least 4 kN/m. The length of the transfer between the drying cylinder and the reversing roll at the most 1000 mm, advantageously at the most 500 mm, determined based on the points of contact of the common tangent while the machine is at a standstill and the possible negative pressure effects have been turned off.
[0015] Besides shrinkage prevention, the negative pressure used/required is affected by the taking into account of the bending of the wire by means of wire tension. The wire bends from the cylinder towards the pocket when the negative pressure in the pocket space is increased, with the result that the point of separation of the wire and, correspondingly, the point of contact of the wire on the next cylinder (in this application, we speak of these terms as points of separation) are displaced upwards on the cylinder towards the upper sealing of the pocket space, thus impairing the efficiency of drying when the web wraps a shorter distance around the circumference of the cylinder. In this description, by the displacement of the point of separation of the wire is meant the displacement of the line of separation in the middle area of the web. In addition, the displacement of the point of separation depends on the tension profile of the wire, the tension being usually smaller in the middle, so that the displacement of the point of separation forms a displacement line whose maximum displacement is less than 200 mm, advantageously less than 60 mm. In the case of a 200 mm displacement, on a cylinder having a diameter of 1830 mm the contact (wrap) of the web with the cylinder, important from the viewpoint of drying, is reduced by 400 mm from the normal drying length of about 3740 mm, which is about 10.7% less, which means that 3 more cylinders would be needed for a dryer section of 30 cylinders and, correspondingly, in the case of a 60 mm displacement considered to be good, one additional cylinder would be enough as compared with the situation without a displacement. In practice, in at least part of the pocket space there is even today a negative pressure, but it is applied to problem areas and therefore comparison is difficult. For example, when the tension of the wire is 4 kN/m, and the negative pressure in the pocket 2 kPa and the displacement 60 mm, the distance between the rolls can be 10 mm or less with the geometry of the cylinder diameter of 1830 mm and the reversing roll diameter of 1500 mm.
[0016] The dependence of the maximum negative pressure (p) in the pocket space on the radius (R) of the cylinder and on the tension (T) of the wire can be expressed by the formula p=T/R, so that, for example, when the tension is 4 kPa and the radius of the drying cylinder is 0.915 m, 4.4 kPa is obtained as the theoretical maximum value of the negative pressure in the pocket space. In practice, the tension profile of the wire and the distance between the rolls shall also be taken into account, which reduces the maximum value, for example, to a value of 3.9 kPa. On the other hand, the formula also makes it possible to examine the tension of the wire and the negative pressure in the pocket T=p×R, so that, for example, when the value of the negative pressure in the pocket is 2 kPa and the radius of the drying cylinder is 0.915 m, 1.83 kN/m is obtained as the theoretical minimum value of the wire tension. In practice, the tension profile of the wire and the distance between the rolls shall also be taken into account, which increases the minimum value, for example, to a value of 2.3 kN/m. When determining the length of the transfer between the drying cylinder and the reversing roll, the shorter said transfer, the larger will be the wrapping angle of the web on the drying cylinder and, thus, the higher the drying capacity. The point of separation of the web from the drying cylinder moves because of the bending of the wire so that it will be the earlier, the larger the distance between the rolls, the smaller the tension of the wire, and the larger the diameter of the drying cylinder. The measurements commonly used: a drying cylinder diameter of 1830 mm and a reversing roll diameter of 1500 mm, are regarded as the normal geometry in this application, although other embodiments are also disclosed in this application. For example, in a situation where the negative pressure in the pocket is 1 kPa, the tension of the wire is 4 kN/m and the distance between the rolls is 200 mm, the displacement of the point of separation is about 120 mm, which is still in a range of a reasonable displacement. On the other hand, when the negative pressure in the pocket is raised to 2 kPa and the distance between the rolls is reduced to 50 mm, it will be necessary to tighten the wire further to a value of 4.5 kN/m for a corresponding displacement and an advantageous range is reached only with a tension of about 7.5 kN/m.
[0017] In accordance with the invention, the reversing cylinders in the drying group applying single-wire draw in a dryer section of a fiber-web machine, such as a paper or board machine, are reversing cylinders or rolls of the type known in themselves in the state of the art, such as, suction rolls, without an internal suction box, of the type marketed by Metso Paper, Inc. under the trademark VacRoll, rolls which are provided with grooves and/or perforations and can have a suction box, and negative pressure can be produced solely by means of a negative pressure component in the pocket space, solely by means of a roll or by means of both of them. The negative pressure acting through the reversing roll or through its grooves and perforations or only through grooves or only through perforations is 500-5000 Pa, advantageously 1000-2500 Pa.
[0018] The geometry defined by cylinders, reversing rolls and the wire can be symmetric, where the reversing roll is in the center line between the cylinders at a selectable distance from the cylinders. In that case, the placement of the frames and the equipment is easy. On the other hand, the reversing roll can be placed closer to one cylinder, whereby a shorter transfer to the reversing roll makes it possible to control the separation of the web from the cylinder.
[0019] The method and device in accordance with the invention is applied in at least a portion of the dryer section, advantageously in an area of dry solids content of 65-90% in the longitudinal direction of the dryer section because the shrinkage of the web mainly occurs in this dry solids content range. Of course, the negative pressure in the pocket, the tension of the wire, and the geometry of the pocket can be adjusted in each drying group in the longitudinal direction of the machine so as to be suitable for the dry solids content range in question. In addition, the concept can be applied outside the dry solids content range, in which case the wire tensions, the negative pressures in the pocket space and the geometry used can be optimized based on runnability.
[0020] In accordance with the invention, a substantially straight shrinkage profile in the cross direction of the web is achieved in which shrinkage is advantageously at a level of 1-2% in the entire web.
[0021] In accordance with one advantageous additional feature of the invention, the gap between the negative pressure component and the reversing cylinder is also sealed with a sealing member, which is a mechanical or a blow seal, to stop the movement of the air flow carried with the reversing cylinder before it enters the gap closing on the reversing cylinder.
[0022] When applying the invention at high running speeds, the creation of boundary-layer air flows can be prevented, when needed, by means of doctors, which are most appropriately placed before the front side of the gap closing between the wire and the reversing roll.
[0023] In accordance with one advantageous additional feature of the invention, the reversing cylinder is arranged to be movable such that the distance of the reversing cylinder with respect to the drying cylinders can be adjusted and in such a way that the reversing cylinder can be arranged to avoid a damaged paper/wire portion of possibly several layers not able to pass through a minimum gap between the drying cylinder and the reversing cylinder, which gap is determined by the combined thickness of the wire and the web, being about 1-2 mm. This advantageous additional feature also makes it possible to move the reversing cylinder, for example, to a wire replacement position, for example, at a distance of 30 mm.
[0024] The arrangement in accordance with the invention is suitable for use in connection with drying groups applying single-wire draw in a dryer section of many different types of fiber-web machines. The structural alternatives of drying cylinders, reversing cylinders, negative pressure components and the drying fabric can be manifold, in themselves known by a person skilled in the art.
[0025] In the following, the invention will be described in more detail with reference to the figures in the appended drawing, but the invention is not meant, by any means, to be narrowly limited to the details of them.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 schematically shows one embodiment of the invention.
[0027] FIG. 2 schematically shows cross-direction shrinkage of paper attached to the wire by means of a pressure difference in accordance with one embodiment of the invention.
[0028] FIG. 3 schematically shows one embodiment of the invention, in which the reversing roll is a grooved roll.
[0029] FIG. 4 schematically shows one embodiment of the invention, in which the reversing roll is a suction roll of the type marketed by Metso Paper, Inc. under the trademark VacRoll.
[0030] FIG. 5 schematically shows one embodiment of the invention, which is provided with an arrangement facilitating the threading of the web in accordance with one advantageous additional feature of the invention.
[0031] FIGS. 6A-6C schematically show examples of the displacement of the point of separation as a function of wire tension.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] FIG. 1 shows one embodiment of the arrangement in accordance with the invention, placed in a group of drying cylinders applying single-wire draw in a dryer section of a paper machine, which figure shows, of the drying group, adjacent drying cylinders 10 and 12 , and a reversing cylinder/roll 11 placed below these in a staggered fashion. A paper web W that is being dried runs on support of a drying wire F from the drying cylinder 10 to the reversing cylinder 11 and further to the next drying cylinder 12 as a normal single-wire draw. A negative pressure component 20 is placed in a pocket space T remaining between the drying cylinder 10 , the reversing cylinder 11 and the next drying cylinder 12 and the drying wire F, which negative pressure component is used for producing a strong negative pressure in the pocket space T to control the cross-direction shrinkage of the paper web W such that the attachment of the web W to the drying wire F is enhanced. Using the negative pressure component 20 , a pressure difference over the web and the wire needed for the adherence of the web W is created by producing in the pocket space T a strong negative pressure area, which is confined by seals 25 , 26 sealing the operating area of the negative pressure component 20 in the pocket space T to the surfaces of the drying cylinders 10 and 12 . In the embodiment shown in the figure, the negative pressure component 20 is provided with mechanical seals 25 , 26 but, when desired, it is possible to use a sealing arrangement accomplished by means of blows, in itself known from the state of the art. In addition, the pocket space is also sealed in the longitudinal direction of the machine in the end areas of the negative pressure component and, across the width of a possible threading zone, an additional sealing arrangement to ensure a negative pressure across the width of a leader strip in the threading process (not shown). It is important to apply/control the negative pressure in the cross direction across the width of the web in order to impart adherence to the entire web but not suck too much through the wire past the part covered by the web, so that the edges of the web can separate from the wire causing problems in shrinkage prevention and in runnability.
[0033] In the embodiment shown in FIG. 1 , the pressure acting on the cylinder with a wire tension of 4 kN/m is about 4 kPa, which is a good value for preventing the cross-direction shrinkage of the web, the cylinder diameter being about 2 m. In that case, the negative pressure in the pocket space T is 3 kPa if the distance between the cylinder and the reversing roll is 15 mm at the most and the tension of the wire is the above-mentioned 4 kN/m. The negative pressure of the reversing roll for holding the web in contact with the wire corresponds to the negative pressure of the pocket space, i.e. 3 kPa.
[0034] In the arrangement of the invention, the distance from the drying cylinder 10 to the reversing cylinder 11 is short, preferably minimized according to the most demanding one of the fiber-web grades to be run, and this length of a common tangent between the points of contact is less than 1000 mm, most preferably 100-500 mm. By this is meant the theoretical path of the wire without a negative pressure in the negative pressure component and when the machine is at a standstill.
[0035] The negative pressure in the pocket produced by means of the negative pressure component 20 in accordance with the invention is 500-5000 Pa, advantageously 1000-2400 Pa depending on the diameter of the drying cylinder, for example, the diameter of the drying cylinder being 1850 mm and the diameter of the reversing roll being 1500 mm, as well as on the wire tension used, as appears from the following Table 1 showing the dependence of the negative pressure in the pocket, the size of the cylinder, and the tension of the wire on one another at a rough level. In the Table, the displacement of the gap opening from the cylinder caused by the bending of the wire has been adopted as a factor that limits the negative pressure in the pocket space.
[0000]
TABLE 1
Negative Pressure in
Cylinder
Theoretical
the pocket (kPa)
diameter (mm)
wire tension
3
1830
2.7
5
1830
4.6
3
3000
4.5
5
1000
2.5
[0036] FIG. 2 shows cross-direction shrinkage of a paper web attached to the wire by means of a pressure difference. The horizontal axis represents the dry solids content of the web and the vertical axis represents the cross-direction shrinkage of the web. The negative pressure used is indicated in the figure by schematic marks (squares and triangles) and, as is clear from the figure, when the negative pressure is 2 kPa, it has been possible to prevent cross-direction shrinkage to a sufficient degree, i.e. to a level of about 1-2%.
[0037] FIG. 3 shows one embodiment of the invention, in which the reversing roll 11 is a grooved roll. This embodiment is suitable for use, for example, when threading imposes no limitations on the choice of the type of reversing roll. In the example of the figure, the negative pressure in the negative pressure component 20 is produced by means of an external negative pressure source 28 . In other respects, the embodiment corresponds to that shown in FIG. 1 . The distance of the seals 25 , 26 from the wire F is maintained even though the negative pressure changes and the structures of the negative pressure component 20 bend because the bending occurs almost in the direction of the surfaces that are being sealed. The negative pressure in the reversing roll 11 can also be generated in other types of reversing roll, when desired, by means of the external negative pressure source 28 .
[0038] As shown in FIG. 4 , when a suction roll of the type marketed by Metso Paper, Inc. under the trademark VacRoll is used as the reversing roll 11 , it is possible to arrange the removal of air from the pocket space T by means of the reversing roll 11 through its shaft 29 .
[0039] In the embodiment according to FIG. 5 , a boundary-layer flow formed on the surface of the reversing roll 11 is prevented by means of a separate member 27 , for example, by means of a sealing member 27 or a doctor placed against the surface of the reversing roll, and a corresponding member can also be placed on the descending run of the wire. The arrangement reduces the generation of positive pressure into the closing gap of the reversing roll at high speeds and at low negative pressures in the pocket.
[0040] In the arrangement in accordance with the invention, the running distance of the wire F and the web W from the drying cylinder 10 to the reversing cylinder 11 is minimized, which reduces the problems of the arrangements known from the state of the art because the bending of the wire does not reach the seals any more, with the result that the seals do not wear even at a high negative pressure. On the other hand, in the threading situation when the web is not sealing the wire, there is less leakage air in the short run between the cylinder and the reversing roll and, thus, a higher negative pressure in the pocket and more reliable threading are also achieved in the threading process.
[0041] FIGS. 6A-6C schematically show the displacement of the point of separation as a function of wire tension. In the exemplifying calculations, the value of 1830 mm has been used as the diameter of the drying cylinder and the value of 1500 mm as the diameter of the reversing roll. In the example of FIG. 6A , the negative pressure in the pocket is 0.5 kPa, in the example of 6 B it is 1.0 kPa and in the example of 6 C it is 2 kPa. The figures show curves with different values of the distance between the surface of the drying cylinder and the surface of the reversing roll. As is clear from the figures, small wire tensions and high negative pressures in the pocket space cause a large displacement of the point of separation, and thus, a decrease in drying capacity, which can be remedied by reducing the distance between the roll surfaces, i.e. by shortening the transfer between the cylinder and the reversing roll. In practice, shrinkage prevention and runnability determine the negative pressure level needed in the pocket space, after which the displacement of the point of separation can be minimized by increasing wire tension and by bringing the roll surfaces closer to each other.
[0042] Above, the invention has been described only with reference to some of its advantageous exemplifying embodiments, but the invention is not by any means meant to be narrowly limited to the details of them. | A fiber-web machine dryer section has a drying group with single-wire draw so the drying wire (F) presses the web (W) against heated cylinder surfaces with the web (W) at the side of the outside curve of reversing cylinders ( 11 ) situated between drying cylinders ( 10, 12 ). A pocket space (T) is formed between two adjacent drying cylinders ( 10 ) and a reversing cylinder ( 11 ) situated between them, and the drying wire (F). A negative pressure component ( 20 ) placed in the pocket space (T) creates a pressure difference over the drying wire (F) and the web (W) for attaching the web (W) to the drying wire (F) so the cross-direction shrinkage of the web (W) is controllable. The wire tension (F) is maintained at a level help control cross-direction shrinkage of the web. The pocket space (T) is sealed by sealing members ( 25, 26 ) to maintain negative pressure in the pocket space. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a divisional application of, and claims priority from, U.S. patent application Ser. No. 10/886,780, filed Jul. 8, 2004, now U.S. Pat. No. 7,299,855, issued on Nov. 27, 2007 and entitled “Die Casting Reciprocator Safety Bar,” which is hereby incorporated by reference for all purposes.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
FIELD OF THE INVENTION
[0004] The present invention relates to automated die casting systems having reciprocating spray systems, and more particularly to a method of operating a reciprocating spray system to prevent the reciprocator from injuring an operator of the die casting system.
BACKGROUND OF THE INVENTION
[0005] Die casting is a manufacturing process for producing accurately dimensioned, sharply defined, smooth or textured-surface metal parts. A steel mold capable of producing tens of thousands of castings in rapid succession is made in at least two sections to permit removal of castings. These sections are mounted securely in a machine and are arranged so that one is stationary (fixed die half) while the other is moveable (injector die half). To begin the casting cycle, the die cavity is coated with a lubricant or mold release material. Then, the two die halves are clamped tightly together by the die casting machine. Molten metal is injected into the die cavity where it solidifies quickly. The die halves are drawn apart and the casting is ejected.
[0006] Die casting cycle times vary from less than one second for small components weighing less than one ounce, to thirty seconds or more for a casting of several pounds or more. Dies are filled quickly (normally between five and forty milliseconds) and metal is injected at high pressures (1,500 to over 4,500 psi). Nevertheless, modern automation technology gives close control over these values, thus producing castings with fine detail, close tolerances and high strength.
[0007] The die casting process has been automated to improve quality control, speed and safety. For example, safety interlocks prevent filling a mold with a shot of molten metal unless the mold is securely clamped shut and an outer door of a system enclosure is closed to protect the system operator. When a mold is opened after a casting cycle and the finished part is removed, an automated reciprocating sprayer or reciprocator may move down between the open die halves to spray on a lubricant on the die cavity. As the reciprocator returns to its rest position, it blows high pressure air on the mold cavity to remove excess lubricant and dry the cavity faces. The reciprocator is typically activated by the operator after opening the safety door to remove the finished die casting. Regulations have been proposed to require a safety door interlock with the reciprocator to insure that the reciprocator cannot move down when the door is open because the operator may still be in the casting enclosure. However, such an interlock arrangement would add a significant amount of time to the casting cycle time, thereby reducing the productivity of the die casting system.
SUMMARY OF THE INVENTION
[0008] The present invention provides a method for operating an automated reciprocator in a die casting system. As a reciprocator is moved between two die halves and a fluid is applied to the dies with the reciprocator, a safety bar is moved ahead of the reciprocator. Any objects in the path of the reciprocator are detected by contact with the safety bar.
[0009] In an embodiment, the method includes stopping operation of the reciprocator when an object is detected by the safety bar.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a simplified plan view of a typical die casting system according to the present invention.
[0011] FIG. 2 is an elevation view of an open mold illustrating operation of a reciprocator according to the present invention.
[0012] FIG. 3 is a side view of a die casting reciprocator showing details of a safety bar according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] FIG. 1 is a simplified plan view of a typical die casting system 10 according to the present invention. A stationary or fixed die half 12 and a moveable or injector die half 14 are shown meeting at a parting line 16 . Above the fixed die half 12 is shown a reciprocator 18 , described in more detail below. The die or mold 12 , 14 is surrounded by an enclosure 20 having an entrance 22 . A door 24 is provided across entrance 22 . A system control panel 26 is typically located near the door 24 . A reciprocator activating switch or button 28 may be provided on the enclosure 20 , just inside the door 24 .
[0014] FIG. 2 is an elevation view of the mold 12 , 14 shown in its open position with the reciprocator 18 beginning its operating cycle. A die face 30 of moveable die half 14 is visible in FIG. 2 . Guide pins 32 are provided to insure proper alignment of the mold 12 , 14 , when the pins 32 engage corresponding holes in the fixed die half 12 . The reciprocator 18 includes a lubricant sprayer 34 with nozzles 36 , air nozzles 38 , and a safety bar 40 all carried on a moveable frame 42 . After the die halves 12 and 14 have opened as illustrated in FIG. 2 , and a finished part has been removed, the reciprocator 18 moves downward as indicated by the arrow 44 . While moving downward, lubricant, which may be a mold release compound carried in water, is sprayed through the nozzles 36 onto the faces of the die cavity. After the reciprocator 18 reaches the bottom of the mold 12 , 14 , the lubricant sprayer 34 is turned off and high pressure air is supplied to nozzles 38 , preferably through the frame 42 . The reciprocator is then move upward to a rest or storage position above the mold 12 , 14 as indicated in FIG. 1 . During the upward movement, the air from nozzles 38 blows off any excess lubricant and dries the faces of the mold cavity, e.g. 30 .
[0015] FIG. 3 provides a side view of a die casting reciprocator 18 showing more details of a safety bar 40 according to the present invention. Parts shown in FIGS. 1 and 2 are given the same reference numbers in FIG. 3 . The frame 42 of the reciprocator 18 may be made of square cross section hollow tubing which may be used to convey high pressure air to the blow off nozzles 38 . Suitable hoses may be provided to convey lubricant to the sprayer 34 and through it to the sprayer nozzles 36 . Conventional automated or robotic systems may be provided for lowering and raising the frame 42 as needed.
[0016] As shown in the figures, the safety bar 40 is a simple rectangular element having length and width dimensions at least as large as the plan view dimensions of the reciprocator as shown in FIG. 1 . The safety bar 40 may be a solid sheet of a suitable material or may be made from a framework of individual parts leaving some open spaces. It is preferred that the all edges of the safety bar be continuous so that it moves through or sweeps out a space having plan view length and width dimensions at least as large as the space through which the reciprocator 18 moves in its downward travel.
[0017] The safety bar 40 is movably supported from the lower side of the reciprocator 18 , e.g. by a pair of bolts 46 attached at their upper ends to the frame 42 . The safety bar 40 may have clearance holes for receiving the bolts 46 . A nut 48 or other retainer means may be attached to the lower end of each bolt 46 below the safety bar 40 to suspend the safety bar 40 at a selected distance below the reciprocator 18 . While gravity tends to hold the safety bar 40 in its lowermost position on the bolts 46 , it is preferred to provide springs 50 around the bolts 46 to further urge the safety bar 40 into this position.
[0018] In this embodiment, a proximity sensor 52 is carried on each end of the safety bar 40 , to detect upward movement of the safety bar 40 relative to the reciprocator 18 . The proximity sensor may be an inductive sensor sold by Turck, Inc. of Minneapolis, Minn. under the Part Number Bi 2-EG08K-AP6X-V1131 and ID Number S4669450. A metal extension 54 may be provided on the frame 42 proximate each of the proximity sensors 52 when the safety bar 40 is in its lowermost position. The hall effect sensors 52 provide a closed circuit between its wire leads 56 when they are near a metal object and an open circuit between leads 56 when they move away from the metal object. In this embodiment, the leads 56 of both sensors 52 are connected in series and the circuit is connected to an input of the control system 26 .
[0019] As noted above, in normal operation of the die casting system of FIGS. 1 and 2 , the operator prefers to activate the reciprocator 18 cycle as he enters the door 22 to remove the just cast part. The reciprocator would then begin it downward travel before the operator can completely remove the finished part and exit the enclosure 20 . During normal operations there is sufficient time for the operator to exit. By following this procedure, a finished part, e.g. a gas grill top or bottom housing, may be cast in a 25 second cycle time. If the operator is required to exit and close the door 24 before the reciprocator can start its cycle, at least 5 more seconds will be added to the cycle time, reducing system productivity by about twenty percent.
[0020] With the system of the present invention, the operator may activate the reciprocator as he enters the enclosure 20 to remove a finished part without danger of being injured by contact with the reciprocator as it cycles. If for any reason the operator does not exit the enclosure 20 , but remains in the travel path of the reciprocator 18 , the safety bar 40 will contact the operator before any other part of the reciprocator can reach the operator. With only slight force on the safety bar 40 , it will move upward relative to the reciprocator 18 and one or both proximity detectors 52 will move away from its corresponding post 54 . The circuit in one or both detectors 52 will open and the control system 26 will instantly stop movement of the reciprocator bar 18 and stop the flow of lubricant through the nozzles 36 . If desired, the control system may be programmed to return the reciprocator to its uppermost or rest position above the mold 12 , 14 . In a preferred embodiment, the control system 26 is programmed to not allow the operator to restart the reciprocator by pushing the button 28 , but to instead require the operator to physically go to the control system 26 and reset the reciprocator.
[0021] While a particular proximity sensor, a hall effect device, was used in the preferred embodiment, it is apparent that many other devices could be substituted. For example, magnetic relays such as those used on home security systems could be used. The metal extensions 54 could be magnets positioned to close such relays carried on the safety bar 40 . Various optical sensors may also be used. Mechanically operated switches or relays may be coupled between the safety bar 40 and the reciprocator 18 to close or open a circuit in response to movement of the safety bar 40 relative to the reciprocator 18 . In the preferred embodiment, the proximity sensor is carried on the safety bar 40 and the material being sensed, e.g. bars 54 , is carried on the reciprocator frame 42 . It is apparent that the sensors 52 could be mounted on the frame 42 and the material being sensed, e.g. a magnet, could be carried on the safety bar 40 .
[0022] While the bolts 46 are shown as fixed to the frame 42 and slidably coupled to the safety bar 40 , it is apparent that the bolts could be fixed to the safety bar 40 and slidably coupled to the reciprocator 18 .
[0023] While the present invention has been described in terms of preventing injury to the operator of the die casting system, it is also useful for preventing property damage. For example, there could be a malfunction of the system which results in the movable die half 14 failing to move to its fully open position. In that case, the reciprocator may collide with the die half 14 damaging the die and/or the reciprocator itself. Damage to either would be expensive to repair and may result in extended downtime for the die casting system. The present invention reduces the chances of such system damage by stopping the reciprocator if it contacts any other part of the die casting system as it cycles downward.
[0024] While the present invention has been illustrated and described with reference to particular components and methods of operation, it is apparent that various substitutions of components and changes in methods of operation can be made within the scope of the present invention as defined by the appended claims. | A method for operating an automated reciprocator for applying lubricant in a die casting system. As a reciprocator is moved between two die halves and a fluid is applied to the dies with the reciprocator, a safety bar is moved ahead of the reciprocator. Any objects in the path of the reciprocator are detected by contact with the safety bar. If the safety bar contacts an object as the reciprocator is moving down, a sensor signals a control system and the reciprocator is stopped. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 62/293,071 (Attorney Docket No. 50174-733.101), filed Feb. 9, 2016, the full disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to the medical technology field, and more specifically to a new and useful system for positioning and contouring a tissue body in an imaging field.
[0004] Early detection of breast cancer and other types of cancer typically result in a higher survival rate. Despite a widely accepted standard of mammography screenings for breast cancer detection, there are many reasons that cancer is often not detected early. In particular, drawbacks of mammography include: limited performance among women with dense breast tissue, a high rate of “false alarms” that lead to unnecessary biopsies that are collectively expensive and result in emotional duress in patients, and low participation in breast screening, as a result of factors such as fear of radiation and discomfort. In particular, the mammography procedure involves compression of the breast tissue between parallel plates to increase the X-ray image quality by providing a more uniform tissue thickness and stabilizing the tissue. However, this compression is typically uncomfortable, or even painful.
[0005] A relatively new ultrasound imaging technique, referred to as ultrasound tomography, promises to be a practical alternative to mammography without tissue compression and many other drawbacks. With ultrasound tomography, the patient lies on a support surface in a prone position with a breast depending through an opening in the surface into a water bath. A ring or other ultrasonic transducer assembly is then scanned vertically to acquire the image data to be analyzed. Some of the proposed ultrasound tomography systems employ a magnetic or other device to capture the nipple region of the breast to extend and stabilize the breast during imaging. While at least partially effective, such prior breast extending apparatus can be uncomfortable, can deform the breast into a conical shape which is not optimum for imaging, do not provide repeatable shaping of the breast, and cannot accommodate breast of differing sizes.
[0006] For these reasons, it would be desirable to provide systems and methods for performing breast and other ultrasound tomography which provide improved positioning of the breast or other tissue body, improved patient comfort, and which accommodate size variations of the breasts and other tissue bodies among different patients and which allow scans to be performed in a repeatable manner in order to monitor changes in a tissue over time in an individual patient. At least some of these objectives will be met by the inventions described and claimed herein.
[0007] 2. Description of the Background Art
[0008] Commonly owned US2014/0276068 and US 2013/0204136 describe an interface system for supporting a patient and exposing a depending breast in an ultrasonic tomography system. U.S. Pat. No. 7,771,360 and U.S. Pat. No. 7,699,783 describe other breast scanning systems having a magnetic capture device for a nipple region of the breast.
SUMMARY OF THE INVENTION
[0009] In a first aspect of the present invention, a tissue positioning system for contouring a patient tissue volume, such as a human breast, comprises an axially displaceable interface having a surface configured to engage and attach the tissue volume or a portion thereof. Typically, a low pressure source or appliance is configured to apply low pressure to or over the surface of the displaceable interface. The low pressure secures a target region of tissue volume, such as a nipple region of a breast, to the surface, and the axially displaceable interface is biased to pull, elongate, and/or contour the tissue volume when the tissue volume is secured to the surface. For example, elongating a breast can cause the breast to assume a generally cylindrical shape to enhance subsequent imaging, treatment, interventions, or the like.
[0010] The axially displaceable interface surface is typically formed from a gel, preferably a gel that is engineered to be acoustically/ultrasonically invisible, e.g. by formulating the gel to have a speed of sound equivalent to water at body temperature and to be disposable (single use) both for hygienic reasons. Preferred gels are cross-linking polysaccharide, such as carrageenan (seaweed derived). The gel pads may be fabricated using conventional techniques, such as mixing an aqueous solution, heating the solution, and pouring into a net-shape mold, cooling).
[0011] In a particular embodiment, the tissue positioning system may further comprise a telescoping, accordion or other extendable/retractable support attached to a side of the displaceable interface opposite to the side engaged by the breast or other tissue volume. The extendable/retractable support typically has an interior with a variable volume. In such cases the low pressure force may be connected to apply a low pressure within the interior of the extendable/retractable support in order to bias the displaceable member. Optionally, a coil spring element is disposed within the interior volume of the extendable/retractable support to axially extend the surface of the displaceable interface and apply a spring force against the tissue volume. In such cases, the vacuum applied internally to the extendable/retractable support will be sufficient to pull and elongate the tissue volume against the spring force of the coil spring.
[0012] In other embodiments of the tissue positioning system the coil spring element may itself serve as the extendable/retractable support attached to the axially displaceable interface. The spring element may comprise, for example, a coil spring which is aligned perpendicularly to the surface of the axially displaceable interface engages the tissue volume. The spring may be covered with a sleeve, shroud, or other containment structure to define a sealed interior for connection to the low pressure source to axially bias displaceable interface against the spring force to pull, elongate, and/or contour the tissue volume captured by the interface surface.
[0013] In a second aspect of the present invention, a system for scanning a breast tissue volume of the patient comprises a table or base having a horizontal surface with an opening therein. The table or base has an upper surface configured to support the patient in a prone position with a breast depending through the opening. An imaging device is disposed below the base and configured to image the breast as it depends through the opening. A vertically displaceable interface has a surface configured to engage tissue surrounding a nipple of the breast, and a low pressure source is configured to apply a low pressure to the surface of the displaceable interface. The low pressure secures the breast tissue to the interface surface, and the vertically displaceable interface is biased to pull, elongate, and contour the breast tissue, typically to “cylindricalize” the breast, while the breast tissue is secured to the interface surface.
[0014] In specific aspects, the imaging device comprises an ultrasonic transducer array, and the system further comprises a receptacle or “well” disposed beneath the opening in the horizontal surface of the base, where the receptacle or well is configured to contain water or other ultrasonically transmissive medium. The ultrasonic transducer array is located within the receptacle or well and is configured to scan breast tissue while the tissue is immersed within the water or other ultrasonically transmissive medium.
[0015] The system for scanning breast tissue typically further comprises a telescoping or other extendable/retractable support having an upper end attached to a side of the displaceable interface opposite the side engaged by the breast tissue and located within the well/receptacle. The extendable/retractable support defines an interior having a variable volume, and the low pressure source is typically connected to apply the low pressure within said interior of the support to draw and engage the breast tissue to the interface.
[0016] The breast tissue scanning system typically further comprises a coil spring element within the interior volume of the extendable/retractable support. The spring element will be expanded or lengthened to position the surface of the axially displaceable interface toward the breast tissue and will typically thereafter apply a spring force that acts against the low pressure or other biasing forces that pull the interface to elongate and cylindricalize the breast. The low pressure source is typically configured to apply a sufficient force to the interface to pull and elongate the breast tissue volume against the spring force of the coil spring element.
[0017] In exemplary embodiments, the imaging device comprises an ultrasonic ring imaging array configured to circumscribe and translate over the breast. The imaging device will typically further comprise a restrictor ring over the ultrasonic ring imaging array, where the restrictor ring circumferentially constricts the breast volume so that breast tissue does not contact the ultrasonic ring imaging array as the ring is translated over the breast. The restrictor ring may have different sizes or shapes as needed, to accommodate different tissue sizes and/or shape to be scanned.
[0018] In a third aspect of the present invention, a method for imaging a patient's breast comprises locating the patient in a prone position with the breast depending downwardly through an opening in a horizontal patient support surface of a table or other base. A surface of a vertically displaceable interface is engaged against the tissue surrounding the nipple of the breast, and a low pressure is applied to the interface surface to seal the breast to the vertically displaceable interface, and the interface is biased vertically downward to elongate and contour the breast. The breast is then imaged with a device disposed below the horizontal patient support surface while the breast remains contoured.
[0019] In specific aspects of the method, imaging comprises ultrasonic imaging and the breast is immersed in a well or other receptacle containing water or other ultrasonically transmissive medium disposed below the opening in the horizontal surface. The imaging device is typically an ultrasonic transducer ring array located within the well which circumscribes breast to effect the scanning.
[0020] The vertically displaceable interface is supported by a telescoping or other extendable/retractable support located within the well, and the support typically has an upper end attached to a lower side of the displaceable interface. The extendable/retractable support typically has an interior with a variable volume, and a low pressure source may be connected to apply low pressure within the interior of the telescoping support to draw and engage the breast tissue to the interior surface. Typically, a coil spring element within the interior volume of the extendable/retractable support biases the surface of the interface vertically towards the breast tissue prior to engagement. The low pressure source typically applies sufficient force to pull and engage the breast tissue volume against the spring force of the coil spring. Imaging typically comprises circumscribing and translating an ultrasonic ring imaging array over the breast, and the ultrasonic ring imaging array may comprise a restrictor ring which displaces the breast so that breast tissue does not contact the ultrasonic ring imaging ray as the ring is translated over the breast.
INCORPORATION BY REFERENCE
[0021] All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The novel features of the invention are set forth with particularity in the appended claims. A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the invention are utilized, and the accompanying drawings of which:
[0023] FIGS. 1A -1C illustrate a breast tomography system of the type that can employ the breast shaping device and tissue restrictor ring of the present invention.
[0024] FIGS. 2A-2C illustrate a first embodiment of a breast shaping device constructed in accordance with the principles of the present invention.
[0025] FIGS. 3A and 3B are detailed views of a gel pad and low pressure connector segment used in the breast shaping device of FIGS. 2A-2C . FIG. 3A is a top perspective view with a portion cut-away, and FIG. 3B is a bottom perspective view with the low pressure connector segment removed.
[0026] FIGS. 4A and 4B are detailed views of a telescoping support for the gel pad and low pressure connector used in the breast shaping device if FIGS. 2A-2C , shown in a vertically extended configuration in FIGS. 4A and vertically retracted configuration in FIG. 4B .
[0027] FIGS. 5A and 5B illustrate an alternative gel pad and low pressure connector configuration having a flat upper surface to enhance cylindrical shaping of the breast.
[0028] FIGS. 6A-6C illustrate a tissue restrictor ring constructed in accordance with the principles of the present invention. FIG. 6A shows the tissue restrictor ring itself. FIG. 6B shows placement of the tissue restrictor ring on a ring imaging transducer relative to a telescoping support supporting the alternative gel pad and low pressure connector configuration of FIGS. 5A and 5B . FIG. 6C shows a variation of the telescoping support supporting with a shaper cup intended to more fully cylindricalize smaller breasts.
[0029] FIGS. 7A-7G illustrate the steps of using an assembly of the tissue restrictor ring, ring imaging transducer, and improved breast shaping outcome with alternate gel pad of FIGS. 6A and 6B in a breast tomography system of the type shown in FIGS. 1A-1C to image a breast.
[0030] FIGS. 8A-8D are breast tomography images taken using a breast tomography system having a breast shaping device in accordance with the principles of the methods of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The following description of preferred embodiments of the invention is not intended to limit the invention to these preferred embodiments, but rather to enable any person skilled in the art to make and use this invention.
[0032] Referring to FIGS. 1A to 1C , a breast tomography system 100 of the type that can employ the breast shaping device and the tissue restrictor ring of the present invention comprises an ultrasonic imaging ring array 102 including a plurality of ultrasound emitters 102 and ultrasonic receivers 106 . The ultrasonic imaging ring array 102 may be configured to surround a breast or other tissue volume so that the plurality of ultrasound emitters 102 emits acoustic waveforms 112 toward the volume of tissue. The plurality of ultrasound receivers 106 is configured to receive acoustic waveforms scattered by the volume of tissue, and a processor 108 is configured to generate a tomographic images based on the received acoustic waveforms as described in commonly owned, copending application nos. PCT/US2016/050014; Ser Nos. 14/817,470; 14/811,316; 18/703,746; 14/819,091; 14/208, 181; 14/015,459; and 13/894,202, the full disclosures of which are incorporated herein by reference. The system 100 can further include a display 110 on which the acoustic data and/or generated image rendering can be displayed, such as to a medical practitioner and/or the patient. The ultrasonic imaging ring array 102 is configured to scan vertically to produce an image of the breast B which depends through an opening or aperture 116 (see FIGS. 7A-7C ) in a table 118 having an upper surface for supporting patient P in a prone position. The breast is immersed in water or other ultrasonically transmissive liquid held in a reservoir enclosure 120 located beneath the table. As described in greater detail below, the breast shaping device and the tissue restrictor ring of the present invention are located within the reservoir enclosure 120 .
[0033] As shown in FIGS. 2A-2C , a breast or other tissue shaping device (BSD) 130 for positioning a tissue body includes a toroidal pad 132 having an opening 134 for receiving a target region on a tissue body, such as a nipple region N on a breast B. A low-pressure or “suction” source 136 is coupled to the toroidal pad 132 through an interior of, or interior passage within, an extendable/retractable supporting column 138 , which is typically a telescoping column including an upper chamber or segment 138 a, a middle segment 138 b, and a lower segment 138 c. While three segments have been found to be a useful number, it will be appreciated that as few as two or as many as five or more segments might also find use. Other non-telescoping designs, such as accordion designs, could also be employed. In all cases, however, the supporting column should be sufficiently sealed so that the low pressure source coupled to the column can be transmitted into the interior of the column and to the toroidal pad 132 .
[0034] The BSD 130 functions to comfortably immobilize a breast B or other tissue body of a patient, such that the tissue body can be properly scanned e.g., for monitoring, for medical diagnostics, etc. Additionally or alternatively, the BSD 130 can pull breast or other the tissue body away from the body of the patient, e.g., the breast can be pulled away from chest wall of the patient, thereby enabling a larger percentage of the tissue body to be scanned, e.g., for lesions. The BSD 130 can additionally or alternatively function to properly position a breast or other tissue body within a scanning region of an imaging system, thereby increasing efficiency in processing of image data or other data. The BSD 130 can additionally or alternatively function to stretch the tissue body, thereby reducing a thickness of tissue structures (e.g., skin) in order to provide an improved scan of the tissue body. Finally, the BSD 130 can provide a sanitary means for positioning the tissue body, for a scanning system that is used for multiple patients.
[0035] In a specific example, the BSD 130 immobilizes a volume of breast tissue to enable scanning of smaller breasts by elongating and contouring the breast relative to the chest wall to reduce glancing angle effects in relation to incident waves on a tissue surface, enable detection of legions closer to the chest wall by pulling a higher percentage of breast tissue away from the chest wall, improving centering of the breast in a scanning region of interest to reduce computational load in post-processing of scan data ,e.g., with sound speed measurements, with attenuation measurements, with reflection measurements, with time of flight measurements, with density measurements, with stiffness measurements, etc., and induce elongation (e.g., “cylindricalize”) of the volume of breast tissue, thereby inducing a reduction in thickness of skin of the breast to improve scan data.
[0036] The BSD 130 is preferably configured to be used within a volume of an ultrasonically transmissive scanning medium (e.g., water) retained within the reservoir enclosure 120 of the ultrasound tomography system 100 . The BSD 130 properly immobilizes the breast or other tissue body within the scanning medium so that the tissue body can be properly scanned without disturbance caused by tissue buoyancy. As such, the system can interface with embodiments, variations, and examples of one or more elements of the system for providing scanning medium described in U.S. application Ser. No. 14/811,316, entitled “System for Providing Scanning Medium” and filed on 28 Jul. 2015, which is herein incorporated in its entirety by this reference. Additionally or alternatively, the system 100 can interface with embodiments, variations, and examples of one or more elements of the patient interface system configured to support the body of a patient during a scan, as described in U.S. application Ser. No. 14/208,181, entitled “Patient Interface System” which has been previously incorporated herein by reference. However, the BSD 130 for positioning a tissue body described herein can additionally or alternatively interface with any other suitable elements/systems.
[0037] As shown in FIGS. 3A and 3B , the toroidal pad 132 is formed from a silicone rubber or similar complaint material, and a bottom surface of the toroidal pad 132 is typically attached to an interface plate 140 with a plurality of holes or perforations 142 therein. The opening 134 is configured to receive a target region of the tissue body, such as the region surrounding the nipple N of the breast B, as seen in FIGS. 1A-1C . The opening 134 will usually have a funnel or conical portion formed in the upper surface of the toroidal pad 132 and functions to comfortably receive ad attach the tissue body during a scan.
[0038] While preferably toroidal, the pad 132 could have other, non-toroidal geometries, such as ovoid, polygonal, and the like. The pad 132 will have a thickness, a top surface, a bottom surface, and opening 134 through the thickness that allows negative pressure to be transmitted to tissue engaged against the top surface and/or received within the opening. Preferably, the dimensions of the pad 132 (in combination with the material properties) provide a pad with a suitable buoyant behavior for scanning applications in a scanning medium used. For instance, the pad 132 can be configured such that it does not float in scanning medium in an undesired manner. In one variation, the footprint of the pad 132 is circular; however, the footprint can alternatively have any other suitable shape (e.g., ellipsoidal, rectangular, polygonal, amorphous, etc.). In one variation, the top surface is approximately frustoconical (e.g., shaped as an inverted funnel) in order to comfortably support a portion of the tissue body. The top surface can alternatively have any other suitable profile (e.g., a profile that is complementary to or matched to a specific tissue body). In another variation, the top surface is substantially planar (although a slight degree of convexity or concavity is acceptable) with low pressure plenums about the periphery. The shape of the bottom surface is less critical, usually being substantially planar; however, in alternative variations, the bottom surface can have any other suitable profile. In one variation, an opening in the bottom surface to connect the low pressure sources is circular and centrally located (e.g., concentric with the inverted funnel of the top surface or configured to branch into plenums about the periphery of the top surface); however, in alternative variations, the opening can alternatively have any other suitable cross section (e.g., ellipsoidal, rectangular, polygonal, amorphous, etc.) and/or be non-centrally located relative to the top surface of the pad 132 . Furthermore, the pad 132 and/or the opening may not have constant cross sections through the thickness of the pad 132 . For instance, the pad 132 can taper in profile from its bottom surface to its top surface, and/or the opening can have a different cross section at the bottom surface in comparison to the cross section of the opening at the top surface, in order to accommodate the reference region of the tissue body and enable immobilization of the tissue body comfortably, by way of the negative pressure generated by the low pressure subsystem 136 .
[0039] In specific examples, the pad 132 has a cylindrical outer surface and has an outer diameter from 0.5 cm to 3 cm; the top surface is an inverted frustoconical surface having a base angle from 5° to 85°, the thickness of the pad is from 1 cm to 5 cm, the bottom surface is substantially planar, and the opening is a circular opening through the thickness of the pad, with a constant cross section having a diameter from 0.5cm to 3 cm. While one opening is described above, the pad 132 can alternatively have multiple openings in order to immobilize the tissue body at multiple points on the surface of the tissue body. In specific examples, the pad 132 is preferably configured as a “one-size-fits-all” element that accommodates a wide variety of breast morphologies; however, the pad 132 can additionally or alternatively be customized to the morphology of each patient being scanned.
[0040] In relation to the top surface and the opening, the reference or target region of the tissue body is preferably a most extreme region of the tissue body (e.g. a region that protrudes or otherwise provides an attachment location such as a nipple on a breast), in the orientation in which the patient interfaces with the pad 132 . In the context of a volume of breast tissue, the reference region can be a most-anterior region of the breast (e.g., the nipple region), such that the nipple region of the breast is retained at the opening of the pad 132 to properly immobilize the breast of a patient who is in a prone position. However, the target or reference region can additionally or alternatively be any other suitable region of a tissue body that facilitates immobilization of the tissue body.
[0041] The pad 132 is preferably composed of a material having a high degree of acoustic transparency, such that the pad does not interfere with proper scanning of regions of the tissue body within the pad 132 . As such, in some variations, the material composition of the pad 132 can thus provide closer focusing at the interface between the tissue body and the pad 132 (e.g., in ultrasound imaging applications). In variations, the pad 132 is composed of a polymeric material (e.g., plastic, hydrogel, etc.), and in specific examples can include a material composed of one or more of: agar, guar bean, and carrageenan; however, the pad 132 can additionally or alternatively comprise any other suitable material (e.g., natural material, synthetic material). For instance, the pad 132 can be composed of a synthetic polymer (e.g., polyurethane) processed to have desired acoustic or other characteristics. The material is preferably substantially stiff, but compliant in supporting the tissue body comfortably; however, the material can alternatively have any other suitable properties (e.g., hardness, stiffness, porosity, transparency, thermal characteristics, optical characteristics, electrical conductivity characteristics, rheological characteristics, etc.). Furthermore, the pad 132 can be configured for single-use applications (e.g., to provide a sanitary option) and/or can be configured to controllably degrade (e.g., in a manner that does not affect fluid handling components of the scanning system) after a certain number of uses in order to prevent repeated uses of the pad 132 . However, the pad 132 can alternatively be configured to be reusable. In a specific example, the pad can comprise a blend of agar, guar bean, and carrageenan, and be configured to have a specific gravity of 1.06 (e.g., slightly heavier than water); however, the pad 132 can have any other suitable composition.
[0042] The interface plate 140 functions to allow the pad 132 to be properly seated at a receiving portion of a low pressure system as described below. In more detail, the interface plate can allow the pad 132 and the opening 134 of the pad 132 to be properly aligned and positioned in relation to the segments 138 a, 138 b, and 138 c of the support column 138 for transmission of a low pressure from source 136 , thereby allowing the target region of the tissue body to be drawn into the opening of the pad 132 .
[0043] Referring to FIGS. 4A and 4B , the lower segment 138 c of the extendable/retractable support column 138 of the BSD 130 is mounted on or through a bottom plate 146 of the reservoir enclosure 120 of the tomography system 100 . The lower segment 138 c is connected to the low pressure source 136 ( FIG. 2A ) by a connector 148 . The middle segment 138 b of the extendable/retractable support column 138 is translatable relative to the lower segment 138 a, and the upper segment 138 c is translatable relative to the middle segment 138 b. During operation, the toroidal pad 132 preferably translates with the upper segment 138 a to a position that comfortably engages the tissue body, and the target region of the tissue body is preferably retained at the opening 134 of the toroidal pad 132 by way of the negative pressure generated by the low pressure system 136 , such that the tissue body is properly immobilized during scanning (e.g., using a tomography system). The low pressure system 136 thus functions to both (1) generate the negative pressure for retaining the tissue body in position and (2) comfortably support the tissue body at an appropriate position during scanning.
[0044] The segments 138 a, 138 b, and 138 c of the column support 138 are preferably substantially cylindrical, having a wall with an appropriate thickness and a longitudinal axis that is parallel to and concentrically aligned with the opening 134 of the pad 132 in assembled system. Furthermore, the upper segment 138 a is preferably oriented vertically, such that the support column 138 can properly immobilize a tissue body (e.g., volume of breast tissue) for a patient who is interfacing with the BSD 130 in a prone position. However, in alternative variations, the segments 138 a, 13 b, and 138 c can have any other suitable shapes (e.g., non-cylindrical, polygonal, prismatic, etc.) and/or orientation that provides proper relative motion between the segments.
[0045] The column 138 including segments 138 a, 138 b, and 138 c can be composed of a polymeric material (e.g., a plastic), a metallic material, a composite material, a ceramic material, a glass, and/or any other suitable material. Some or all of the segments 138 a, 138 b, and 138 c are preferably configured to support the negative pressures and/or positive pressures implemented in the BSD 130 without deformation. The segments, however, can alternatively have any other suitable composition and/or be configured with any other suitable mechanical properties. In some cases, one or more of the segments 138 a, 138 b, and 138 c can include stops configured to define limits of the relative range of motion of the segments. Additionally or alternatively, the expansion range of the segments can be defined in any other suitable manner, as described in more detail below.
[0046] The lower segment 138 c preferably has a base region and a superior region, wherein the base region is coupled to the base plate 146 of a imaging tank in the reservoir enclosure 120 associated with the tomography system 100 , and the superior region is open to interface with the middle segment 138 b and upper segment 138 a. Preferably, the low pressure source 136 connects with the lower segment 138 c via the connector 148 near the base, but the low pressure source 136 can additionally or alternatively interface with any of the segments at any level in the column. Still alternatively, the low pressure source 136 can interface with an internal portion of the supporting column 138 or can be connected to the opening 134 in the pad 132 by a separate conduit.
[0047] Preferably, the low pressure source 136 can generate a negative pressure of up to approximately 200 mmHg in order to retain the tissue body in a comfortable manner (and as regulated by the U.S. Food and Drug Administration, in some embodiments). In one variation, the low pressure source can provide a negative pressure over a range that includes the range between 100 and 125 mmHg, which, in a specific embodiment, can properly immobilize the tissue body without causing discomfort. However, the low pressure source 136 can alternatively generate pressures over any other suitable range, and can be configured to generate negative pressures and/or positive pressures. Furthermore, the low pressure source 136 can be configured to generate appropriate pressures during different phases of scanning (e.g., in relation to patient preparation, initialization, mid-scan, scan completion, etc.).
[0048] For instance, in some variations, the low pressure source 136 can provide a higher negative pressure (e.g., 125 mmHg) during initialization phases when the tissue body of the patient is first being immobilized; however, once the tissue body is properly immobilized and scanning initiates, the pressure value can be reduced (e.g., to 50 mmHg), thereby increasing comfort while still allowing the tissue body to be effectively retained in position. Finally, when scanning is completed, the negative pressure can be eliminated, or even reversed (e.g., to expel the tissue body from the low pressure subsystem). In relation to varying the low pressure during operation of the system, the low pressure established by the low pressure source 136 can be adjusted manually (e.g., using an external control module). However, the pressure established by the low pressure source 136 additionally or alternatively can be adjusted automatically (e.g., by using pressure sensors that enable coordination between the low pressure source 136 and phases of scanning established by related systems, by using a mechanism that automatically reduces or increases pressure during scanning phases as described in more detail below, etc.).
[0049] The low pressure source 136 can be controlled with any suitable controller and, as such, can have an associated safety mechanism such that a maximum pressure value is never exceeded. In a specific example, the maximum pressure can be 200 mmHg; however, in alternative variations, the maximum pressure can be any other suitable pressure value. The low pressure source 136 can additionally or alternatively include a manual shutoff valve and/or any other suitable shutoff system.
[0050] The column segments 138 a, 138 b, and 138 c are configured to be translatable relative to each other in a telescoping manner and the contiguous interiors of the segments coupled the opening 134 of the pad 132 to the low pressure source 136 . In some variations, the telescoping structure can also function as a portion of a mechanism that automatically adjusts low pressures provided by the low pressure source 136 , during different phases of scanning/patient orientation relative to the system. The segments 138 a, 138 b, and 138 c are preferably configured to form a sufficiently tight sliding fit such that the interface between the segments prevents a significant low pressure leak from occurring, while still allowing sliding motion between the first and the second chambers 130 , 140 to occur.
[0051] Preferably, the segments 138 a, 138 b, and 138 c are concentrically aligned, such that each segment can provide a telescoping mechanism that allows the tissue body to be properly supported, at the appropriate depth within the scanning tank during scanning.
[0052] In one variation the support column 138 includes a coil spring 150 which is in extension and which pushes the segments 138 a, 138 b, and 138 c apart so that the column is in its fully extended configuration, as shown in FIGS. 2A and 4A . The spring 150 also serves to smooth out oscillations resulting from floatation of the pad 132 in water or other ultrasonically transmissive medium. The spring 150 can also provide an appropriate counterforce to facilitate proper latching of the pad 132 to the coupling interface 150 and/or of the tissue body to the pad 132 . In smoothing out oscillations, the spring 150 can thus contribute to mass-spring-damper behavior of the low pressure subsystem 136 in interfacing with the tissue volume. In variations, the spring has a spring constant from 0.5 to 10 N/cm; however, the spring 150 can alternatively have any other suitable spring constant. As such, in relation to dynamically supporting the tissue body at a suitable depth within the scanning tank, the spring can allow the segments 138 a, 138 b, and 138 c to passively provide support, while reducing oscillations when the breast or other tissue body interfaces with the pad 132 , until the tissue body reaches a natural resting state within the scanning tank.
[0053] In similar, but alternative variations, the spring can be replaced with magnetic elements, wherein opposing polarities of the magnetic elements can provide spring-like behavior between the column segments 138 a, 138 b, and 138 c. Still alternatively, the segments 138 a, 138 b, and 138 c can be configured to translate relative to each other with the assistance of an actuator (e.g., a hydraulic actuator, a linear actuator, etc.) that allows the first and the support column 138 to have expanded and contracted configurations. The support column can alternatively be configured to have expanded and contractions in any other suitable manner.
[0054] As mentioned above, in some variations, the segments 138 a, 138 b, and 13 c can also function as a portion of a mechanism that automatically adjusts low pressures provided by the low pressure source 136 , during different phases of scanning/patient orientation relative to the system. In one such variation, the middle segment 138 b its down stroke, can include appropriate cutout portions that cut off the inlet of the low pressure source 136 into the first chamber 130 , thereby automatically reducing the negative pressure as the tissue body settles into the position in which it is immobilized. Additionally or alternatively, in another variation, motion of one segment relative to another segment can open and/or close a valve associated with the low pressure source 136 , in order to modulate pressure. Other variations of modulating pressure can, however, operate in any other suitable manner.
[0055] In variations, the pad 132 can translate with the upper segment 138 a as low pressure generated within the column retracts the column and pulls down the target region of the tissue body, such as the nipple region N of the breast B, as shown in FIGS. 2B (where the nipple is first attached, reducing pressure within the column) and FIG. 2C where the breast is pulled down to a position that comfortably supports the tissue body for scanning. For breast scanning, this pulling cylindricalizes the volume of breast tissue, and draws breast tissue away from the chest wall, such that the tissue body is properly immobilized during scanning (e.g., using a tomography system).
[0056] Referring now to FIG. 5A and 5B , an alternative interface pad 156 has a flat or planar upper surface 158 which is typically circular with a single hole 161 in the center of the surface. The hole is intended to accommodate a patient's breast nipple as will be described in detail below. In contrast to toroidal pad 132 described previously which draws the low pressure through a central passage, the interface pad 156 has four annularly placed peripheral plenums 166 to distribute a low pressure about the surface's periphery. This arrangement allows a larger target region surrounding the patient's nipple to be secured to the flat surface which in turn improves the cylindricalization of the breast. The peripheral plenums provide improved attached to the peri-areolar region of the breast. In contrast, the smaller low pressure funnel of toroidal pad 132 will shape the breast in a more conical configuration which may be less desirable for overall breast imaging. In some instances, however, the conical breast presentation may allow better visualization of the sub-areolar regions for masses underlying the nipple, e.g., to detect papillomas and other cancerous lesions.
[0057] As best seen in FIG. 5B , each of the peripheral plenums 160 is connected to a lower opening 170 by curved connecting channels which are formed in between an outer shell 162 and a dome-shaped insert 164 . The interface 156 may thus be molded from any of the polymers described previously in a simple, two-part molding process where the outer shell 162 and insert 164 may thereafter be joined by adhesives, ultrasonic welding, or other conventional techniques. Interface pad 156 may be connected to an expandable/retractable column 138 in the same manner as was described for toroidal pad 132 .
[0058] Referring now to FIG. 6A and 6B , a restrictor ring or plate 172 may be placed over and attached to the ultrasonic ring imaging array 102 in order to displace breast tissue as the transducer is vertically scanned over the breast, as will be described in greater detail below. The restrictor ring 172 will have an inner aperture or opening 174 which has dimensions which are smaller than those of the inside of the imaging array 102 , thus creating an “overhang” or “offset” to push tissue away from the active inner surface of the array. Typically, the restrictor ring 172 will provide an overhang of at least 1 cm, and typical dimensions for both the restrictor ring and the imaging array are set forth in Table 1 below.
[0000]
TABLE 1
BROAD RANGE (cm)
SPECIFIC RANGE (cm)
d RR
25-30
~27
l
12-22
16-20
w
10-22
12-20
d o
25-30
~27
di
20-25
~22
[0059] The restrictor ring 172 will be relatively stiff so that it will not bend or deform when engaging the breast tissue. It will also typically have a relatively thin profile, usually being from 2 to 3 mm thick, to minimize any deleterious effect on imaging. In some cases, the restrictor ring 172 may be made from materials, such as Dekin® polymer, to reduce out-of-plane scattering. The interior opening 174 of the ring 172 may be circular but in many embodiments will be ovoid or tear-shaped with the typical dimensions given in Table 1. Tomography systems 100 may be provided with an inventory of differently sized restrictor plates 172 corresponding to different breast sizes. In this way, an imaging system can be optimized for many women with differing anatomies.
[0060] FIG. 6C shows an alternative breast shaper concept where a cylindrical cup 182 is secured to an upper surface of a connector disc 180 which in turn is supported on an extendable/retractable support column 138 . The shaper cup 182 may have particular benefit for women with smaller volume breast tissue (e.g., cup size A), whereby even a restrictor ring 172 with the smallest inner diameter (w) and the peripheral suction alternative gel pad ( FIG. 5A /B) would still lead to a conical overall transition from the chest wall to the peri-areolar region. Therefore, shaper cup 182 could virtually encircle nearly all breast tissue of a smaller breast, engage the entire breast with the gentle suction and elongate the breast upon retraction, while providing near-complete cylindricalization of all available breast tissue. This embodiment could also be envisioned for larger breasts as needed. The shaper cup 182 includes an upper portion 184 having a diameter in the range from 10 cm to 20 cm, where the dimensions of the ultrasonic ring imaging array 102 and the restrictor ring 172 are generally in the ranges set forth in Table 1. A smaller transition region 186 is connected directly to the connector disc 180 so that low pressure induced in the column 138 , typically by a recirculating water or other media flow, is transferred to an interior of the upper portion 184 . In this way, the region of the breast B surrounding the nipple N can be drawn into the upper portion 184 where the walls of the cup 182 will cylindricalize the breast for optimized imaging, intervention, and the like. The cup 182 will preferably be formed from an ultrasonically transparent material when ultrasonic imaging is being used.
[0061] Referring now to FIG. 7A through 7G , a breast tomography system employing both the tissue shaping device and the breast restrictor ring of the present invention will be described. As shown in FIG. 7A , the interface pad 156 is initially supported on the column 138 in its vertically extended position maintained by the spring force of coil spring 150 . A low pressure is maintained in the interior of support column by a circulating fluid flow 138 maintained by a pump 136 which draws the water or other ultrasonically transmissive medium downwardly through the peripheral plenums 160 . As the patient lowers her breast B through the opening 116 in the table 118 , as shown in FIG. 7B , the nipple N is received in the center hole 161 of the flat upper surface 158 . As the patient continues to lower her breast, the breast tissue is drawn against the flat surface by the reduced pressure created by the fluid flying through the peripheral plenums 160 until the front region of the breast surrounding the nipple N is flattened against the flat surface 158 of interface pad 156 , as shown in FIG. 7C .
[0062] Once the breast B is flattened against the flat surface 158 of the interface pad 156 , the pressure within the interior of the support column 138 will be lowered, causing a force which acts against spring 150 which causes the column to vertically retract or collapse, as shown in FIG. 7D . The force supplied by the pump 136 against the breast B can be controlled in many ways, and the breast will be lowered and elongated by an amount proper to optimize imaging, as shown in FIG. 7D .
[0063] Once the breast has been properly positioned, the ring imaging array 102 and the restrictor ring 174 will be raised to scan the length of the breast as shown in FIGS. 7E through 7G . In FIG. 7E , the circumference of the breast is such that the interior edges of the restrictor ring do not contact the breast. As the assembly of the transducer 102 and ring 172 continues to be raised, as shown in FIG. 7F , the interior edge of the ring 172 will begin to contact the breast and displace the breast away from the interior of the transducer ring 102 . As the assembly of the imaging array 102 and restrictor ring 174 rises further, as shown in FIG. 7G , the interior edge of the restrictor ring 174 will significantly displace the breast tissue inwardly, avoiding interference with the imaging function of the array 102 .
[0064] Example images generated with an ultrasonic tomography system equipped with a BSD of the present invention are shown in FIGS. 8A-8D .
[0065] Embodiments of the system, methods, and protocols of the present invention and variations thereof can be embodied and/or implemented at least in part by a machine configured to receive a computer-readable medium storing computer-readable instructions. The instructions are preferably executed by computer-executable components preferably integrated with the system and one or more portions of a processor and/or a controller. The computer-readable medium can be stored on any suitable computer-readable media such as RAMs, ROMs, flash memory, EEPROMs, optical devices (CD or DVD), hard drives, floppy drives, or any suitable device. The computer-executable component is preferably a general or application specific processor, but any suitable dedicated hardware or hardware/firmware combination device can alternatively or additionally execute the instructions.
[0066] The FIGURES illustrate the architecture, functionality and operation of possible implementations of systems, methods and computer program products according to preferred embodiments, example configurations, and variations thereof. In this regard, each block in a flowchart or block diagram may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block can occur out of the order noted in the FIGURES. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.
[0067] As a person skilled in the art will recognize from the previous detailed description and from the figures and claims, modifications and changes can be made to the preferred embodiments of the invention without departing from the scope of this invention defined in the following claims.
[0068] While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is intended that the following claims define the scope of the invention and that methods and structures within the scope of these claims and their equivalents be covered thereby. | A tissue positioning system for contouring a patient tissue volume includes an axially displaceable interface having a surface configured to engage a breast or other tissue volume. A low pressure source applies a partial low pressure to the surface of the displaceable interface to secure the tissue volume to the surface, and the axially displaceable interface is biased to pull and contour the tissue volume when the tissue volume is secured to the surface. The axially displaceable interface is typically mounted on a telescoping support and the biasing is provided by the same low pressure used to secure the tissue volume. | 0 |
BACKGROUND OF THE INVENTION
The invention regards a method of operating a programmable sewing machine, an automat or the like, as well as a drive and control apparatus for performing the method.
DE-OS 37 22 962 discloses a method for operating a programmable sewing machine in which a specific program type is selected prior to inputting the sewing machine functions and prior to inputting one of the available sequences of program parts within each program type. The operator then additionally inputs different sewing parameters, e.g. the number of stitches per seam.
In the prior art, seams or seam lengths are defined by the connection of two points on a material to be sewn and are obtained by sewn stitches. While the number of stitches of the seams can be selected by the operator, the sequence in which the seams are concatenated is preprogrammed. Moreover it is possible to predefine specific events which occur as a function of the seam or of the sewing of the stitches. For example, a time with a preselected duration can elapse after the end of a seam with a preselected number of stitches. During the time e.g. the sewn part is conveyed away from the sewing machine and stacked. For this purpose the sewing machine control device has different outputs, which can be activated as a function of the seam or the number of stitches. Thus, for example, an output can be provided, which is switched in during a number of stitches programmed by the operator at the start of the seam, another output is switched in for a time programmed by the operator after stopping the needle at the end of the seam or an output is switched in throughout the entire seam length.
However, such control devices suffer from the disadvantage that, due to the way the sequence is programmed, the operator cannot associate a random output with a random seam or seam length. It is also not possible to switch in an output for a specific or non-specific time at a random point in the sewing sequence, or to insert or non-specific waiting time at a random point in the sewing machine sequence. This means that a given sequence of the sewing process is predetermined in a fixed manner and the parameters of number of stitches or time can only be modified within this fixed sequence.
Moreover it is not possible to make the execution of a seam or a time in the sewing process dependent on events that might occur during any arbitrary point or time of the sewing process.
The problem posed to the invention is therefore to provide a method for operating a sewing machine and an apparatus for controlling the same, which permits a greater flexibility in the working sequence, which inter alia leads to a time saving.
SUMMARY OF THE INVENTION
According to the invention there is provided a method for operating a programmable sewing machine, an automat or the like in which by means of input elements associated with a control device, program parts predetermining the operation are selected, connected together and/or linked. The sewing machine is controlled accordingly, and the seams or seam lengths are predetermined by sewn stitches between two points of a material to be sewn. Predetermined outputs associated with the control unit are switched as a function of the performance of the stitches. The stitch elements, defined by sewn stitches, and the time elements, defined as time connections between two points of the operation, can be interlinked in a random sequence preselected by the operator in accordance with the operation, so that both when performing the stitch elements and also the time elements, outputs can be switched in controlled by the control device.
Due to the fact that, in addition to the seam defined by the number of stitches, a so-called time element is given, far more different operations can be set and selected by the operator without requiring a change to the basic program, i.e. without having to change the EPROM provided in the control or any other memory with the program. In the time element the connection between two points of an operation is carried through as the time between the two points.
BRIEF DESCRIPTION OF THE DRAWINGS
An apparatus for performing the method according to the invention is shown in two embodiments in the drawings and is explained in greater detail hereinafter together with the method.
FIG. 1 diagrammatically illustrates the arrangement of the control for performing the method according to a first embodiment.
FIG. 2 diagrammatically illustrates the arrangement of the control for performing the method according to a second embodiment.
FIG. 3 shows a first example of a piece of textile material to be sewn with the method according to the invention.
FIG. 4 shows a second example of a piece of textile material to be sewn with the method according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 a sewing machine 1 is operated by means of a motor 2. The motor 2 is connected to a main microprocessor system 3, hereinafter called main microprocessor 3, which receives information on the position of the needle of the sewing machine 1 through a synchronizer 4. The main microprocessor 3 has several machine-specific inputs and outputs 5 and is connected to a pedal 6 by means of which the operator can control the sewing process. The basic program for the sewing processes to be selected is stored in the memory of the main microprocessor 3, which can e.g. be in the form of an EPROM. By means of an operator control panel 7, which can e.g. have a matrix-like input field for the different parameters, the operator can carry out the desired inputting of sewing parameters and the sequence of seams, as will be described hereinafter. The inputted information is stored in an EEPROM associated with the main microprocessor 3. As a function of the stored basic program and the inputted parameters and the sequence, programmable inputs and outputs 8 are switched.
FIG. 2 shows an embodiment in which a sewing machine with a conventional prior art control was subsequently equipped so that the method according to the invention can be performed. There is a secondary microprocessor system 9 for the standard sewing machine control and also a main microprocessor with memory 10, which controls the secondary microprocessor 9 and, in accordance with FIG. 1, the programmable inputs and outputs 8.
For processing the method a "stitch element" and a "time element" are defined. A stitch element represents the known connection between two points of an operation by sewn stitches, and a time element represents the connection between two points of an operation considered as the time between the two points. Thus, the time element is not a real, physical seam, but rather a time concept.
During the inputting or programming of the working sequence of the sewing process by the operator, i.e. the inputting of the sequence of seams, in this embodiment twelve seams can be successively linked. These can be both stitch elements, i.e. effectively sewn seams, and time elements during which a time elapses while something is to take place. One seam or element can occur more than once in the sequence defined by parameters EL01 to EL12. These parameters can each be given a letter between A and L standing for the elements A to L. The inputting of programming can e.g. be performed by means of keys on the operator control panel 7. To be able to determine the end of the sequence, the input "END" is associated with one of these parameters. An example is EL01 - K, EL02 - B, EL03 - F and EL04 - END, i.e. the thus defined operation comprises three elements in the order K - B - F, whereby these elements can be time elements or stitch elements. Further parameters associated with the elements indicate what is to be carried out during the processing of the elements.
The duration and incorporation into the working sequence are significant for defining the time element. A time element can have a specific or a non-specific duration. A specific element occurs if the start and finish of the element are known, if it is e.g. 200 ms long. A time element has a non-specific duration, if the end of the element is not known. For example a started element can continue until a key is activated. A maximum time can be given as the upper limit for the time element, so that faulty situations can be detected. If e.g. the key is not activated within 5 s (maximum time), then a fault exists and a corresponding fault indication takes place.
As far as the incorporation of a time element into the working sequence is concerned, it can take place in the "foreground" or in the "background". It takes place in the foreground if the following element can be started only after the end of the time element. It takes place in the background if the following element can be started before the end of the time element, i.e. immediately after starting the time element. The time element then runs parallel to the following element.
A time element does not influence the state of the sewing motor 2, i.e. the motor e.g. rotates with a constant speed during the time element if it had a constant speed before the start of the latter. However, if the motor was stationary before the start of the time element, it is not brought into motion.
With respect to the elements, one or more outputs 8 can be connected in and this, applies both with regard to a stitch element and with regard to a time element. If e.g. an output is to be switched in at the end of a number of stitches for a specific time, then, prior to the sewing process, first a stitch element and subsequently a time element are inputted. The stitch element has a specific number of stitches and the time element a specific duration, during which the output is switched in. In the prior art the basic program in such a case was so fixed that the stitch element was always followed by a time during which the output was switched in. The time had a fixed association with the stitch element, so that the sequence of the stitch element with the following time element could not be modified by the operator.
The start and end conditions must be pre-established as parameters for each element of the operating sequence. The start condition is that which must be fulfilled after the end of the previous element, so that the next element is started. At the start condition, the operator can choose between (a) pedal 6 toed forwards, (b) photocell covered, (c) one or more inputs and (d) a combination of the first three possibilities. The photocell is associated with the sewing machine and it reacts to the presence of material in the vicinity of the needle. The inputs 8 are switched as a function of externally performed operations, e.g. by a limit switch or the like. It is also possible to take the end of the previous element in the sequence as the start condition, without having to additionally choose one of the possibilities (a) to (d).
The end condition is that which must be fulfilled in order to introduce the end of the seam. As the end condition the operator can choose between (a) pedal 6 heeled backwards, (b) photocell uncovered, (c) one or more inputs, (d) a stich count and (e) a combination of the first four possibilities. In the case of the time element with a specific duration, the end of the predetermined duration is simultaneously the end condition for the time element itself.
In addition to the start and end condition a skip condition can be used to avoid the execution of an element or elements dependent on an event or events that can occur during the sewing operation. If the skip condition is fulfilled, the element or elements will not be executed and the operation will continue to the next executable element in the sequence. As the skip condition the operator can choose between (a) an input that can be activated or deactivated, (b) a photocell that can be covered and uncovered, (c) an output that can be on or off, (d) the motor that can be running or not, (e) another element that has been executed or not, and (f) any combination of the first five possibilities.
The fulfillment of the skip condition, and consequently the skipping of the execution of the element or elements, does not affect the execution of the other elements in the sequence, unless the execution of one or more of the other elements is dependent on an event that would have occurred during the skipped elements.
Hereinafter the method of the invention is further illustrated by three different examples. The operating sequence for the individual examples can be predetermined and inputted by the operator, whereas in the prior art a different basic program was necessary for each example.
According to FIG. 3 it is necessary to sew a tablecloth 11 while inserting a label 12. Seam or element A is to be sewn first. Through the operator control panel 7 the operator inputs the parameters associated with the stitch element A. In the present case the start condition selected is "pedal 6 toed forwards" and "photocell covered", while the end condition is a specific number of stitches (stitch count). The second element is constituted by a time element and the start condition is the end of element A. The time element B is undetermined and is ended by pressing a key. During time element B the presser foot is raised, so that the label can be inserted. This key, which is associated with an input, simultaneously forms the start condition for element C, whose end condition is "photocell uncovered". The start condition for element D is inputted as "pedal 6 toed forwards" and the end condition is the same as for element C. For element E the start condition is also "pedal 6 toed forwards" and as the end condition "photocell uncovered" is inputted, while additionally selecting the parameter "thread trim" at the end of element E.
By toeing the pedal 6 forwards and as a function of the values and parameters inputted by means of the operator control panel 7, the main processor 3 controls the sewing machine 1 in such way that first element A is sewn. In accordance with the preset number of stitches the motor 2 stops with the needle in the down position. During the undefined time element B, the operator can then insert label 12. Element C is started by means of an input, which is activated by the operator by pressing a key after inserting the label. When the tablecloth 11 has advanced to such an extent that the photocell after sewing C is uncovered and the photocell offset stitches between the position at which the photocell is located and the needle, have been sewn, the motor 2 stops with the needle in the down position. On toeing pedal 6 forwards, the element D starts, and then correspondingly the second element D. The same end conditions as for element C are processed. Element E is sewn in the same way, and at the end thereof the thread is trimmed. The sequence for the sewing operation for a tablecloth with label is A - B - C - D - D - E - END.
In case two types of tablecloth are being sewed, e.g. alternatively during the operating, one with label 12 and without any label, the skip condition of time element B can be defined as "photocell uncovered"(ply sensor), in which case time element B will not be executed if the photocell does not detect the presence of the label during the sewing time, and the operating will continue with seam C, which then has "end of the previous seam" as the start condition. The operator can concentrate at the sewing operating, knowing that the control apparatus will react to the presence or absence of the label 12 accordingly. The skip condition can be programmed by the operator.
For the second example the sewn material is to be stacked at the end of an operation. If at the aforementioned tablecloth sewing operation, a device moves the tablecloth from the sewing table to a stack, a signal of specific duration must be outputted by the main microprocessor 3 at the end of the operation, activating an output through which the device is controlled. This is obtained in that a time element F is defined, which has as the start condition the end of the preceding element (element E). During this time element an output is switched in. The sequence for the new operation is A - B - C - D - D - E -F - END.
As a further example, according to FIG. 4 the seam 13 of a vest 14 is sewn. The vest is placed on two driving rollers whereof one is stationary and the other mobile. The vest covers a photocell, which is taken as the start condition for a first time element. This element has been previously inputted as a time element with an undefined duration. During the time element once again an output 8 is activated. The signal applied to the output immediately following the insertion of the vest ensures that the movable driving roller is brought into a position in which the vest is slightly stretched. The signal remains active during the time element. A limit switch is located in this position and by means of a programmable input 8 informs the main microprocessor 3 or 10 that the desired position of the movable driving roller has been reached. The time element A is ended. The output is not switched off, because the vest must also be slightly stretched during sewing (element B). The stitch element B starts immediately due to the start condition "end of the previous element" following the time element A and is ended when a previously inputted number of stitches has been sewn, i.e. the stitch count serves as the end condition. The output is then switched off and the vest can be removed from the driving rollers. The sequence for the operation for sewing the vest 14 is then A - B - END.
It is obviously also possible to input other parameters, e.g. concerning the front or back backtacks, the speeds and the like. | A programmable sewing machine is disclosed in which, by means of input elements associated with a control device, the program parts predetermining the operation are selected, connected together and/or linked, the sewing machine being controlled accordingly, and the seams or seam lengths being predetermined by sewn stitches between two points of a material to be sewn and in which as a function of the performance of the stitches predeterminable outputs associated with the control unit are switched. Stitch elements, defined by sewn stitches, and time elements, defined as the time connections between two points of the operation, are interconnected in a random order preselectable by the operator in accordance with the operation. When performing both stitch elements and time elements, outputs can be switched in controlled by the control device. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 09/847,926, filed May 3, 2001, now U.S. Pat. No. 6,398,609, issued Jun. 4, 2002, which is a continuation of application Ser. No. 09/626,481, filed Jul. 26, 2000, now U.S. Pat. No. 6,276,982, issued Aug. 21, 2001, which is a continuation of application Ser. No. 09/472,571, filed Dec. 27, 1999, now U.S. Pat. No. 6,133,057, issued Oct. 17, 2000, which is a continuation of application Ser. No. 09/260,214, filed Mar. 1, 1999, now U.S. Pat. No. 6,059,625, issued May 9, 2000.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to methods of fabricating field emission arrays. Particularly, the present invention relates to field emission array fabrication methods wherein the emitter tips and their corresponding resistors are fabricated through a single mask. More particularly, the present invention relates to field emission array fabrication methods that employ only one mask to define the emitter tips and their corresponding resistors and that do not require a mask to define the column lines thereof.
2. Background of the Related Art
Typically, field emission displays (“FEDs”) include an array of pixels, each of which includes one or more substantially conical emitter tips. The array of pixels of a field emission display is typically referred to as a field emission array. Each of the emitter tips is electrically connected to a negative voltage source by means of a cathode conductor line, which is also typically referred to as a column line.
Another set of electrically conductive lines, which are typically referred to as row lines or as gate lines, extends over the pixels of the field emission array. Row lines typically extend across a field emission display substantially perpendicularly to the direction in which the column lines extend. Accordingly, the paths of a row line and of a column line typically cross proximate (above and below, respectively) the location of an emitter tip. The row lines of a field emission array are electrically connected to a relatively positive voltage source. Thus, as a voltage is applied across the column line and the row line, electrons are emitted by the emitter tips and accelerated through an opening in the row line.
As electrons are emitted by emitter tips and accelerate past the row line that extends over the pixel, the electrons are directed toward a corresponding pixel of a positively charged electro-luminescent panel of the field emission display, which is spaced apart from and substantially parallel to the field emission array. As electrons impact a pixel of the electro-luminescent panel, the pixel is illuminated. The degree to which the pixel is illuminated depends upon the number of electrons that impact the pixel.
Numerous techniques have been employed to fabricate field emission arrays and the resistors thereof. An exemplary field emission array fabrication technique includes fabricating the column lines and emitter tips prior to fabricating a dielectric layer and the overlying grid structure, such as by the methods of U.S. Pat. No. 5,302,238, issued to Fred L. Roe et al. on Apr. 12, 1994, and U.S. Pat. No. 5,372,973, issued to Trung T. Doan et al. on Dec. 13, 1994. Alternatively, a field emission array may be fabricated by forming the dielectric layer and the overlying grid structure, then disposing material over the grid structure and into openings therethrough to form the emitter tips, such as by the technique disclosed by U.S. Pat. No. 5,669,801, issued to Edward C. Lee on Sep. 23, 1997. Such conventional field emission array fabrication methods typically require the use of masks to independently define the various features, such as the column lines, resistors, and emitter tips, thereof.
Another exemplary method of fabricating field emission arrays is taught in U.S. Pat. No. 5,374,868 (hereinafter “the '868 Patent”), issued to Kevin Tjaden et al. on Dec. 20, 1994. The fabrication method of the '868 Patent includes defining trenches in a substrate. The trenches correspond substantially to columns of pixels of the field emission array. A layer of insulative material is disposed over the substrate, including in the trenches thereof. A layer of conductive material and a layer of cathode material (e.g., polysilicon) are sequentially disposed over the layer of insulative material. A mask may then be disposed over the layer of cathode material and the emitter tips and their corresponding column lines defined through the cathode material and “highly conductive” material layers, respectively. The method of the '868 Patent is, however, somewhat undesirable in that the mask thereof is not also employed to fabricate resistors, which limit high current and prevent device failure. Moreover, in the embodiment of the method of the '868 Patent that employs a single mask to fabricate both the emitter tips and their corresponding column lines, neither the “highly conductive” material nor the cathode material is planarized. Thus, the layer of cathode material may have an uneven surface and the heights of the emitter tips defined therein may vary substantially. In embodiments of the method of the '868 Patent where the layer of “highly conductive” material is planarized, only the emitter tips are defined through the mask.
Accordingly, there is a need for a field emission array fabrication process that employs a minimal number of mask steps to define emitter tips of substantially uniform height, their corresponding resistors, and their corresponding column lines.
BRIEF SUMMARY OF THE INVENTION
The present invention includes a method of fabricating the pixels of a field emission array and, in particular, defining emitter tips and their corresponding resistors by employing a single mask. The field emission array fabrication method of the present invention may also include electrically isolating adjacent column lines from one another with requiring the use of an additional mask. Field emission arrays fabricated in accordance with the inventive method are also within the scope of the present invention.
The method of the present invention includes defining a plurality of substantially mutually parallel conductive lines on a substrate. In order to define the conductive lines, a layer of conductive material may be deposited onto the substrate. The conductive lines may be defined from the conductive layer by known processes. Alternatively, conductive material may be selectively deposited onto the substrate, as known in the art, to define the conductive lines.
One or more layers of semiconductive material or conductive material, from which the emitter tips and their corresponding resistors of the field emission array will be defined, may be disposed over each of the conductive lines and over the regions of the substrate that are exposed between adjacent conductive lines. The layer or layers of semiconductive material or conductive material are also referred to herein as the emitter tip-resistor layer or as the emitter tip layer and resistor layer, respectively. The emitter tip and resistor layer or layers may be disposed over the conductive lines and the substrate by known processes and in a thickness that corresponds to a desired height of the emitter tips and their corresponding resistors. As each of the conductive lines protrudes somewhat from the surface of the substrate, a cross section of the emitter tip and resistor layer or layers has a peak and valley appearance. The peaks of the emitter tip and resistor layer or layers are disposed substantially above the conductive lines, while the valleys of the emitter tip and resistor layer or layers are disposed substantially between adjacent column lines. Due to this peak and valley appearance, if the emitter tip and resistor layer or layers are planarized, the heights of the emitter tips and the resistors are defined somewhat by the relative heights of the conductive lines and the thickness of material remaining above the conductive lines following planarization.
A layer of mask material may be disposed over the emitter tip and resistor layer or layers. Such a mask material may be removed from substantially above the conductive lines (i.e., from above the “peaks”) by known processes to define a so-called “hard mask” from the remaining mask material (i.e., the regions located in the “valleys”). Upon exposure of regions of the emitter tip and resistor layer or layers, regions of the emitter tip and resistor layer or layers disposed above the substantially longitudinal center portion of each of the conductive lines may be substantially removed by known processes to expose the substantially longitudinal center portion of the conductive lines. Exemplary processes that may be employed to remove material from these regions of the emitter tip and resistor layer or layers include, without limitation, the use of etchants that are selective for the material or materials of the emitter tip and resistor layer or layers over the mask material.
The emitter tip and resistor layer or layers may be planarized by known processes, such as by chemical-mechanical planarization (“CMP”). Upon such planarization, the peaks and possibly portions of the valleys proximate the surface of the uppermost layer of semiconductive material or conductive material are removed and a substantially planar surface is formed.
The emitter tips and resistors of the field emission array may be defined through the remaining portions of the emitter tip and resistor layer or layers by disposing a mask over the exposed surface of the field emission array and defining apertures therethrough in locations to facilitate the selective removal of portions of the emitter tip and resistor layer or layers through the apertures in order to define the emitter tips and resistors. The mask may be disposed upon the field emission array by known processes, such as by the use of a photoresist material and by exposing and developing selected regions of the photoresist material to define the mask and the apertures therethrough. The emitter tips and resistors may be defined by known processes, such as by the use of etchants for the material or materials of the emitter tip and resistor layer or layers. Preferably, as regions of the emitter tip and resistor layer or layers are removed from the substantially longitudinal center portion of each of the conductive lines and as the emitter tips and resistors are defined, at least a lateral edge of the conductive lines remains covered with a material of the emitter tip and resistor layer or layers.
Adjacent columns of pixels of the field emission array may be electrically isolated from each other by removing at least the substantially longitudinal center portion of each of the conductive lines. An etchant that is selective for the conductive material of the conductive lines over the material or materials of the emitter tip and resistor layer or layers may be employed to remove conductive material from the substantially longitudinal center of each of the conductive lines and, thereby, to define the column lines and to electrically isolate adjacent column lines from one another.
The present invention also includes field emission arrays that have been fabricated in accordance with the method of the present invention. Thus, a field emission array according to the present invention may include a substrate with at least one resistor thereon, at least one lateral conductive layer, or column line, laterally adjacent the resistor, and at least one emitter tip disposed on the resistor. The substrate of the field emission array is exposed between adjacent column lines.
Other features and advantages of the present invention will become apparent to those of skill in the art through a consideration of the ensuing description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a cross-sectional schematic representation of a field emission array that may be fabricated in accordance with the method of the present invention;
FIG. 2 is a schematic cross-sectional representation of the field emission array of FIG. 1, illustrating the blanket disposition of a layer of conductive material over a surface of a substrate;
FIG. 3 is a schematic cross-sectional representation of the field emission array of FIG. 2, illustrating patterning of the layer of conductive material to define substantially mutually parallel conductive lines over the substrate;
FIG. 3A is a schematic top view of the field emission array of FIG. 3;
FIG. 4 is a schematic cross-sectional representation of the field emission array of FIG. 3, illustrating the disposition of an emitter tip-resistor layer over exposed portions of the substrate and over the substantially mutually parallel conductive lines;
FIG. 4A is a schematic cross-sectional representation of a variation of the field emission array of FIG. 4, wherein the emitter tip-resistor layer comprises a layer of resistor material and a layer of emitter tip material disposed over the layer of resistor material;
FIG. 5 is a schematic cross-sectional representation of the field emission array of FIG. 4, illustrating the disposition of a mask layer over the emitter tip-resistor layer;
FIG. 6 is a schematic cross-sectional representation of the field emission array of FIG. 5, illustrating the removal of regions of the mask layer disposed substantially above the conductive lines to define a hard mask from the mask layer;
FIG. 7 is a schematic cross-sectional representation of the field emission array of FIG. 6, from which portions of the emitter tip-resistor layer disposed over the conductive lines have been removed through the hard mask;
FIG. 8 is a schematic cross-sectional representation of the field emission array of FIG. 7, with the hard mask removed therefrom and illustrating planarization of the emitter tip-resistor layer;
FIG. 8A is a schematic cross-sectional representation of the field emission array of FIG. 4A, from which portions of the emitter tip-resistor layer disposed above the conductive lines have been removed, and the remaining surface of the emitter tip layer has been planarized;
FIG. 9 is a schematic cross-sectional representation of the field emission array of FIG. 8, illustrating the disposition of a mask over the emitter tip-resistor layer;
FIG. 10 is a schematic cross-sectional representation of the field emission array of FIG. 9, illustrating patterning of the emitter tip-resistor layer through apertures of the mask; and
FIG. 11 is a schematic cross-sectional representation of the field emission array of FIG. 10, illustrating the definition of column lines and the electrical isolation of adjacent columns of pixels by removing a substantially longitudinal center portion of each of the conductive lines.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1, a field emission array 10 is illustrated. Field emission array 10 includes a substrate 12 upon which various features of field emission array 10 , including the column lines 14 , resistors 16 , and emitter tips 18 thereof may be fabricated. A pixel 11 of field emission array 10 may include one or more emitter tips 18 and their associated, underlying resistor 16 or resistors. Each resistor 16 and its associated emitter tip 18 may be connected to, or otherwise in communication with, a relatively negative voltage source by means of one or more column lines 14 , or lateral conductive layer, which are preferably disposed laterally adjacent a corresponding resistor 16 .
With reference to FIG. 2, materials that may be employed as substrate 12 in the present invention include, without limitation, silicon, gallium arsenide, other semiconductive materials, silicon wafers, wafers of other semiconductive materials, silicon on glass (“SOG”), silicon on insulator (“SOI”), silicon on sapphire (“SOS”), and bare glass.
With continued reference to FIG. 2, a layer 20 of conductive material is disposed over substrate 12 . Conductive materials, such as doped silicon, polysilicon, doped polysilicon, chromium, aluminum, molybdenum, copper, or other metals, may be employed as layer 20 . The conductive material of layer 20 may be disposed over substrate 12 by known processes, such as by physical vapor deposition (“PVD”) (e.g., sputtering) or by chemical vapor deposition (“CVD”) (e.g., low pressure CVD (“LPCVD”), atmospheric pressure CVD (“APCVD”), or plasma-enhanced CVD (“PECVD”)) processes. Layer 20 may be blanket deposited over substrate 12 or selectively deposited thereover.
With reference to FIGS. 3 and 3A, if layer 20 is blanket deposited over substrate 12 , layer 20 may be patterned by known processes, such as by masking and etching techniques, to define substantially mutually parallel conductive lines 22 therefrom. If layer 20 is selectively deposited, the substantially mutually parallel conductive lines 22 may be fabricated during deposition of the conductive material of layer 20 .
Turning now to FIG. 4, a layer 24 of semiconductive material or conductive material, which is also referred to herein as a second layer or as an emitter tip-resistor layer, is disposed over conductive lines 22 and the regions of substrate 12 that are exposed between adjacent conductive lines 22 . Since conductive lines 22 protrude somewhat from substrate 12 and layer 24 is disposed thereover in a substantially consistent thickness, layer 24 has a peak and valley appearance, with peaks 26 being located above conductive lines 22 and valleys 28 , which are also referred to herein as depressions, being located between adjacent conductive lines 22 .
Exemplary semiconductive materials that may be employed as layer 24 include, without limitation, single-crystalline silicon, amorphous silicon, polysilicon, and doped polysilicon. These materials may be deposited as known in the art, such as by chemical vapor deposition techniques. Of course, conductive materials having the desired properties and that are useful in fabricating emitter tips 18 and resistors 16 may also be employed in layer 24 and may be disposed over conductive lines 22 and the exposed regions of substrate 12 by known processes.
Alternatively, it may be desirable to fabricate emitter tips 18 and resistors 16 from different semiconductive materials or conductive materials. For example, it may be desirable to fabricate resistors 16 from polysilicon, while a material such as single-crystalline silicon or amorphous silicon may be more desirable for fabricating emitter tips 18 . Accordingly, with reference to FIG. 4A, a variation of the field emission array may include a resistor layer 24 a′ and an emitter tip layer 24 b′ . Resistor layer 24 a′ is disposed over conductive lines 22 and the regions of substrate 12 exposed between adjacent conductive lines 22 . Emitter tip layer 24 b′ is disposed over resistor layer 24 a′ . As with layer 24 of FIG. 4, resistor layer 24 a′ and emitter tip layer 24 b′ may each have a peak and valley configuration.
Turning now to FIG. 5, a mask layer 42 of mask material may be disposed over emitter tip-resistor layer 24 . Preferably, the material or materials of emitter tip-resistor layer 24 are selectively etchable with respect to the mask material. Accordingly, materials such as metals, metal oxides, silicon oxides, doped silicon oxides (e.g., borophosphosilicate glass (“BPSG”), phosphosilicate glass (“PSG”), borosilicate glass (“BSG”), etc.), or silicon nitrides may be employed as the mask material. Mask layer 42 may be disposed upon emitter tip-resistor layer 24 by known processes, such as by physical vapor deposition (“PVD”), chemical vapor deposition, growing the mask material onto the surface of emitter tip-resistor layer 24 , or spinning the mask material thereon, depending upon the type of mask material employed.
Referring now to FIG. 6, a so-called “hard mask” 44 may be formed on emitter tip-resistor layer 24 by removing the regions of mask layer 42 that are disposed substantially between conductive lines 22 . These regions of mask layer 42 may be removed by known processes, such as by known planarization techniques, such as by the chemical-mechanical planarization (“CMP”) or chemical-mechanical polishing techniques taught in U.S. Pat. Nos. 4,193,226 and 4,811,522, the disclosures of both of which are hereby incorporated in their entireties by reference. As hard mask 44 is formed, the portions of emitter tip-resistor layer 24 that are disposed substantially above at least the substantially longitudinal center portion of conductive lines 22 are exposed through hard mask 44 .
FIG. 7 illustrates the removal of portions of emitter tip-resistor layer 24 that are exposed through hard mask 44 and the exposure of at least substantially longitudinal center portions 34 of conductive lines 22 through emitter tip-resistor layer 24 . Preferably, the removal of these substantially longitudinal center portions 34 of emitter tip-resistor layer 24 is substantially anisotropic. The material or materials of the exposed portions of emitter tip-resistor layer 24 may be removed by known processes, such as by the use of etchants that are selective for one or more materials of emitter tip-resistor layer 24 over the mask material of hard mask 44 . Preferably, at least a peripheral lateral edge portion 36 of selected column lines 22 remains covered by emitter tip-resistor layer 24 so as to facilitate the subsequent removal of only a portion of the selected conductive lines 22 .
The use of a hard mask facilitates isolation of adjacent pixels independent of the heights of emitter tips 18 and resistors 16 (see FIG. 1 ). Accordingly, when such a hard mask 44 is employed, the relative heights of emitter tips 18 and resistors 16 are not determined by the height of conductive lines 22 , as would be the case if conductive lines 22 were exposed during the definition of emitter tips 18 and resistors 16 (i.e., resistors 16 need not have substantially the same height as conductive lines 22 ).
Hard mask 44 may be removed from emitter tip-resistor layer 24 by known techniques, such as planarization processes (e.g., CMP) or the use of etchants that etch the material of hard mask 44 with selectivity over the material or materials of emitter tip-resistor layer 24 . FIG. 8 illustrates field emission array 10 with the hard mask removed therefrom.
As shown in FIG. 8, the peaks 26 (see FIGS. 4 and 4A) and possibly portions of valleys 28 (see FIGS. 4 and 4A) have been substantially removed from the exposed surface of layer 24 during the definition and/or removal of hard mask 44 (see FIGS. 6 and 7) therefrom. Layer 24 may be planarized by known processes, such as CMP.
With reference to FIG. 8A, if emitter tip layer 24 b′ (see FIG. 4A) is planarized, such as by known chemical-mechanical planarization techniques, the portions of emitter tip layer 24 b′ that remain between adjacent conductive lines 22 preferably have a thickness that is sufficient to fabricate emitter tips 18 (see FIG. 1) of a desired height therefrom.
Referring now to FIG. 9, the remainder of layer 24 may be patterned by disposing a mask 30 thereover and selectively removing portions of layer 24 through mask 30 . Known techniques may be employed to dispose mask 30 over layer 24 , and possibly over the exposed regions of conductive lines 22 , such as disposing a layer of photoresist material over layer 24 , and exposing and developing selected regions of the photoresist material to define apertures 32 therethrough in desired locations.
Turning now to FIG. 10, selected portions of the remainder of layer 24 may be removed through apertures 32 of mask 30 by known techniques, such as etching, to define emitter tips 18 and resistors 16 . Either wet etching processes or dry etching processes may be employed. As emitter tips 18 may be conically shaped, the use of isotropic etching techniques is preferred. For example, if either single-crystalline or amorphous silicon is employed to fabricate emitter tips 18 (i.e., if these materials are employed as layer 24 ), wet etchants, such as mixtures of nitric acid (HNO 3 ) and hydrofluoric acid (HF), may be employed in known wet etch processes to remove material from selected regions of layer 24 . As the exposure of conductive lines 22 through layer 24 and the definition of emitter tips 18 and resistors 16 from layer 24 may be effected through a single mask, each of these processes is said to occur substantially simultaneously for purposes of this disclosure. Preferably, as layer 24 is patterned, the material of layer 24 is not removed from (i.e., is maintained over) at least one peripheral edge portion 36 of each of conductive lines 22 .
If mask 30 or portions thereof remain following the definition of emitter tips 18 and resistors 16 , mask 30 may be removed from the surface of field emission array 10 by known processes. Any etchants may also be removed from field emission array 10 by known processes, such as by washing field emission array 10 .
FIG. 11 depicts field emission array 10 following the removal of the conductive material of at least the substantially longitudinal center portion 34 of each conductive line 22 . The conductive material of substantially longitudinal center portion 34 is substantially removed such that the underlying regions of substrate 12 are exposed and a lateral conductive layer 38 remains laterally adjacent each resistor 16 .
Each column line 14 preferably comprises a lateral edge portion 36 that remains from at least one of the conductive lines 22 that was previously adjacent the resistor 16 . The remaining lateral edge portion 36 of a patterned conductive line 22 , which is preferably disposed laterally adjacent its associated resistor 16 , is also referred to herein as a lateral conductive layer 38 . Preferably, each column line 14 includes two lateral conductive layers 38 with at least one resistor 16 disposed therebetween.
Thus, as conductive lines 22 are patterned, column lines 14 are formed and adjacent columns of pixels 11 or emitter tips 18 are substantially electrically isolated from each other. If an etchant or etchants are employed to pattern conductive lines 22 , any remaining etchants may be removed from field emission array 10 after the desired patterning has been performed. Etchants may be removed by known processes, such as by washing field emission array 10 .
The conductive material of substantially longitudinal center portion 34 of conductive lines 22 may be removed therefrom by known processes, such as by known etching techniques. While either dry etching or wet etching techniques may be employed to pattern conductive lines 22 , substantially anisotropic etching of conductive lines 22 is preferred so as to facilitate the formation of lateral conductive layers 38 of substantially uniform thickness. For example, if conductive lines 22 comprise polysilicon, a dry etchant, such as a chlorine etchant, a fluorine etchant, or a combination thereof (e.g., SF 6 and Cl 2 ), may be employed in a dry etch process, such as glow-discharge sputtering, ion milling, reactive ion etching (“RIE”), reactive ion beam etching (“RIBE”), or high-density plasma etching.
Conductive lines 22 may be patterned at any point when substantially longitudinal center portions 34 are exposed. For example, conductive lines 22 may be patterned prior to disposing layer 24 onto substrate 12 , after conductive lines 22 are exposed through layer 24 , or after emitter tips 18 and resistors 16 are defined.
The method of the present invention requires fewer fabrication steps than conventional field emission array fabrication processes. Accordingly, the method of the present invention may also facilitate a reduction in failure rates and production costs of field emission arrays.
Although the foregoing description contains many specifics and examples, these should not be construed as limiting the scope of the present invention, but merely as providing illustrations of some of the presently preferred embodiments. Similarly, other embodiments of the invention may be devised which do not depart from the spirit or scope of the present invention. The scope of this invention is, therefore, indicated and limited only by the appended claims and their legal equivalents, rather than by the foregoing description. All additions, deletions and modifications to the invention as disclosed herein and which fall within the meaning of the claims are to be embraced within their scope. | An emission structure includes a resistor with at least one emitter tip thereover and at least one substantially vertically oriented conductive element positioned adjacent the resistor. The conductive element may contact the resistor. A method for fabricating the emission structure includes forming at least one conductive line, depositing at least one layer of semiconductive or conductive material over and laterally adjacent the at least one conductive line, and forming a hard mask in recessed areas of the surface of the uppermost material layer. The underlying material layer or layers are patterned through the hard mask, exposing substantially longitudinal center portions of the conductive lines. The remaining semiconductive or conductive material is patterned to form the emitter tip and resistor. At least the substantially central longitudinal portion of the conductive trace is removed to form the conductive element. | 7 |
BACKGROUND OF THE INVENTION
This invention refers to a knitting method for a buttonhole formed on overlapping parts of a knit product such as a cardigan and a knit fabric having buttonholes.
In the prior art, fabric is knitted and then the buttonholes are made in the fabric, in making a buttonhole on a fabric, a hole is formed on the fabric first and then the hole is stitched with a string attached along the edge of the hole by using a stitching machine.
Generally, two types of buttonholes are known, which are lateral type and vertical type. The buttonholes are lateral relative to the wale direction of the knit fabric. However, when a knit product having lateral buttonholes is put on and laterally stretched, loops forming the edge of the buttonhole are stretched out and the string attached along the buttonhole is released. Therefore, the vertical type of buttonhole is preferred for a knit product.
However, there is a problem that in case a button is held by a vertical buttonhole, the buttonhole opens unpleasantly by being stretched in a lateral direction. Thus, the design is damaged and the value of the product is degraded.
Further, a problem is that in the prior art buttonholes are formed by using another machine. The use of another machine to form the buttonholes leads to a complex knitting procedure and lowering of productivity.
OBJECT AND SUMMARY OF THE INVENTION
The present invention is provided in view of the above problems, and an object is to prevent damage to the shape of a product by employing a lateral buttonhole and to form buttonholes within a knitting procedure of a fabric.
A knitting method of a buttonhole for a knit product by using a flat knitting machine in the present invention comprises the steps of: binding off a desired number of loops in a wale direction of the knit product at a starting point of forming the buttonhole, the length of the loops corresponding to a desired width of a buttonhole, and releasing the loops from the knitting needles to form a bottom peripheral portion of the buttonhole, and forming an upper peripheral portion of the buttonhole above the bottom peripheral portion of the buttonhole.
The forming method of the upper peripheral portion of the buttonhole comprises: a step of increasing the loops one by one by employing a knitting method that is called "split-knit" from one end to the other end of the bottom peripheral portion of the buttonhole, wherein a loop held on a needle is made to be held also on another needle and a new loop is formed on the former needle, or a step of forming loops at both ends of an upper peripheral portion on both ends of the bottom peripheral portion of the buttonhole.
Further, a fabric having buttonholes comprises a bottom peripheral portion of a buttonhole which is formed by binding off some adjacent loops in a wale direction, of which the length of the loops corresponds to the width of a buttonhole, at the beginning of the buttonhole of a fabric knitted by using a flat knitting machine, an upper peripheral portion of the buttonhole is formed above the bottom peripheral portion of the buttonhole by a loop forming means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a buttonhole formed on a knit fabric knitted by the method in the present invention,
FIG. 2 is an explanatory drawing for marks used in knitting courses,
FIGS. 3-1 to 3-38 are explanatory drawings of knitting courses for a buttonhole in a knit fabric in the embodiment 1,
FIGS. 4-1 to 4-10 are explanatory drawings of knitting courses for a buttonhole in a second embodiment,
FIGS. 5-1 to 5-10 are explanatory drawings of knitting courses for a buttonhole in a knit fabric in a third embodiment,
FIGS. 6-1 to 6-8 are explanatory drawings of knitting courses for a buttonhole in a knit fabric in a fourth embodiment, and
FIGS. 7-1 to 7-11 are explanatory drawings of knitting courses for a buttonhole in a knit fabric in a fifth embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A knitting method for forming a buttonhole in a knit product of the present invention will be described with reference to the drawings hereinafter.
Embodiment 1
A flat knitting machine comprising front and rear needle beds which movably support knitting needles employed in the present embodiment, and FIGS. 3-1 to 3-38 show knitting courses of a buttonhole 2 laterally formed on a cardigan 1 as shown in FIG. 1.
Further, marks used in the drawings are explained in FIG. 2, alphabetical capital letters A, B, C, D, E, . . . represent knitting needles of the front needle bed 3, alphabetical small case letters a, b, c, d, e, . . . represent knitting needles of the rear needle bed 4, and rightward numeral and letter P denote the distance of movement of the rear needle bed 4.
First, knitting starts from a bottom end 1a of the cardigan 1, and tubular knit fabric on which the buttonhole 2 is to be formed is knitted by the front and rear knitting needles as shown in knitting courses of FIGS. 3-1 to 3-2.
At the beginning of knitting the buttonhole 2, a loop is formed on the front knitting needle H which places at the right-end of the buttonhole 2 as shown in FIG. 3-3 and then the loop held on the knitting needle H is transferred to the rear knitting needle h which holds a loop in FIG. 3-4.
Next, the two loops held on the rear knitting needle h are transferred to the front knitting needle G after the rear needle bed 4 is moved 1 pitch leftward. Then, the front knitting needle G now holds three loops and the front knitting needle H and the rear knitting needle h become empty.
The knitting courses in FIGS. 3-3 to 3-5 are repeated in FIGS. 3-6 to 3-8 and in FIGS. 3-9 to 3-11 for predetermined times, and when knitting comes to the left-end of the buttonhole 2, at the front knitting needle E, for example, a supplied yarn is tucked on the front knitting needle C and forms a loop on each of the front knitting needles E, D as shown in FIG. 3-12.
After the loop held on the front knitting needle E is transferred to the rear knitting needle e in FIG. 3-13, the rear needle bed 4 is moved 1 pitch leftward and then the loop held on the rear knitting needle e is transferred to the front knitting needle D in FIG. 3-14. As a result, a bottom peripheral portion 2a of the buttonhole 2 is formed on the front knitting needles H to E.
After the bottom peripheral portion 2a of the buttonhole 2 is formed, a top peripheral portion 2b of the buttonhole 2 is formed as described below.
In FIG. 3-15, a loop held on the front knitting needle D is made to be held also on the rear knitting needle d. In FIG. 3-16, a new loop is formed on the rear knitting needle d, and the new loop is transferred to the front knitting needle E after the rear needle bed 4 is moved 1 pitch rightward in FIG. 3-17. Thus the front knitting needle E which was empty in FIG. 3-14 holds a loop now, that is, a number of stitches has increased.
The procedure to increase stitches as in FIGS. 3-15 to 3-17 is repeated in FIGS. 3-18 to 3-20, FIGS. 3-21 to 3-23 and FIGS. 3-24 to 3-26 for predetermined times and then the front knitting needles E to H which were empty in FIG. 3-14 come to hold a loop respectively.
In FIG. 3-27, the loop held on the front knitting needle H is made to be held also on the rear knitting needle h. In FIG. 3-28, a new loop is formed on the rear knitting needle h, and the new loop is transferred to the front knitting needle I after the rear needle bed 4 is moved 1 pitch rightward in FIG. 3-29. Then the front knitting needle I holds two loops which reinforce the right-end portion of the buttonhole 2.
On the other hand, the rear knitting needles d to h which have been knitting the back knitting part of the tubular knit fabric consisting of front and back knitting parts are empty at the buttonhole 2. In this place, after the rear needle bed 4 is moved 1 pitch leftward in FIG. 3-30, the loops held on the front knitting needles D to H are made to be held also on the rear knitting needles d to h respectively.
Accordingly, new loops are formed on the front knitting needles A to C by supplying a yarn in FIG. 3-31, and in FIG. 3-32, new loops are formed on the rear knitting needles a to j by supplying a yarn, thus the back knitting part at the top peripheral portion 2b of the buttonhole 2 is knitted.
In FIG. 3-33, a yarn tucked on the front knitting needle K is supplied to the front knitting needle J to A and loops are formed on them. In FIG. 3-34, a yarn is supplied to the rear knitting needles a to j and the front knitting needles K to V and a loop is formed on each of them. Further, in FIG. 3-35, a yarn is supplied to the front knitting needles A to V to form loops on them, and in FIG. 3-36, a yarn is supplied to the rear knitting needles a to j and loops are formed on them. Furthermore, in FIG. 3-37, a yarn tucked on the front knitting needle K is supplied to the front knitting needle J to A and loops are formed on them.
By repeating the knitting courses in FIGS. 3-34 to 3-37 for predetermined times, the body part of the cardigan 1 is formed.
In this way, the lowest buttonhole 2 and the knitting fabric around the buttonhole 2 is knitted.
The above knitting courses for the buttonhole 2 and the knitting fabric around the buttonhole 2 are repeated for expected times.
In the above embodiment, the back knitting part at the top peripheral portion 2b of the buttonhole 2 in the tubular knit fabric is knitted by using a method of making one loop be held on two confronting knitting needles. However, it is needless to say that loops may be formed on the rear knitting needles by supplying a yarn in a zigzag pattern between the front knitting needles and the empty rear knitting needles.
Embodiment 2
In a knitting method for a buttonhole in a knit product in the embodiment 2, the bottom peripheral portion 2a of the buttonhole 2 is formed in the same way as the embodiment 1, but on and after FIG. 3-14, the embodiment 2 employs a knitting procedure that is different from that in the embodiment 1 for knitting the top peripheral portion 2b of the buttonhole 2 as described below.
After the bottom peripheral portion 2a of the buttonhole 2 is formed on the front knitting needles H to E, that is, after a knitting course in FIG. 4-1, a yarn is supplied in a zigzag pattern between the front knitting needles D to I and the rear knitting needles d to h as shown in FIG. 4-2. In FIG. 4-3, a yarn is supplied to the loops which have been formed on the front knitting needles D to H to form new loops and at the same time the old loops are transferred to the rear knitting needles d to h.
Further, in FIG. 4-4, a yarn tucked on the front knitting needles C and I forms loops on the front knitting needles D to H and the loops are transferred to the rear knitting needles d to h in FIG. 4-5 in the same way as shown in FIG. 4-3. In FIG. 4-6, a yarn is supplied to the front knitting needles A to C to form loops on them and in FIG. 4-7, a yarn is supplied to the rear knitting needles a to j to form loops on them.
Furthermore, a yarn tucked on the front knitting needle K is supplied to the front knitting needles A to J to form loops on them in FIG. 4-8, and in FIG. 4-9, a yarn is supplied to the rear knitting needles a to j and the front knitting needles K to V and a loop is formed on each of the knitting needles.
By repeating the knitting courses in FIGS. 4-7 to 4-10 for predetermined times, the body part of the cardigan 1 is knitted.
In this way, the lowest buttonhole 2 and the knitting fabric around the buttonhole 2 in the cardigan 1 are knitted.
The above knitting courses for the buttonhole 2 and the knitting fabric around the buttonhole 2 are repeated for a necessary number of courses.
The procedure to form the buttonhole 2 in the embodiment 2 has an advantage that it needs a less number of knitting courses than that in the embodiment 1.
Embodiment 3
In a knitting method for a buttonhole in a knit product in the embodiment 3, the bottom peripheral portion 2a of the buttonhole 2 is formed in the same way as the embodiment 1, but on and after FIG. 3-14, the embodiment 2 employs a knitting procedure that is different from that in the embodiment 1 for knitting the top peripheral portion 2b of the buttonhole 2 as described below.
After the bottom peripheral portion 2a of the buttonhole 2 is formed on the front knitting needles H to E, that is, after a knitting course in FIG. 5-1, a yarn is supplied in a zigzag pattern between the front knitting needles D to I and the rear knitting needles d to h as shown in FIG. 5-2. In FIG. 5-3, a yarn tucked on the front knitting needle C is supplied to the front knitting needles D to H to form loops on them.
Further, in FIG. 5-4, a yarn is supplied to the rear knitting needles d to h to form loops and the yarn is also tucked on the front knitting needle I. In FIG. 5-5, the loops held on the front knitting needles D to H are made to be held also on the rear knitting needles d to h.
Furthermore, a yarn is supplied to the front knitting needles A to C to form loops on them in FIG. 5-6 and a yarn is supplied to the rear knitting needles a to j to form loops on them in FIG. 5-7.
Subsequently, a yarn tucked on the front knitting needle K is supplied to the front knitting needles A to J to form loops on them in FIG. 5-8. Further, in FIG. 5-9, a yarn is supplied to the rear knitting needles to j and then front knitting needles K to form loops on them.
By repeating the knitting courses in FIGS. 5-7 to 5-10 for predetermined times, the body part of the cardigan 1 is knitted.
In this way, the lowest buttonhole 2 and the knitting fabric around the buttonhole 2 in the cardigan 1 are knitted.
The above knitting courses for the buttonhole 2 and the knitting fabric around the buttonhole 2 are repeated for a necessary number of courses.
Embodiment 4
In a knitting method for a buttonhole of a knit product in the embodiment 4, the bottom peripheral portion 2a of the buttonhole 2 is formed in the same way as the embodiment 1, but on and after FIG. 3-14, the embodiment 2 employs a knitting procedure that is different from that in the embodiment 1 for knitting the top peripheral portion 2b of the buttonhole 2 as described below.
After the bottom peripheral portion 2a of the buttonhole 2 is formed on the front knitting needles H to E, that is, after a knitting course in FIG. 6-1, a yarn is supplied in a zigzag pattern between the front knitting needles D to I and the rear knitting needles d to h as shown in FIG. 6-2. In FIG. 6-3, a yarn is supplied to the loops which have been formed on the front knitting needles D to H to form new loops and at the same time the old loops are transferred to the rear knitting needles d to h.
In FIG. 6-4, a yarn is supplied to the front knitting needles A to C to form loops on them, and after that, a yarn is supplied to the rear knitting needles a to j to form loops on them as shown in FIG. 6-5.
Further, a yarn tucked on the front knitting needle K is supplied to the front knitting needles A to J to form loops on them in FIG. 6-6. In FIG. 6-7, a yarn is supplied to the rear knitting needles a to i and the front knitting needles J to V to form loops on them.
By repeating the knitting courses in FIGS. 6-5 to 6-8 for predetermined times, the body part of the cardigan 1 is knitted.
In this way, the lowest buttonhole 2 and the knitting fabric around the buttonhole 2 in the cardigan 1 are knitted.
The above knitting courses for the buttonhole 2 and the knitting fabric around the buttonhole 2 are repeated for necessary times.
Embodiment 5
In a knitting method for a buttonhole in a knit product in the embodiment 5, the bottom peripheral portion 2a of the buttonhole 2 is formed in the same way as the embodiment 1, but on and after FIG. 3-14, the embodiment 2 employs a knitting procedure that is different from that in the embodiment 1 for knitting the top peripheral portion 2b of the buttonhole 2 as described below.
After the bottom peripheral portion 2a of the buttonhole 2 is formed on the front knitting needles E to H, that is, after a knitting course in FIG. 7-1, a yarn is supplied in a zigzag pattern between the front knitting needles D to I and the rear knitting needles d to h as shown in FIG. 7-2. In FIG. 7-3, a yarn tucked on the front knitting needle C is supplied to the front knitting needles D to H to form loops on them.
In FIG. 7-4, a yarn is supplied to the rear knitting needles d to h to form loops on them. In FIG. 7-5, a yarn is supplied in a zigzag pattern between the front knitting needles D to I and the rear knitting needles d to h. In FIG. 7-6, a yarn is supplied to the front knitting needles A to C to form loops on them.
Further, a loop is supplied to the rear knitting needles a to j to form loops on them in FIG. 7-7, and subsequently in FIG. 7-8, a yarn tucked on the front knitting needle K is supplied to the front knitting needles A to J to form loops on them. In FIG. 7-9, a yarn is supplied to the rear knitting needles a to j and the front knitting needles K to V to form loops on them.
By repeating the knitting courses in FIGS. 7-8 to 7-11 for predetermined times, the body part of the cardigan 1 is knitted.
In this way, the lowest buttonhole 2 and the knitting fabric around the buttonhole 2 in the cardigan 1 are knitted.
The above knitting courses for the buttonhole 2 and the knitting fabric around the buttonhole 2 are repeated for a necessary number of courses.
In the above embodiments, a flat knitting machine having a pair of front and rear needle beds is used. However, it is needless to say that a flat knitting machine used in the invention is not limited to the one having such a construction but two pair of confronting needle beds might be provided on the flat knitting machine.
The foregoing relates to a preferred exemplary embodiment of the invention, it being understood that other variants and embodiments thereof are possible within the spirit and scope of the invention, the latter being defined by the appended. | A method for knitting a buttonhole in a knit product by using a knitting machine for forming the remainder of the knitted product employing the following steps: feeding a thread to a front knitting needle, transferring the loop held on the front knitting needle to a corresponding rear knitting needle, racking the needle bed leftward, transferring the two loops to a front needle, repeating the above steps leftward to form a bottom peripheral portion if the buttonhole, hooking a loop held on the front needle, racking and transferring the loop rightward to an empty front needle, repeating the steps rightward to increase the number of loops on the front knitting needles. | 3 |
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to control systems for recovery of refrigerant from air conditioning systems.
2. Description of Prior Art
Fluorocarbons have been widely used as the refrigerant in chiller units for air conditioning, or HVAC, systems. Some of the most widely used fluorocarbons have been types of chlorinated fluorocarbon (CFC) sold under the trademark FREON®. In recent years, environmental concerns have arisen about fluorocarbon or CFC refrigerants and their possible harmful effects on the earth's atmosphere. Although until recently only disfavored for environmental reasons, it has now become unlawful to purposefully vent chlorinated fluorocarbon refrigerants to the atmosphere. For this and other reasons, the cost of such refrigerants has increased significantly. Although accidental leakage from system failures or breakdowns is not unlawful, it has become a very expensive and undesirable situation.
Generally, existing HVAC units have a graphite rupture disk on a centrifugal chiller unit as a portion of the original equipment. The disk has been designed to rupture when the system refrigerant pressure reached a specified excess pressure limit, typically 15 psig or so. In the past, refrigerant which escaped in the event of disk rupture was vented into the atmosphere.
Certain types of systems are available which attempt to limit or reduce the venting of refrigerant. These systems use a relief valve which opens at the excess pressure limit and closes again at a certain fraction or percentage (such as two-thirds) of the pressure limit. However, these systems allow repeated cycles of opening the relief valve, to vent refrigerant at the excess pressure limit, with subsequent closing of the relief valve. Eventually, unless the excess pressure problem was corrected, the entire charge of refrigerant could be vented in increments to the atmosphere.
SUMMARY OF INVENTION
Briefly, the present invention provides a new and improved system for refrigerant recovery in emergency situations. The system according to the present invention includes a pressure sensor to sense pressure of excess pressure refrigerant escaping from an air conditioning unit. Operation of the air conditioning unit is stopped in the event that excess pressure in the refrigerant is sensed, and an alarm is activated. A transfer conduit is provided to convey the excess pressure refrigerant to a refrigerant recovery unit, and a transfer valve is included in the transfer conduit. The transfer valve is opened in response to excess pressure refrigerant conditions so that the excess pressure refrigerant is transported to the recovery unit, reducing the escape of the refrigerant. The apparatus of the present invention also preferably includes a relief valve in fluid communication with the refrigerant recovery unit so that excess pressure refrigerant may be recovered instead of venting it into the atmosphere. Alternatively, but less preferred, the relief valve may initially allow excess pressure refrigerant to be vented from the air conditioning unit to the atmosphere.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a system according to the present invention.
FIG. 2 is a schematic electrical circuit diagram of the system of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the drawings, the letter A designates generally an apparatus according to the present invention in the form of a control system for an air conditioning or HVAC unit or system. The apparatus of the present invention is adapted for recovery of refrigerant and control of the venting of such refrigerant in the event of high pressure conditions in the air conditioning unit. Typically, the refrigerant in the unit is a chlorinated fluorocarbon (CFC), although it should be understood that other refrigerants are recoverable with the apparatus of the present invention.
The apparatus A is connected to an HVAC unit U, typically at a chiller 10, by a conduit 12 and a conventional flange mounted pressure sensitive mechanism 14 in the form of a graphite rupture disk. The rupture disk 14 is intended to rupture in the event that pressure of the refrigerant in the unit U exceeds an established limit, usually in the range of about 15 psig. In the past, the refrigerant has been vented to the atmosphere in its entirety usually at rupture of the disk or in successive stages, as detailed above.
A vibration absorber 16 is typically connected at the output of the pressure-sensitive rupture disk 14 and connects a relief conduit 18 of the apparatus A to the air conditioning unit U. In the event that the vibration absorber 16 is not used, the relief conduit 18 itself connects the apparatus A directly to the rupture disk 14 and thus to the air conditioning unit U. The relief conduit 18 conveys excess pressure refrigerant from the rupture disk 14 to a relief valve R and a pressure sensor S.
The relief conduit 18 is shown in the preferred embodiment as a conduit section connected by fittings to other conduits or tubing in the apparatus A. It should be understood that the fittings and connections shown are given by way of example and that other fluid transport connections may also be used. For example, the relief conduit 18 may be directly connected to the vibration absorber 16 rather than through a fitting 19, as shown.
The pressure sensor S is connected by a tube or conduit 20 to the relief conduit 18. The pressure sensor S includes a pressure sensitive electrical switch 22 (FIG. 2) which closes in the event of excess pressure refrigerant in the relief conduit 18.
The apparatus A also includes a transfer valve T in fluid communication with the relief conduit 18. The transfer valve T is a solenoid operated valve, opening and closing in response to a solenoid 24 which is electrically connected in a control circuit arrangement 26 (FIG. 2) operating under control of the pressure/electric switch 22.
The transfer valve T when open permits refrigerant in the relief conduit 18 to pass into a transfer conduit 28. The transfer conduit 28 is in fluid communication between the transfer valve T and a conventional refrigerant recovery unit 30, which may be of any suitable type. The recovery unit 30 includes a starter motor 32 electrically connected (FIG. 2) in the control circuit 26 with the pressure/electric switch 22.
If desired, several apparatus A according to the present invention may be connected at their respective transfer conduits 28 through a manifold arrangement 34 shown schematically in common to the refrigerant recovery unit 30.
The relief valve R is in fluid communication with the relief conduit 18, either directly or through additional conduits and connecting fittings. A strainer section 35 is provided, either in the relief conduit 18 or in another of the connecting conduits or fittings, to receive broken pieces of the rupture disk 14. In this manner, broken pieces of the rupture disk 14 do not interfere with operation of the relief valve R, the transfer valve T or the pressure sensor S.
The relief valve R is operable to open at a predetermined pressure, usually at or near the rupture pressure of the disk 14, to permit escaping refrigerant to pass into an outlet conduit 36. The outlet conduit 36 may be connected directly or through other pipes, fittings or connectors between the relief valve R and the pipe 38. The particular connection arrangement depends upon location of the components of the apparatus A at the site and other factors.
The outlet conduit 36 is connected at an outlet opposite the relief valve R to a conduit or pipe 38. Preferably, the pipe 38 is connected to the refrigerant recovery unit 30, as is the transfer conduit 28. In this manner, substantially all of the refrigerant escaping on rupture of the disk 14 is transported to the recovery unit 30 where it may be recovered. This is desirable for environmental, as well as, economic reasons. In some situations, however, the conduit or pipe 38 may in the alternative serve to vent limited initial portions of the escaping refrigerant to the atmosphere.
The control circuit 26 is electrically connected to a suitable electrical power supply at power supply terminals 40 (FIG. 2) and 42. The pressure/electrical switch 22 and a control relay coil 44 are electrically connected between the power supply terminals 40 and 42. The relay coil 44 includes normally open contacts 46, 48 and 50 as well as normally closed contact 52. The normally open contact 46 electrically connects an alarm 54 between the power supply terminals 40 and 42 when the coil 44 receives current. The alarm 54 may be a light or other signal emitter, or other visible or audible alarm, including a telemetry unit.
The normally open contact 48 electrically connects a solenoid coil 56 of the solenoid 24 between the power supply terminals 40 and 42 when the control relay coil 44 receives current. The solenoid coil 56 in this condition causes the solenoid 24 to open the transfer valve T, allowing escaping refrigerant from the disk D in the relief conduit 18 to pass into the transfer conduit 28 and thence into the recovery unit 30.
The normally open contact 50 electrically connects the starter motor 32 of the recovery unit 30 between the power supply terminals 40 and 42 when the control relay coil 44 receives electrical current. When the starter motor 32 is so energized, the recovery unit 30 begins operation, recovering the refrigerant present in the transfer conduit 28 and, where it is so connected, in the pipe 38.
The normally closed contact 52 is designed to open when the control relay coil 44 receives current. The contact 52 is electrically connected at its output terminals 60 and 62 into the control circuit of the HVAC unit U. When the contact 52 opens, the control circuit of the unit U is de-energized, stopping operation of the air conditioning unit U, typically at the chiller 10.
In the operation of the present invention, the HVAC unit U operates in the normal manner until the pressure of the refrigerant in the unit U exceeds the pressure limit of the rupture disk 14. At this point, the excess pressure refrigerant ruptures the disk 14 and passes into the relief conduit 18 to both the pressure sensing mechanism S and the relief valve R. The pressure/electric switch 22 in the pressure sensor S closes at this point, allowing current to flow through the control relay coil 44 in the control circuit 26.
The escaping refrigerant in the relief conduit 18 also passes into the relief valve R. Depending upon the pressure setting of the relief valve R, an initial portion of the escaping refrigerant may pass into the outlet conduit 36 and pipe 38 and therefrom into the recovery unit. Alternatively, in the event that the pressure setting of the relief valve R is higher than that of the pressure/electric switch 22, the relay coil 44 causes the normally open contacts 46, 48, and 50 to close, and the normally closed contacts 52 to open.
The contacts 46 on closing permit electrical current to flow to the alarm 54, while the contacts 48 on closing energize the solenoid coil 56, causing the transfer valve T to open. When the transfer valve T opens, the refrigerant in the relief conduit 18 passes into the transfer conduit 28 to the recovery unit 30. Contemporaneously with the operation of the solenoid coil 56, the contacts 50 on closing permit electrical current to flow to the starter motor 32 of the recovery unit, so that recovery of the refrigerant present in the transfer conduit 28 and the pipe 38 may begin.
At the same time that the normally open contacts 46, 48, and 50 close, the normally closed contacts 52 open, interrupting operation of the control circuit of the HVAC unit U. At this point, the operation of the unit U is stopped.
From the foregoing, it can be seen that the apparatus A according to the present invention activates recovery of the refrigerant from the air conditioning unit U in the event of excess pressure in the unit U. Operation of the air conditioning unit U is stopped in the event of such excess pressure in the refrigerant being sensed, and the alarm 54 is activated. Contemporaneously, the transfer valve T is opened in response to excess pressure refrigerant conditions so that the excess pressure refrigerant is transported to the recovery unit 30 through the transfer valve T and transfer conduit 28.
In this manner, escape of the pressurized refrigerant is substantially reduced. With the apparatus A, the relief valve R is preferably in fluid communication through the pipe 38 to the refrigerant recovery unit 30 so that excess pressure refrigerant which might otherwise pass through the relief valve R, and be vented to the atmosphere, may be recovered as well.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape, materials, components, circuit elements, wiring connections and contacts, as well as in the details of the illustrated circuitry and construction and method of operation may be made without departing from the spirit of the invention. | A system is provided at the emergency pressure release in an air conditioning refrigerant system. The system protects the environment from venting of the pressurized refrigerant. The system also permits recovery of the refrigerant for subsequent use or for environmentally safe disposal. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 13/587,863, filed Aug. 16, 2012, which claims priority from U.S. Provisional Application No. 61/605,119, filed Feb. 29, 2012, which applications are incorporated herein by reference in their entirety.
BACKGROUND
The Document Object Model (DOM) is an application programming interface (API) for HTML and XML documents. It defines the logical structure of documents and ways for documents to be accessed and manipulated. One objective for DOM is to provide a standard programming interface that can be used in a wide variety of environments and applications. Generally, DOM provides a hierarchical tree structure having a plurality of nodes in parent/child relationships. Using this structure, script programs can examine and dynamically change a web page.
Other languages can be associated with object models different than DOM. However, whatever model is used, it is desirable to allow programmers to build documents, navigate their structure, and add, modify, or delete elements and content.
Even with well-defined object models, authoring pages that can be used across different platforms can be challenging. For example, different pages often need to be created based on whether the page is to be displayed on a server or a client, despite an overlap in content between the pages. In one simple example, a server-side page can display headers and footers that are not displayed on a client page. In such a situation, two different pages need to be created even if the content is the same.
SUMMARY
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
A method and apparatus are disclosed for combining server-supplied user interface elements with client-supplied user interface (UI) elements. The server-supplied user interface elements can be received by a client device and inserted into a client-supplied object model, such as a Document Object Model (DOM). The object model can then be used to render a page, such as a webpage.
By injecting server-supplied user interface elements into a client object model, the client can intelligently combine UI elements from a server with UI elements from a client. In the situation where there are conflicting or overlapping UI elements, the client device can modify the object model to eliminate such conflicts or overlaps. Thus, the client's access to user information stored on the client device can be used to modify server-supplied UI elements. Additionally, by being able to dynamically modify the object model, a page can be created for different platforms and then modified in the object model.
The foregoing and other objects, features, and advantages of the invention will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an example architecture that can be used where client-supplied UI elements and server-supplied UI elements are combined in a client object model.
FIG. 2 shows an example page having blended server-supplied UI and client-supplied UI.
FIG. 3 shows combining server-side and client-side UI elements in an object model.
FIG. 4 is a flowchart of a method for inserting server-supplied user interface elements into the Client object model.
FIG. 5 is a flowchart of a method for inserting server-supplied user interface elements into a Document Object Model.
FIG. 6 is an example client computing environment that can be used for any of the embodiments described herein.
DETAILED DESCRIPTION
FIG. 1 illustrates an exemplary system that can be used for implementing embodiments described herein. A controller 110 (e.g., processor, FPGA, microcontroller, etc.) can receive user interface (UI) elements from a server computer 120 via a network 122 , such as the Internet. The UI elements can include icons, menus, controls (e.g., text boxes, buttons, hyperlinks, drop-down lists, check boxes, radio buttons, etc.), commands, content, etc. The received UI elements 130 can be inserted into an object model 132 stored in memory 136 on a client device. In the case where the UI elements are in HTML, the object model 132 can be a Document Object Model (DOM). Although the description generally uses HTML, XML and DOM as examples, it is understood that the embodiments herein are not limited to those specific languages and object models. Rather, any markup language and object model can be used. The controller 110 can blend the UI elements 130 from the server with client UI elements 140 in the same object model 132 . Being in the same object model allows a script or other program executing on the controller 110 to manipulate the server UI elements 130 and the client UI elements 140 in a like manner. Additionally, style information from the server can be applied to any rendered page. Using the object model 132 , the controller 110 can assist in rendering on a display 150 (a separate renderer can also be used) a combination of the server UI elements 152 and client UI elements 154 obtained from the object model. The controller 110 can check whether the network 122 is connected to the client device and make intelligent decisions about formatting the display 150 through manipulation of the object model 132 . For example, some or all of the server UI elements 130 can be suppressed if there is not a network connection. Additionally, the area on the display 150 can be expanded for the client UI elements 154 . In an offline mode, previously cached server responses stored in local memory or disk on the client device can be used.
It will be understood by those skilled in the art that building an object model on the client device using server-supplied UI elements and client-supplied UI elements is fundamentally different than simply rendering a page that pulls in images or text from a server computer, as such images or text are not copied to the object model and cannot be manipulated by a client script.
FIG. 2 shows an example user interface 210 that can include a combination of images, such as is shown at 220 , and text, as is shown at 230 . The text can be downloaded XML content that is reformatted into HTML for display. User interface elements 240 and 250 can also be included in the user interface. The user interface elements 240 are sourced by the client, such as from local memory or cache, while the user interface elements 250 are sourced from the server. In both cases, the user interface elements 240 , 250 are inserted into an object model prior to rendering the user interface 210 . The server-supplied content 250 can include style information so that a portion of the look and feel of the user interface 210 can be controlled by a server computer. Typically, the server-supplied content 250 is in HTML, but other content can be supplied by the server, such as Cascading Style Sheets (CSS), scripting languages (e.g., javascript), etc. The local content 240 can have a look and feel supplied by the client device, while the server-supplied content 250 can have a look and feel controlled by the server computer. Additionally, the server content can inherit style from the local content, if needed.
FIG. 3 shows a script engine 310 that can be executed on the controller 110 ( FIG. 1 ). The script engine 310 can build the object model using various elements sourced from the client and the server. In the simple illustrated example, the script engine 310 can determine that server-supplied UI element 1 , shown at 320 , is the same as client UI element 1 , shown at 330 . Thus, the script engine 310 can compare the client-supplied user interface elements with the server-supplied user interface elements, and, if there is a match, can suppress one of the UI elements to reduce redundancy. In the case of FIG. 3 , UI element 320 is not copied into the object model or is otherwise removed from the object model. UI element 350 is determined not to be the same as a client supplied UI element. As such, it is copied and inserted into an object model 360 . As shown at 370 , the UI element 350 can be inserted between tags in the object model. For example, when the object model 360 is a DOM, the tags can be division tags (also called div tags). The script engine 310 can search the object model for the tags and insert the server-supplied UI elements between the div tags. Style information, such as color, font, size or any other look and feel elements can also be inserted in the object model using the tags. Thus, using this structure, the server can control the look and feel of the user interface on a client computer. The script engine 310 can further check a network connection as shown at 380 . If the network is currently down, the script can retrieve previously cached server UI elements stored on the client device, or the script engine can suppress the previously received UI elements received from the server computer and expand the client-supplied UI elements. The script engine 310 can further execute a script and manipulate the server supplied UI elements while they are in the object model 360 .
FIG. 4 shows a flowchart of a method for combining client-side and server-side UI elements. In process block 410 , UI elements including style information for look and feel can be received from a server computer. As previously explained, the UI elements can be in HTML, CSS, javascripts, or any other desired code or data for rendering a page, such as an application page or webpage. In process block 420 , the UI elements are inserted into an object model, such as a DOM. By inserting the UI elements in the DOM, the client-supplied UI elements and the server-supplied UI elements are merged into a single model to be rendered. In process block 430 , the object model is rendered with the client and server UI elements combined.
FIG. 5 is a flowchart of a method for integrating server-supplied UI elements and client-supplied UI elements. In process block 510 , user interface elements are received from a server computer. The user interface elements can include executable code, style sheets, content, etc. In process block 520 , the UI elements including style information can be copied into a DOM. In process block 530 , the server-supplied and client-supplied user interface elements can be displayed in a user interface using the DOM.
FIG. 6 illustrates a generalized example of a suitable computing environment 600 in which several of the described techniques and tools may be implemented. The computing environment 600 is not intended to suggest any limitation as to scope of use or functionality, as the techniques and tools may be implemented in diverse general-purpose or special-purpose computing environments. The computing environment 600 is a client device, which can be a mobile device (e.g., cell phone, smartphone, handheld computer, Personal Digital Assistant (PDA), etc.) or desktop computer.
With reference to FIG. 6 , the computing environment 600 includes one or more processing units 610 , 615 and memory 620 , 625 that can be used in implementing a computing device. In FIG. 6 , this most basic configuration 630 is included within a dashed line. The processing units 610 , 615 execute computer-executable instructions. A processing unit can be a general-purpose central processing unit (CPU), processor in an application-specific integrated circuit (ASIC) or any other type of processor. In a multi-processing system, multiple processing units execute computer-executable instructions to increase processing power. For example, FIG. 6 shows a central processing unit 610 as well as a graphics processing unit or co-processing unit 615 . The memory 620 , 625 may be volatile memory (e.g., registers, cache, RAM), non-volatile memory (e.g., ROM, EEPROM, flash memory, etc.), or some combination of the two, accessible by the processing unit(s). The memory 620 , 625 stores software 680 implementing one or more innovations for combining client and server UI elements.
A computing environment may have additional features. For example, the computing environment 600 includes storage 640 , one or more input devices 650 , one or more output devices 660 , and one or more communication connections 670 . An interconnection mechanism (not shown) such as a bus, controller, or network interconnects the components of the computing environment 600 . Typically, operating system software (not shown) provides an operating environment for other software executing in the computing environment 600 , and coordinates activities of the components of the computing environment 600 .
The tangible storage 640 may be removable or non-removable, and includes magnetic disks, magnetic tapes or cassettes, CD-ROMs, DVDs, or any other medium which can be used to store information in a non-transitory way and which can be accessed within the computing environment 600 . The storage 640 can store instructions for the software 680 implementing one or more innovations disclosed herein for combining client-supplied and server-supplied UI elements.
The input device(s) 650 may be a touch input device such as a keyboard, mouse, pen, or trackball, a voice input device, a scanning device, or another device that provides input to the computing environment 600 . The output device(s) 660 may be a display, printer, speaker, CD-writer, or another device that provides output from the computing environment 600 .
The communication connection(s) 670 enable communication over a communication medium to another computing entity. The communication medium conveys information such as computer-executable instructions, audio or video input or output, or other data in a modulated data signal. A modulated data signal is a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media include wired or wireless techniques implemented with an electrical, optical, RF, or other carrier.
The techniques and tools can be described in the general context of computer-readable media. Computer-readable media are any available tangible media that can be accessed within a computing environment. By way of example, and not limitation, with the computing environment 600 , computer-readable media include memory 620 , storage 640 , and combinations of any of the above.
The techniques and tools can be described in the general context of computer-executable instructions, such as those included in program modules, being executed in a computing environment on a target real or virtual processor. Generally, program modules include routines, programs, libraries, objects, classes, components, data structures, etc. that perform particular tasks or implement particular abstract data types. The functionality of the program modules may be combined or split between program modules as desired in various embodiments. Computer-executable instructions for program modules may be executed within a local or distributed computing environment.
The terms “system” and “device” are used interchangeably herein. Unless the context clearly indicates otherwise, neither term implies any limitation on a type of computing system or computing device. In general, a computing system or computing device can be local or distributed, and can include any combination of special-purpose hardware and/or general-purpose hardware with software implementing the functionality described herein.
For the sake of presentation, the detailed description uses terms like “determine” and “select” to describe computer operations in a computing environment. These terms are high-level abstractions for operations performed by a computer, and should not be confused with acts performed by a human being. The actual computer operations corresponding to these terms vary depending on implementation.
Although the operations of some of the disclosed methods are described in a particular, sequential order for convenient presentation, it should be understood that this manner of description encompasses rearrangement, unless a particular ordering is required by specific language set forth below. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed methods can be used in conjunction with other methods.
Any of the disclosed methods can be implemented as computer-executable instructions stored on one or more computer-readable storage media (e.g., non-transitory computer-readable media, such as one or more optical media discs, volatile memory components (such as DRAM or SRAM), or nonvolatile memory components (such as hard drives)) and executed on a computer (e.g., any commercially available computer, including smart phones or other mobile devices that include computing hardware). Any of the computer-executable instructions for implementing the disclosed techniques as well as any data created and used during implementation of the disclosed embodiments can be stored on one or more computer-readable media (e.g., non-transitory computer-readable media). The computer-executable instructions can be part of, for example, a dedicated software application or a software application that is accessed or downloaded via a web browser or other software application (such as a remote computing application). Such software can be executed, for example, on a single local computer (e.g., any suitable commercially available computer) or in a network environment (e.g., via the Internet, a wide-area network, a local-area network, a client-server network (such as a cloud computing network), or other such network) using one or more network computers.
For clarity, only certain selected aspects of the software-based implementations are described. Other details that are well known in the art are omitted. For example, it should be understood that the disclosed technology is not limited to any specific computer language or program. For instance, the disclosed technology can be implemented by software written in C++, Java, Pert, JavaScript, Adobe Flash, or any other suitable programming language. Likewise, the disclosed technology is not limited to any particular computer or type of hardware. Certain details of suitable computers and hardware are well known and need not be set forth in detail in this disclosure.
The disclosed framework allows the client to blend UI elements delivered from the Internet with UI already on the client. This allows for sensitive business logic to be executed on the server, where it is more secure and updatable. These UI elements can then be seamlessly blended with client elements. For example, HTML, CSS and Javascript can be delivered securely from the Internet and injected into Client's DOM. This method allows code delivered from the server to blend with UI elements generated on the client. This is valuable because the client has access to user information that the server does not have.
In view of the many possible embodiments to which the principles of the disclosed invention may be applied, it should be recognized that the illustrated embodiments are only preferred examples of the invention and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims. We therefore claim as our invention all that comes within the scope of these claims. | A method and apparatus are disclosed for combining server-supplied user interface elements with client-supplied user interface elements. The server-supplied user interface elements can be received by a client device and inserted into a client-supplied object model, such as a Document Object Model (DOM). The object model can then be used to render a page, such as a webpage. By injecting server-supplied user interface elements into a client object model, the client can intelligently combine UI elements from a server with UI elements from a client. In the situation where there are conflicting or overlapping UI elements, the client device can modify the object model to eliminate such conflicts or overlaps. | 7 |
[0001] The sector of the art to which the present invention is related, is that of earthquake-resisting structures and the part of Geophysics which deals with Seismology
BACKGROUND OF THE INVENTION
[0002] The state of the art considers earthquakes to be practically unpredictable. The main causes which produce an earthquake are plate tectonics, and there immediate effects are elastic forces, which originating at the focus or hypocentre, traverse the Earth (longitudinal or primary waves and transverse or secondary waves).
[0003] When these forces reach the surface, at the earthair or earth-water interface, they produce surface forces of different intensity or wavelength, Love waves, Rayleigh waves, long or L waves).
[0004] The surface waves are the most destructive, acting on structures in both the horizontal and vertical directions endeavouring to displace them. This is propagated through the foundations to the rest of the structure, producing tremors and twisting.
[0005] Investigations carried out up to now, deal with the causes of earthquakes, and all that can contribute to the prediction thereof in order to avoid disasters (in 1975, the Chinese were able to predict an earthquake in the Haicheng region). Moreover, attempts are being made to dampen their destructive effects, designing buildings in a pyramidal, symmetrical form, with the lifts in the centre, and reinforcing the structures, even with concrete enriched with carbon fibres.
[0006] Another field of research is attempting to achieve ductile materials and in turn resistant, which will absorb or dampen the seismic waves.
[0007] The ideal situation would be to dampen or destroy the seismic wave before it has an effect on the foundations. Along these lines, investigations carried out with electro-rheological materials allow to foresee that in the near future foundations will be able to be made taking these properties into account.
[0008] These materials have the quality that whilst a current of electricity is passed through the mass they remain in a solid state—rigid, and when it stops, it changes in a matter of milliseconds to a gelatinous state, which absorbs the seismic waves better.
[0009] In Spain, the valid Regulation is: Seismic Resistant Construction Standard, NCSE 94
DESCRIPTION OF THE INVENTION
[0010] In order to give a greater understanding of the invention, the most relevant concepts that have been taken into consideration are stated briefly:
[0011] 1.—All seismic wave forces are inter-reactive by contact, needing an ideal medium for their propagation.
[0012] 2.—The longitudinal or primary seismic and similar waves act like sound waves, and are transferred through solids and liquids.
[0013] 3.—The transversal or secondary and similar waves are propagated only through solids.
[0014] 4.—Incompressibility of liquids.
[0015] 5.—A contact interactive force cannot be propagated through a vacuum.
[0016] 6.—A force line cannot be transmitted through a liquid.
[0017] 7.—Pascal's Theorem has been taken into consideration in its full context.
[0018] 8.—The proportions have been deliberately exaggerated in the drawings for a better explanation.
[0019] 9.—Only direction, sense and point of application have been considered in the forces.
[0020] The aim of the invention is to isolate the foundations from the elastic forces of earthquakes, by means of anti-seismic plates, thus avoiding that the static balance of the constructed system is destroyed (buildings, bridges, etc.) and so that the seismic waves are not propagated to the rest of the construction.
[0021] The anti-seismic plates, FIG. 1—are receptacles preferably having a square shape and of variable thickness, which are divided into two parts—FIG. 2—.
[0022] In part (A), a liquid or semi-liquid has been introduced under a small amount of pressure. This is for the purpose of converting the seismic wave under pressure and destroying its line of force.
[0023] In part (B), the vacuum has been produced to prevent the propagation of the longitudinal waves, given that these are propagated through solids and fluids, but not through a vacuum.
[0024] The anti-seismic plates have to support large pressures. In part (A) the incompressibility of liquids has been taken into consideration, and in part (B) (where the vacuum is produced) some separators ( 2 ) have been fitted between the faces ( 1 and 3 ), preferably having a spherical shape to obtain the greatest resistance possible with the minimum contact.
[0025] In FIG. 2, it is highlighted that the face ( 1 ) and face ( 3 ) have a small amount of flexibility. This is so that the mechanical force of the seismic wave will apply pressure on the liquid in the receptacle (A).
[0026] Face ( 4 ) of FIG. 2 will always be in contact with the construction system, as can be seen in FIG. 3.
[0027] Following the order of frequency of the elastic force of the earthquake, it first acts on face ( 1 ) FIG. 2-, this puts force on the separators ( 2 ), and these on face ( 3 ), this on the liquid of receptacle (A), where the force is converted into pressure on face ( 4 ), an this face on the construction system. In FIG. 3 we have the correct assembly of the anti-seismic plates ( 2 ), in the base of the plate ( 1 ) and its sides or perimeter. The perimeter plates (if it is not a single plate that surrounds the base plate), will be joined from one to the other by the part of receptacle (A) so that the liquid reacts for the whole of the perimeter at the same moment. Force (F1) represents the static force of the building, force (F2) is the reaction of the ground, this force can be substituted by any other force that is equal or less (earthquake) without it breaking the static balance.
[0028] Force (F3)—FIG. 3—is considered as the superficial seismic force, this force applies pressure on the liquid (A), this in turn exercises a pressure that surrounds the plate and tries to compress it. These forces are equal and opposing hence, it becomes cancelled out.
[0029] Force (F4) would be the imbalance of the faces. Force (F3) would be the action and force ‘F4’ the reaction.
ADVANTAGES
[0030] The advantages to be highlighted are:
[0031] The damping or cancelling of seismic waves is achieved, avoiding tremors and twisting in the buildings, which allows different projects to be carried out.
[0032] An attempt is made to avoid the psychological effect of the earthquake on people who are in the buildings, which is where it is felt.
[0033] Its application can be adapted to any construction, which allows it to cover large areas so as to protect infrastructures, water, gas pipes, etc.
[0034] It can be applied to dampen vibratory movements of machines, sound waves, etc., likewise for the support of beams or decking for bridges, etc.
DESCRIPTION OF THE DRAWINGS
[0035] [0035]FIG. 1.—Elevation
[0036] [0036]FIG. 2.—Cross-section of the anti-seismic plate:
[0037] (A) space occupied by the liquid; (B) space where the vacuum has been made;
[0038] ( 1 ) external face in contact with the ground; ( 2 ) separators of faces ( 1 ) and ( 3 );
[0039] ( 3 ) separation between the faces (A) and (B); ( 4 ) external face in contact with the construction system.
[0040] [0040]FIG. 3.—( 1 ) base plate and pillar; ( 2 ) plates; (F1) static force; (F2) reaction force of the ground; (F3) superficial force of the earthquake; (F4) force from imbalance of the faces.
[0041] [0041]FIG. 4.—Cut elevation in order to be able to appreciate the plates.
[0042] [0042]FIG. 5.—Section of FIG. 4:
[0043] ( 1 ) pillar; ( 2 ) plates; ( 3 ) base plate; ( 4 ) box that surrounds the base plate; ( 5 ) perimeter wall that surrounds the building; ( 6 ) insulating concrete; ( 7 ) insulating float concrete for the support of the plates: ( 8 ) reinforced base plate for building bracing; ( 9 ) air or fill cavity; ( 10 ) bedding or steel reinforced plate with expansion joints for the walls and pillars; ( 11 ) ground.
[0044] [0044]FIG. 6.—( 1 ) conical base plate and pillar; (2) plates; (F1) lateral force of the earthquake; (F2) force from imbalance; (R 1 ) and (R 2 ) components of (R 3 ); (R 3 ) result in a downward direction.
[0045] [0045]FIG. 7.—underground wall:
[0046] ( 1 ) concrete fill; ( 2 ) plates; ( 3 ) ground; (F1) earthquake force.
[0047] By way of description but without limitation, three forms of the preferred construction are detailed, as the characteristics are different.
[0048] In the construction of buildings and similar constructions, a double anti-seismic barrier is highlighted that is made up of the perimeter wall and the base of the building, with the anti-seismic plates being as big as possible, communicated from one to the other (in a closed circuit) for the purpose of the liquid reacting at the same moment. It will be made up of a reinforced slab to brace the entire building and to protect the base plate if considerable cracks are produced in the ground.
[0049] A preferred form of the construction is shown in FIGS. 4 and 5:
[0050] After emptying the land, the perimeter wall ( 6 ) is straightened with insulating concrete and also the base of the foundations ( 7 ), the anti-seismic plates ( 2 ) are installed and then the iron corresponding to the reinforced slab ( 8 ) the walls ( 5 ) and that which is surrounding the base plate or box ( 4 ). The slab ( 8 ) is concreted, subsequently the plank moulding for or the walls ( 5 ) is made and the box that will contain the base plate ( 4 ). Once concreted and the panel forms removed, the anti-seismic plates ( 2 ) are installed in the interior of the box, thus protecting the base plate.
[0051] One single plate will be installed on the base of the base plate, and for the perimeter (in this case four sides, FIG. 4) will also be a single plate ( 2 ) FIG. 4, in the case of there being four plates, the part corresponding to the liquid (A) FIG. 2 would have to be communicated in a closed circuit.
[0052] The iron grid of the base plate ( 3 ) is installed, and the iron of the pillar ( 1 ) and then concreted. The spaces ( 9 ) can be an air cavity or be filled with gravel or something similar in order to achieve static strength. The bed or sole ( 10 ) will have an expansion joint with the walls and with the pillars. The ground is represented as N o ( 11 ) in FIGS. 4 and 5.
[0053] In FIG. 6, a base plate is shown which is worth mentioning because of its conical shape. This is specially suitable in projects for building with low static weight or isolated base plates (bridges, elevated roads, etc.). It can have other shapes such as a pyramid or cylinder, etc.
[0054] The aim of these types of base plates is to present the lowest surface possible to the superficial seismic waves and to form angles of refraction, in this way making it easier for the force to be propagated to where there is least resistance offered, specifically surrounding the base plate ( 1 ) in addition to obtaining a resultant force that pushes downwards or anchoring, which is added to the static force.
[0055] In a diagrammatic manner, the following explanation is stated only by way of taking in the idea of its qualities.
[0056] Force (F1)—FIG. 6, is the force of the superficial seismic waves that act on the base plate ( 1 ), part of this force surrounds the base plate and is propagated upwards on meeting the least resistance, and the other part of the force acts on the seismic plate ( 2 ), producing a pressure in the liquid, which on applying pressure in a perpendicular way to the walls which contain it gives us the results (R 1 ) and (R 2 ) (it is understood that two opposing points of the perimeter have been considered where the resultants are formed).
[0057] From the resultants (R 1 ) and (R 2 ), we obtain another resultant called (R 3 ) which produces a vertical force downwards.
[0058] The excavation for the base plates is normally in a cubic form; hence, the rest of the space is filled with harsh concrete to obtain a static force on the plate that counteracts the force (F2), which if broken down produces two forces, one horizontal and the other vertical in an upward direction.
[0059] The purpose of the underground walls—FIG. 7—is to protect the constructions already made from the superficial seismic waves, these being the most destructive.
[0060] The seismic force (F1),—FIG. 7—is propagated through the ground ( 3 ) and the harsh concrete fill ( 1 ), acting on the plates ( 2 ) and these in turn on the ground in a uniform manner.
[0061] The efficiency of these walls is relative, as although they cancel out the Love waves, they can allow the rest of the seismic waves, on having different wave lengths, to transfer part of the force to underneath the wall. This method of construction would require studies of distance, depth, etc.
[0062] It is thought that this idea of underground walls would be more effective or practical using electro-rheological materials if the costs will allow. The carrying out of this would be very | The invention aims at isolating the foundations and the remaining part of the building from the earthquake. The antiseismic plates ( 2 ) are hermetic containers divided into two parts. Vacuum has been produced in part “B” so that most of the longitudinal or primary seismic waves propagating through the solids and fluids are cancelled. A pressurized liquid has been introduced into part “A” to cancel the transversal or secondary waves that propagate through the solids. “F1” is the lateral force of the surface seismic wave acting upon the plate and producing a pressure on the liquid pressing against the base ( 1 ) with nil results. “F4” is the decompensation of the faces pressing against the ground. The invention can be used in all types of foundations and large surfaces to preserve infrastructures, etc. It can alternatively be used for conical bases, buried walls, beam supports, etc. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of the filing of U.S. Provisional Patent Application Ser. No. 60/803,984, entitled “Electromagnetic Engine”, filed on Jun. 6, 2006, and the specification thereof is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates in general to electric motors.
BRIEF SUMMARY OF THE INVENTION
[0003] A contact system for energizing an electromagnetic engine of the present invention includes a fixed first contact set having an axial face and at least a first electrical connector disposed on at least a portion of the axial face. The first contact set is connected to an electrical power source. The contact system includes a rotatable second contact set having an axial face adjacent the axial face of the first contact set and a plurality of spaced apart second electrical connectors extending along the axial face. Each of the second electrical connectors are connected to a set of electromagnetic coils and the second electrical connectors energize a predetermined number of the electromagnetic coils when the second electrical connectors engage with the first electrical connector during rotation of the second contact set.
[0004] Alternatively, the first electrical connector comprises a canted coil. Alternatively, the second electrical connectors comprise a plurality of spring-loaded button contacts. Alternatively, the first contact set is adapted to be mounted in an electromagnetic engine housing. Alternatively, the second contact set is adapted to be mounted on a rotatable shaft. The second electrical connectors may be connected to predetermined electromagnetic coils to induce a rotation of the shaft.
[0005] Alternatively, the first electrical connector extends along a predetermined annular distance of the axial face of the first contact set. The predetermined annular distance may be sized to allow a predetermined number of the second electrical connectors to engage with the first electrical connector. Alternatively, the second electrical connectors are equally annularly spaced apart on the axial face of the second contact set.
[0006] In another embodiment, the present invention provides an electromagnetic engine that includes at least one housing defining an airspace therein, a first contact set disposed within and attached to the at least one housing and connected to an electrical power source, and a controller connected to the electrical power source, a stator ring assembly disposed within and attached to the at least one housing and connected to the controller. The controller is operable to intermittently energize at least a portion of the stator ring assembly. The electromagnetic engine includes a rotor assembly disposed within and rotatably engaged with the at least one housing. The rotor assembly includes a shaft and a second contact set and disposed radially inwardly from the stator ring assembly. The second contact set includes a plurality of electrical connectors. The electrical connectors intermittently engage with the first contact set to energize the rotor assembly, the rotor assembly and the stator ring assembly producing an electromotive force to spin the shaft during operation of the electromagnetic engine.
[0007] Alternatively, the rotor assembly and the stator ring assembly produce the electromotive force by repulsion. The rotor assembly and the stator ring assembly may produce the electromotive force by attraction and repulsion. Alternatively, the engine further comprises a plurality of housings and/or electromagnetic engines mounted on the shaft. Alternatively, the first contact set comprises at least one canted coil disposed on an axial face of a housing. The canted coil may extend for a predetermined annular distance along the first contact set housing. Alternatively, the second contact set further comprises a plurality of annularly spaced spring-loaded button contacts. The button contacts may be equally annularly spaced apart on the second contact set.
[0008] Alternatively, the stator ring assembly comprises a plurality of radially inwardly extending posts having electric wire wound thereon and forming stator windings, the stator windings connected to the power source, and the rotor assembly comprises a plurality of radially outwardly extending posts having electric wire wound thereon and forming rotor windings, the rotor windings connected to the second contact set. The stator windings may create an electromagnet of a predetermined polarity when energized and the electrical connectors may be connected to a predetermined number of rotor windings and may create an electromagnet of a predetermined polarity opposite the polarity of the stator windings when energized.
[0009] Alternatively, the engine further comprises a switching mechanism connected to the controller. Alternatively, the controller is selected from the group consisting of software, hardware, and combinations thereof. Alternatively, the stator ring assembly is attached to the housing by a plurality of bushings and fasteners. The bushings may comprise a nonmagnetic material.
[0010] Alternatively, the engine further comprises a plurality of cooling holes formed in the housing to allow air flow through the airspace of the housing. Alternatively, the engine further comprises a demagnetization system for demagnetizing magnetic energy present in at least the housing, the stator assembly, the rotor assembly, and the shaft. Alternatively, the engine further comprises a plurality of stator ring assemblies and rotor assemblies spaced along a length of the shaft, each of the stator ring assemblies and rotor assemblies disposed in at least another housing.
[0011] Objects, advantages and novel features, and further scope of applicability of the present invention will be set forth in part in the detailed description to follow, taken in conjunction with the accompanying drawings, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0012] The accompanying drawings, which are incorporated into and form a part of the specification, illustrate one or more embodiments of the present invention and, together with the description, serve to explain the principles of the invention. The drawings are only for the purpose of illustrating one or more preferred embodiments of the invention and are not to be construed as limiting the invention. In the drawings:
[0013] FIGS. 1 , 1 A and 1 B are end and side views, respectively, of an embodiment of an electromagnetic engine of the present invention;
[0014] FIG. 2 is an exploded perspective view of the electromagnetic engine of FIG. 2 ;
[0015] FIG. 3 is an end view of a partially assembled electromagnetic engine of FIG. 2 ;
[0016] FIGS. 3A , 3 B and 3 C are end views on enlarged scales showing the ring posts, rotor posts, and wings of the electromagnetic engine of the present invention;
[0017] FIG. 4 is a perspective view of a partially assembled electromagnetic engine of FIG. 2 ;
[0018] FIG. 5 is an exploded perspective view of contact sets and rotor of the electromagnetic engine of the present invention;
[0019] FIGS. 6A and 6B are perspective views, respectively, of a partially assembled electromagnetic engine of FIG. 2 ;
[0020] FIGS. 7 and 8 are end views of a partially assembled electromagnetic engine of the present invention showing sequencing;
[0021] FIG. 9 is a block diagram showing electrical connections of the electromagnetic engine of the present invention;
[0022] FIG. 10 is a schematic perspective view of air flow through the electromagnetic engine of the present invention; and
[0023] FIG. 11 is a block diagram of a demagnetization system of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] FIGS. 1-11 illustrate an electromagnetic engine according to an embodiment of the present invention, indicated generally at 100 . The engine 100 has outer housings 1 and 3 and at least one intermediate housing 2 preferably formed from aluminum, magnesium, plastic, a combination thereof, or any other suitable material. Crankshaft or shaft 7 extends along the center axis of the electromagnetic engine 1 . Shaft 7 is preferably circular in cross section and includes a plurality of keys 12 formed thereon. Roller bearings 13 are mounted along the crankshaft 7 within the engine cylinder housing 2 and thrust bearings (not shown) are preferably mounted at the opposite ends of the engine housing 1 , 3 . End 34 of the crankshaft 7 preferably has a smaller diameter to mount a thrust bearing thereon and extends from the engine housing 3 to connect to a load 68 (best seen in FIG. 9 ), such as transfer mechanism or an assistive device (not shown) to help cause movement, work or lift. End 33 of crankshaft 7 opposite end 34 preferably has a smaller diameter to mount an opposite thrust bearing and may extend through the engine housing 2 to connect to load 68 , such as a fan, bell housing, or other device, to run an air-conditioning compressor, a generator, an air pump or similar devices or any device to help cause movement, work or lift, as will be appreciated by those skilled in the art.
[0025] The outer electromagnetic ring 4 is preferably formed from a magnetic and/or electrically conductive material and is connected to the engine housings 1 , 2 , or 3 with a plurality of bushings 16 , best seen in FIG. 4 . Bushings 16 are preferably formed from a non-magnetic material and in a preferably circular shape to cooperate with a corresponding plurality of annularly spaced openings 29 formed in face 49 of outer electromagnetic ring 4 . A plurality of bolts and washers or similar fasteners each preferably formed from non-magnetic material extend through each opening 29 and into a corresponding plurality of holes 48 formed in engine cylinder housing wall face 35 such as by a threaded connection or the like.
[0026] Outside electromagnetic ring 4 is fixed in relationship with respect to engine housings 1 , 2 and 3 . Cylinder airspace 20 is defined as the distance between face 49 of the outer electromagnetic ring 4 and engine housing wall face 35 . Bushings 16 , with bolts and washers maintain this fixed relationship within the cylinder airspace 20 of the electromagnetic engine cylinder housings 1 , 2 and 3 .
[0027] A plurality of electromagnetic ring posts 21 extend radially inwardly from an inner circumference of outer electromagnetic ring 4 , forming a ring or stator assembly 91 , best seen in FIG. 4 The number of ring posts 21 can be increased or decreased as needed by the user depending on power or efficiency needs. Preferably, ring posts 21 are formed from a magnetic and/or electrically conductive material and are equally spaced in an annular formation along inner circumference of outer electromagnetic ring 4 . Each of the electromagnetic ring posts 21 includes electromagnetic ring post neck 22 defined by concave outer edges 54 and outer radial electromagnetic post face 24 . Preferably, outer electromagnetic ring post neck 22 includes four concave side edges 54 that are rounded to a predetermined shape. The airspace 20 defined between the outer electromagnetic ring post necks 22 is substantially circular.
[0028] Wire coil or winding 23 of a predetermined size is preferably wrapped or coiled about outer electromagnetic post neck 22 of the outer electromagnetic ring post 21 , preferably with multiple windings perpendicular to the outer electromagnetic ring post neck 22 and in a predetermined direction. The wire winding 23 from each ring post 21 is connected by suitably sized wiring that passes through the wire chase 32 formed in engine cylinder housings 2 and 3 and further connected to electrical converter 47 , best seen in FIG. 9
[0029] At least one and preferably a plurality of inner electromagnetic rotors 5 are mounted perpendicular to the crankshaft 7 and are preferably spaced equidistant along the length of shaft or crankshaft 7 between the outside thrust bearings. The electromagnetic rotor 5 is preferably formed from a magnetic and/or electrically conductive material and is preferably circular in shape and extends radially outwardly from crankshaft 7 . Crankshaft keys 12 , preferably formed from a non-magnetic material in a predetermined elongated shape, are located along the length of shaft 7 and engage with crankshaft opening 51 formed in inner electromagnetic rotor 5 . Preferably, each key 12 extends from the center axis of shaft 7 at a predetermined angle with respect to the longitudinal axis of shaft 7 , as seen in FIG. 4 .
[0030] A plurality of electromagnetic posts 25 extend radially outwardly from an outer circumference of electromagnetic rotor 5 . The number of posts 25 can be increased or decreased as needed by the user depending on power or efficiency needs. Preferably, posts 25 are formed from a magnetic and/or electrically conductive material and are equally spaced in an annular formation along the outer circumference of rotor 5 . Each of electromagnetic rotor posts 25 include electromagnetic rotor post neck 26 defined by concave outer edges 56 and outer radial electromagnetic rotor post face 27 . Preferably electromagnetic rotor post neck 26 includes four concave edges 56 that are rounded to a predetermined shape. The cylinder airspace 20 defined between electromagnetic rotor post necks 26 is substantially circular.
[0031] Wire coil or winding 23 a of a predetermined size is preferably wrapped or coiled with multiple windings perpendicular to the electromagnetic rotor post neck 26 of electromagnetic rotor post 25 in a predetermined direction that is preferably opposite that of the windings 23 of electromagnetic ring posts 21 . Each electromagnetic rotor post 25 is wired separately and the wire from windings 23 a preferably passes through a plurality of wire chases 31 , which is formed in or partially embedded in the rotor wall face 36 of electromagnetic rotor 5 that extends radially inwardly along rotor wall face 36 towards crankshaft 7 . Preferably, each wire chase 31 is formed in opposing rotor wall faces 36 of electromagnetic rotor 5 in an alternating pattern of wire chases 31 , whereby wire chases 31 from posts 1 , 3 , 5 , 7 , and 9 (best seen in FIGS. 7 and 8 ) are formed in one wall face 36 and wire chases 31 from posts 2 , 4 , 6 , 8 , and 10 (best seen in FIGS. 7 and 8 ) are formed in an opposite wall face 36 . These alternating wire chases 31 are partially imbedded or formed for the purpose of providing protection and/or for efficient utilization of space, and for proper positioning of alternating sequencing or patterns related to the electromagnetic rotor posts 25 , as will be appreciated by those skilled in the art. Preferably, each wire from windings 23 a extends through wire chases 31 to inner contact set 17 . Each electromagnetic ring post 21 and each electromagnetic rotor post 25 is wired in a predetermined alternating pattern, such as with electromagnetic rotor 5 with alternating wiring being as an example of 1, 3, 5, 7, 9 etc. (best seen in FIGS. 7 and 8 ) being in odd pattern or sequence and/or 2, 4, 6, 8, 10, etc being in even pattern or sequence on opposite sides and depending on the need and/or power demand of engine 100 , as will be appreciated by those skilled in the art. Shaft 7 , inner contact set 17 , electromagnetic rotor 5 , and electromagnetic rotor posts 25 form a rotor assembly, indicated generally at 92 and best seen in FIG. 6A .
[0032] Inner contact set 17 of contact assembly 19 is mounted within recess 60 formed in each wall face 36 of electromagnetic rotor 5 and preferably includes spacer 61 , contact holder 62 , and a plurality of button contacts 63 arranged in a preferably equally spaced annular formation on an axial face of contact holder 62 . Inner contact set 17 is attached to rotor 5 and, therefore, rotates with shaft 7 . Button contacts 63 are preferably spring-biased electrical connectors or the like. Outer contact set 18 of contact assembly 19 is preferably mounted in a recess of inside wall face 35 of housings 1 or 3 or mounted to an exterior surface of the housings 2 and includes electrical contact 64 on axial face 65 thereof extending on at least a portion of axial face 65 . Outer contact set 18 and electrical contact 64 are preferably formed from an electrically conductive material such as, but not limited to, copper, silver, gold, or similar materials therefore, is fixed on electromagnetic rotor 5 with a plurality of screws or other fasteners deemed appropriate and/or necessary by the user and does not rotate with shaft 7 . Electrical contact 64 is preferably a canted coil, such as a BalContact™ canted coil spring manufactured by Bal Seal Incorporated, or the like. The outer contact set 18 is electrically connected with inner contact set— 17 by the engagement of button contacts 63 and canted coil 64 . Canted coil 64 is preferably connected by wiring of a predetermined size to an electrical power source or supply 67 , best seen in FIG. 9 .
[0033] Referring now to FIG. 9 , there is shown the outer contact set 18 of the contact set 19 is electrically connected to an electrical converter 47 , such as the NRI Electrical Enhancement System or the like, which uses the inherent electrical properties of magnetics and the inherent magnetic properties of electrons to cause changes in electrical patterns thereby enhancing power output which is further electrically connected to suitable switching mechanism 37 . Preferably, switching mechanism 37 , such as software and/or hardware that will change the power frequency and/or range of power based on current usage and/or power demands and/or reductions made on the system or the like, is mounted in a suitable location external to the electromagnetic engine housings 1 , 2 and 3 of engine 100 . Switching mechanism 37 is connected by suitably sized wiring to controller or control device 50 which is preferably receives a user input 66 , such as a gas, hand, voice or foot input, so that power from electrical power supply 67 to the electromagnetic ring posts 21 of electromagnetic ring 4 and electromagnetic rotor posts 25 of electromagnetic rotor 5 can be increased or decreased as needed. Electrical power source or supply 67 is any suitable electrical power source such as, but not limited to, a battery, a plurality of batteries, fuel cells or other suitable electrical power sources or the like. Controller 50 is connected to rotor posts 21 of electromagnetic ring 4 through switching mechanism 37 and electrical converter 47 in order to energize and de-energize, respectively, coils or windings 23 a of rotor posts 21 . Controller 50 is preferably, but is not limited to, software and/or hardware that maintains and/or controls the power input, power output, sequencing or patterns, sensing either input or output from sensors, interfacing with other software/hardware that maintains sensors, interface network, temperature of such equipment as mentioned above, positioning of electromagnetic rotor 5 and/or outer electromagnetic ring 4 , control of air flow through the said cylinder airspace 20 , and proper control of engine efficiency on street, highway or off-road power usage or the like. Controller 50 preferably receives a plurality of inputs such as from engine 100 including, but not limited to, load on crankshaft 7 , rotational position of crankshaft 7 , the number and location of energized and de-energized ring posts 21 and rotor posts 25 , and the like. Controller 50 , in combination with switching mechanism 37 , determines the sequence based on the operating conditions and/or an output from controller 50 , such as by sending signals and/or commands to switching mechanism 37 . Controller 50 maintains and/or controls input and/or output from sensors including but not limited to signals, either digital or analog, from and/or to temperature, positioning, sequential timing and/or power demands of posts of electromagnetic rotor 5 and outer electromagnetic ring 4 , user input control device 66 , power ratings and current flows both in and out of the engine 100 , air flow control devices, heating/cooling devices for user comfort, demagnetization systems, maintenance and/or control of super- or ultracapacitors or the like or any other devices connected to controller 50 and/or part of engine 100 . Electrical converter 47 such as the NRI Electrical Enhancement System or the like, which uses the inherent electrical properties of magnetics and the inherent magnetic properties of electrons to cause changes in electrical patterns thereby enhancing power output is preferably electrically connected to electrical storage device 69 , such as a super or ultracapacitor or the like such as but not limited to such devices as Maxwell Technologies Ultracapacitors or Tavrima Supercapacitors, which is further connected to outer electromagnetic ring 4 . Mechanical grounding 70 connects to outer electromagnetic ring 4 , electromagnetic rotor 5 , inner contact 17 , outer contact 18 , control device 50 , and user input 66 .
[0034] Referring now to FIGS. 7 and 8 , non-limiting examples of the electrical sequencings between the outer electromagnetic ring posts 21 of the outer electromagnetic ring 4 and the electromagnetic rotor posts 25 of the electromagnetic rotor 5 are discussed. As an example, windings 23 of outer electromagnetic ring posts 21 of the outer electromagnetic ring 4 are numbered 1, 2, 3, 7, 8 9 and are energized by controller 50 to produce an electromagnet of a predetermined polarity and, preferably substantially simultaneously, windings 23 a of electromagnetic rotor posts 25 of the electromagnetic rotor 5 numbered 1, 2, 3, 6, 7, 8 are energized to produce an electromagnet or electromagnetic coil of a polarity opposite that of electromagnetic ring posts 21 by the electrical connection between the canted coils 64 and the buttons 63 of contact set 19 and thereby produce an electromotive force to spin or rotate shaft 7 .
[0035] By virtue of the opposite polarities of electromagnets of ring posts 21 and rotor posts 25 , shaft 7 and, therefore, rotor 5 begin to rotate by magnetic repulsion, for example in a clockwise direction, as indicated by an arrow 90 in FIG. 7 . Those skilled in the art will appreciate that rotor 5 may rotate in either a clockwise or counterclockwise direction. As rotation of shaft 7 occurs by repulsion, outer electromagnetic ring posts 21 numbered 1 and 7 are de-energized by controller 50 as faces 27 of rotor posts 26 pass the halfway point of the ring post face 24 and outer electromagnetic ring posts 21 of the outside electromagnetic ring 4 numbered 4 and 10 are energized by controller 50 . On the electromagnetic rotor 5 , the electromagnetic rotor posts 25 numbered 1 and 6 are de-energized and the electromagnetic rotor posts 24 numbered 4 and 9 are energized to produce an electromagnet as they just pass the halfway point by the respective engagement and disengagement of the electrical connection between the canted coils 64 and the buttons 63 as shaft 7 and rotor assembly 92 rotates. The halfway point (of faces 24 and 27 ) is determined when the midline of the electromagnetic rotor posts 25 of the electromagnetic rotor 5 pass the midline of the outer electromagnetic ring post 21 of the outer electromagnetic ring 4 . The sequence or corkscrew pattern continues in a predetermined direction from the repulsion (i.e. the ring posts 21 and rotor posts 25 next in clockwise position as shown in FIGS. 7-8 ) between the outer electromagnetic ring posts 21 and the electromagnetic rotor posts 25 until a complete revolution has occurred. The electrical sequences recited above are “examples only” and are by no means the only sequences that can occur within this embodiment of present invention.
[0036] In an embodiment of the present invention, there may be six electromagnetic ring posts 21 of the outer electromagnetic ring 21 and six electromagnetic rotor posts 25 of the electromagnetic rotor 5 energized to produce or energize respective opposing electromagnets. Once a full rotation has occurred, the sequence repeats unless a change occurs, such as the controller 50 and/or switching mechanism 37 determining that a change in the sequence is needed based on changed operating conditions. The controller 50 and switching mechanism 37 may also increase or decrease electrical power to the outer electromagnetic ring posts 21 of the outer electromagnetic ring 4 and to the electromagnetic rotor posts 25 of the electromagnetic rotor 5 based on the inputs to controller 50 .
[0037] In an embodiment of the present invention utilizing a plurality of engines 100 mounted on shaft 7 , the corkscrew pattern would have the same sequencing as described above, except that the electromagnetic rotor 5 and the outer electromagnetic ring 4 of the various engines 100 are angled relative to one another at a predetermined rotational distance from the previous and/or subsequent electromagnetic rotor 5 and outer electromagnetic ring 4 based on the position of keys 12 , best seen in FIG. 4 . Each subsequent electromagnetic rotor 5 and each outer electromagnetic ring 4 is placed at a predetermined distance in rotation from the previous electromagnetic rotor 5 and previous outer electromagnetic ring 4 based on the position of keys 12 . As a result of this predetermined rotational distance, the outer electromagnetic ring posts 21 are energized by the controller 50 and switching mechanism 37 in the corkscrew pattern and the electromagnetic rotor posts 25 are energized in the corkscrew pattern based on the electrical connection between the various canted coils 64 and the buttons 63 . Based on the various inputs to controller 50 , controller 50 and switching mechanism 37 may increase or decrease electrical power to the outer electromagnetic ring posts 21 of the outer electromagnetic ring 4 and to the electromagnetic rotor posts 25 of the electromagnetic rotor 5 .
[0038] A sequence utilizing full power of engine 100 occurs when all selected outer electromagnetic ring posts 21 and all selected electromagnetic rotor posts 25 such as at start up, passing or change in transition or terrain or the like, if engine 100 , for example, is utilized as propulsion for an automotive vehicle or the like. A lower powered sequence utilizing fewer selected outer electromagnetic ring posts 21 and electromagnetic rotor posts 25 occurs for highway or decreased demand interval (lower speeds but continuous motion) or the like. The corkscrew pattern utilizing selected outer electromagnetic ring posts 21 and electromagnetic rotor posts 25 occurs in alternating sequences in embodiments of the present invention that comprise multiple outer electromagnetic rings 4 and electromagnetic rotors 5 each mounted on shaft 7 with a corresponding number of intermediate housings 2 , such as for heavy power needs, lifting, to create lift or the like. Alternatively, controller 50 and switching mechanism 37 may energize and de-energize ring posts 21 to produce an electromagnet of varying polarity such that rotation occurs by magnetic attraction and/or magnetic repulsion. Those skilled in the art will appreciate that other sequences may be utilized while remaining within the scope of the present invention.
[0039] As the electromagnetic engine 100 operates and rotation occurs in a predetermined direction such as 90 shown in FIG. 7 , air, either free flow or induced, as shown in FIG. 10 preferably flows in a direction indicated by an arrow 74 through the upper intake inlet 38 and the lower intake inlet 39 and to the upper intake air passage 8 and the lower intake air passage 9 . The air then flows through the upper cylinder intake 40 and the lower cylinder intake 41 flowing into the cylinder airspace 20 . Air flows through cylinder airspace 20 , flowing through and around and thereby cooling outer electromagnetic ring 4 , electromagnetic rotor 5 , contact set 19 and crankshaft 7 . The air then flows through upper cylinder exhaust port 42 and lower cylinder exhaust port 43 into upper exhaust air passage 10 and lower exhaust air passage 11 through the upper exhaust outlet 44 and lower exhaust outlet 45 in a direction indicated by an arrow 75 to atmosphere or an exhaust mechanism (not shown). The passage of air through the respective passages 8 , 9 , 20 , 38 , 39 , 40 , 41 , 42 , 43 , 44 and 45 of the electromagnetic engine 100 helps the electromagnetic engine 100 function more efficiently and maintains a desired temperature range within airspace 20 which helps to boost power through and from engine 100 .
[0040] In FIG. 11 there is shown demagnetization system 52 for the prevention of electromagnetic energy buildup on components within proximity to where magnetic energy may be present. If provided, system 52 functions when power is shut off to the outer electromagnetic ring 4 and electromagnetic rotor 5 and when the presence of magnetic energy is detected by a system 52 , such as by a signal from controller 50 . The demagnetization contacts 53 are placed in predetermined locations along the electromagnetic engine housings 1 , 2 , 3 which will then allow the demagnetization system 52 to demagnetize the electromagnetic engine cylinder housings 1 , 2 , 3 from magnetic energy that may be present. Demagnetization contacts (not shown) are placed in predetermined locations around the inner roller bearing seats 72 , outer thrust bearing seats 71 and 73 to demagnetize the inner roller bearings 13 and the outer thrust bearings from magnetic energy that may be present. Demagnetization contacts are placed around electromagnetic rings 4 and around the electromagnetic rotor 5 in predetermined locations will demagnetize any magnetic energy that may be present in electromagnetic rings 4 and around the electromagnetic rotors 5 .
[0041] Although the invention has been described in detail with particular reference to these preferred embodiments, other embodiments can achieve the same results. Variations and modifications of the present invention will be obvious to those skilled in the art and it is intended to cover in the appended claims all such modifications and equivalents. The entire disclosures of all references, applications, patents, and publications cited above are hereby incorporated by reference. | A contact system for energizing an electromagnetic engine includes a fixed first contact set connected to an electrical power source and having an axial face and a first electrical connector disposed on at least a portion of the axial face. The contact system includes a rotatable second contact set having an axial face adjacent the axial face of the first contact set and a plurality of spaced apart second electrical connectors extending along the axial face. The second electrical connectors are connected to a set of electromagnetic coils and energize a predetermined number of the electromagnetic coils when the second electrical connectors engage with the first electrical connector during rotation of the second contact set. The present invention also provides an electromagnetic engine having a housing, a first contact set, a controller, and stator ring and rotor assemblies that produce an electromotive force to spin a shaft of the engine. | 7 |
This application is a continuation-in-part of co-pending U.S. Ser. No. 07/805,121, filed Dec. 11, 1991 now abandoned, which is a continuation-in-part of U.S. Ser. No. 07/426,336, filed Oct. 24, 1989, now abandoned, which is a continuation-in-part of U.S. Ser. No. 07/58,002, filed Jun. 4, 1987, now U.S. Pat. No. 4,920,209, which is a continuation-in-part of U.S. Ser. No. 06/782,638, filed Oct. 4, 1985, now abandoned, which is a continuation-in-part of U.S. Ser. No. 06/667,233, filed Nov. 1, 1984, now abandoned.
BACKGROUND OF THE INVENTION
A major goal of biomedical research is to provide protection against viral disease through immunization. One approach has been to use killed vaccines. However, large quantities of material are required for killed vaccine in order to retain sufficient antigenic mass. In addition, killed vaccines are often contaminated with undesirable products during their preparation. Heterologous live vaccines, using appropriately engineered adenovirus, which is itself a vaccine, Chanock R. M. et al., JAMA, 195, 151 (1967), seem an excellent immunogen. Our invention concerns live oral vaccines using adenovirus as vector.
Presently marketed adenovaccine comprises live, infectious adenoviruses in an enteric-coated dosage form. Upon administration to the patient to be vaccinated, the virus is carried past the upper-respiratory system (where disease-producing infection is thought to occur), and is released in the intestine. In the intestine, the virus reproduces in the gut wall, where, although it is not capable of causing adenoviral disease, nevertheless induces the formation of adenovirus antibodies, thus conferring immunity to adenoviral disease. In our invention, live, infectious adenovirus which has been engineered to contain genes coding for antigens produced by other disease-causing organisms is administered in an enteric-coated dosage form. Upon release in the intestine the virus will reproduce in the gut wall, will separately express both the adenoviral antigen and the pathogen surface antigen, and will induce the formation of antibodies or induce cell mediated immunity to both adenovirus and the other disease-causing organism. By "live virus" is meant, in contradistinction to "killed" virus, a virus which is, either by itself or in conjunction with additional genetic material, capable of producing identical progeny. By "infectious" is meant having the capability to deliver the viral genome into cells.
Approximately 200,000 persons in the United States are infected each year with Hepatitis B virus. In addition, there is a strong correlation between hepatitis B infection and liver cancer. The presently marketed vaccines against hepatitis B are injectable products containing hepatitis antigen obtained from the blood plasma of healthy carders or from expression by recombinant microorganisms.
There are two major hepatitis B viral antigens: the surface antigen (HB S A g ) and the core antigen (HB C A g ). The antigenic structure of HB S A g is somewhat complex. There is a common group-specific determinant, a. In addition, there are two sets of mutually exclusive type-specific determinants d or y and w or r. The HB C A g is of a single antigenic type. It is known that production of antibody against HB S A g or HB C A g confers immunity against hepatitis B infection.
Several groups have employed recombinant DNA techniques to synthesize the HB S A g by microorganisms. HB S A g has been synthesized in Escherichia coli in the form of a fusion protein (Edman, J. C. et al., Nature, 291, 503 (1981)). It has also been synthesized in yeast using the ADH promoter (Valenzuela et al., Nature 298, 347 (1982)) or acid phosphatase promoter (Miyanohara et al., Proc. Natl. Acad. Sci. USA, 80, 1 (1983)). The expression of HB S A g by Adenovirus in eukaryotic cell strains has also been proposed (Rutter et at., European Patent Publication 62,574 (1982), and described (Perricaudet, et al., European Patent Publication 185,573 (1986)), as has the possibility of using adenoviruses modified at the E3 region by the insertion of recombinant DNA in the constitution of live vaccines, Bailay et al., EMBO Journ. 4, 3861 (1985). Saito et al. describe the construction of an adenovirus containing hepatitis B viral DNA (J. Virol. 54, 711 1985). Vaccinia virus has been used as a vector to produce a live virus vaccine to hepatitis virus (Smith et al., Nature, 302, 490 (1983)).
Rotaviruses are a major cause of acute gastroenteritis in infants. These viruses possess a genome of eleven double-stranded RNA segments enclosed in a capsid. The capsid contains an inner and outer shell. One of the outer shell proteins, VP7, is a glycoprotein that reacts with serotype-specific neutralizing antibodies (Kalica, A. R. et al., Virology, 112, 385 (1981)). This protein is coded for by gene 9 of the human type 1 (Wa) rotavirus. Gene 9 of type 1 human rotavirus has recently been cloned in E. coli and its sequence determined (Richardson, M. et al., J. Virol., 51, 860 (1984)).
Adenoviruses contain a linear duplex DNA molecule (m.w. 20×106-25×106) that codes for 20-30 polypeptides. Many of these are incorporated into the viral particle which is morphologically complex and has a sophisticated assembly process. Previously SV40 T antigen has been expressed using an adenovirus recombinant (Solnick, D. Cell, 24, 135 (1981), Thummel, C. et at., Cell, 23, 825 (1981), Gluzman, Y. et al., in Eukaryotic viral Vectors, p. 187, Cold Spring Harbor (1982)). Also mouse dihydrofolate reductase has been expressed using an adenovirus recombinant (Berkner, K. and Sharp, P. A., Nucleic Acids Research, 12, 1925 (1984)).
Roy Curtiss III, in European Patent Publication 80,806 (1983) proposes a method for producing immunity to microbial diseases by the administration of a microbe containing a foreign gene which will express an antigen of a second microbe to which immunity is desired. He states that preferred oral preparations are enteric-coated. Dulbecco proposes recombinant adenovirus vaccines in which the surface protein of adenovirus is modified to contain in its structure a segment of foreign protein which will produce a desired biological response on administration to animals (PCT International Publication Number WO 83/02393 (1983)).
SUMMARY OF THE INVENTION
The invention sought to be patented in its method of treatment aspect comprises a method for producing antibodies or cell mediated immunity to an infectious organism in a warm-blooded animal which comprises orally administering to said warm-blooded animal, in an enteric coated dosage form, live recombinant adenoviruses in which the virion structural protein is unchanged from that in the native adenovirus from which the recombinant adenovirus is produced, and which contain the gene coding for the antigen corresponding to said antibodies or inducing said cell mediated immunity.
The invention sought to be patented in a subgeneric method of treatment aspect comprises a method for producing antibodies to hepatitis-B virus, rotavirus, or HIV in a warm-blooded animal which comprises orally administering to said warm-blooded animal live recombinant adenoviruses in which the virion structural protein is unchanged from that in the native adenovirus from which the recombinant adenovirus is produced, and which contain the gene coding for, respectively, a hepatitis-B antigen, a rotavirus antigen, or an HIV antigen.
The invention sought to be patented in its composition aspect comprises a vaccine for producing antibodies or cell mediated immunity to an infectious organism in warm-blooded animals comprising live recombinant adenoviruses in which the virion structural protein is unchanged from that in the native adenovirus from which the recombinant adenovirus is produced, and which contain the gene coding for the antigen corresponding to said antibodies or inducing said cell mediated immunity, said vaccine being formulated in an enteric coated dosage form.
The invention sought to be patented in a subgeneric composition aspect comprises a vaccine for producing antibodies to hepatitis-B virus, rotavirus, or HIV in warm-blooded animals, comprising live recombinant adenoviruses in which the virion structural protein is unchanged from that in the native adenovirus from which the recombinant adenovirus is produced, and which contain the gene coding for, respectively, a hepatitis-B antigen, a rotavirus antigen, or an HIV antigen, said vaccine being formulated in an enteric-coated dosage form.
DETAILED DESCRIPTION OF THE INVENTION
EXAMPLE 1
Adenovirus Vectors
Three adenovirus vectors (Gluzman, Y. et al., in Eukaryotic Viral Vectors p. 187, Cold Spring Harbor Laboratories, 1982) can easily be constructed. To maximize the length of foreign DNA that can be inserted, two expendable regions of the viral genome may be deleted, early regions 1 or early region 3 (E1 and E3), or both, of the adenovirus type 5 viral genome. ΔE1 is created by an in vivo recombinational event between a plasmid and a modified adenoviral DNA. (All plasmids described in this specification are propagated in E. coli). The plasmid is formed by insertion of adenoviral DNA sequences between 0 and 17 map units into pBR322 and subsequently, using restriction endonuclease digestion and ligation, deleting sequence between 1.4 and 9.1 map units and placing an Xbal restriction site at this junction. This plasmid is denoted in the art as pAC. The modified adenoviral DNA which contains a single Xbal restriction site at 4.0 map coordinates is formed as follows. Xbal cleaves wild type Ad5 DNA at four sites: 4, 29, 79, and 85 map. units. Modified DNA lacking sites at 29, 79, and 85 is isolated by cutting Ad5 DNA with Xbal, transfecting the DNA and isolating the modified adenovirus which lacks Xbal sites at positions 29 and/or 79. This procedure is repeated again and modified adenovirus is isolated containing only the Xbal site at position 4. Such modified adenoviruses can also be readily constructed using techniques of oligonucleotide-directed mutagenesis (Smith, M., and Gillam, S. (1981) in Genetic Engineering, Setlow, J. K. and Hollaender, A., Eds. Vol. 3, pp. 1-32, Plenum, New York). In this technique the Xbal restriction sites are destroyed using chemically synthesized oligonucleotides designed to produce silent changes in the amino acid coding regions defined by the respective Xbal restriction endonuclease sites. Vector ΔE3 is constructed by deletion of ΔE3 region sequences. Two modified adenoviruses (type 5) are formed by the procedures outlined above. One contains no Xbal sites, the other contains only the Xbal sites at map coordinates 29, 79, and 85. The left half of DNA of the mutant containing no Xbal sites is joined with the right half of DNA of the mutant containing Xbal sites at 79 and 85, forming a modified adenovirus containing Xbal sites at only 79 and 85 map coordinates. Cleavage of this DNA with Xbal followed by religation forms the ΔE3 viral DNA deleting the ΔE3 region between 79 and 85 map coordinates and placing a single Xbal cloning site at this junction. ΔE1 ΔE3 may be constructed by deletions in both regions in a similar manner.
In a fashion similar to construction of ΔE1, ΔE3, and ΔE1ΔE3 vectors of adenovirus type 5, vectors of adenovirus types 4 and 7 are formed. For example, in adenovirus type 7, the ΔE3 region is deleted between the Xbal site at 80.5 map coordinates and the EcoR1 site at map coordinate 85.
EXAMPLE 2
6X Series Plasmids (For Hb S A g and rotavirus VP7)
Plasmids that allow the placement of the adenovirus 2 late promoter upstream from DNA coding for hepatitis B surface antigen or rotavirus VP7 followed by SV40 splicing signals may be constructed. Each of these is flanked by Xbal sites for insertion into the adenovirus ΔE1, ΔE3, or ΔE1ΔE3 vectors.
a. p6XH
Plasmid 6XH contains an Xbal linker at -400 bp of the Ad2 major late promoter and an Eco RI site at +33 bp, 8 bp before the end of the first adenovirus late leader. This is followed by an Eco RI linker at 26 bp preceding the ATG of HB S A g followed by HB S A g sequence of 678 bp to another Eco RI linker at 809 bp. This is followed by SV40 sequence extending from 2753-2516 bp on the SV40 map. These sequences are all inserted into the large pBR322 Bam HI to Eco RI fragment via XbaI linkers.
b. p6XR
Plasmid p6XR is made by joining the rotavirus VP7 gene with Eco RI linkers at nucleotide 6 and 1036 to the Ad2 major late promoter containing an Xbal site at -400 bp and an Eco RI linker at +331 and attaching SV40 sequences from 2753-2516 behind the VP7 gene with an Eco RI linker at 2753 (SV40 map coordinate) and an Xbal site at 2516 bp. This cassette is inserted into the large Eco RI to BamH fragment of pBR322.
c. Transfer of plasmid sequences to the viral DNA vector and production of recombinant adenovirus.
The transfer of the cassette of promoter-foreign gene-terminator to the adenovirus vector is done either as follows or by in vivo recombination (see detailed example below). The purified adenovirus vector DNA is cleaved with a restriction endonucleose followed by treatment with calf intestine alkaline phosphatase to prevent self ligation. Plasmid derived sequences are obtained by cleavage of p6XH or p6XR with XbaI. These are then ligated to the adenoviral vector DNA. Either 293 cells, (Graham, et al., Gen. Virol., 86 10 (1978)), Hela cells, or Wi-38 cells are then transfected with the ligation mixture and overlayed with agar. Plaques are picked 7-10 days later and viral stocks prepared.
EXAMPLE 3
Expression Assays
Three types of assays have been used to assess expression of hepatitis B surface antigen and rotavirus VP7. These are:
a. Indirect immunofluorescence.
Either mouse monoclonal antibodies or rabbit antisera are used to detect expression of recombinant ΔE1 and ΔE3 virus stocks containing HB S A g or VP7 DNA sequences. Counterstaining is with goat anti-mouse or anti-rabbit FITC.
b. Immunoprecipitation.
Immunoprecipitation of HB S A g or rotavirus VP7 in cells infected with the recombinant adenoviruses is done using either mouse monoclonal antibodies or rabbit polyclonal antisera against HB S A g or rotavirus VP7 and protein A Sepharose CL4B.
c. RIA
Expression of HB S A g is also tested by a commercially available radioimmunoassay (Ausria, Abbott Labs.).
EXAMPLE 4
Immunogenic Nature of the Recombinant Adenovirus
Live, lyophilized recombinant adenovirus contained in an enteric coated capsule is assessed for immunogenicity by administration (104-105 50% infectious dose/tablet) to hamsters or chimpanzees and testing for antibody levels and protection from challenge.
The presently marketed adenovirus vaccine contains living lyophillized adenovirus of either type 4 or type 7 mixed with inert ingredients prepared in enteric coated tablets. Administration of tablets (approximately 10 4 TCID 50 of virus) results in selective gastrointestinal infection without illness. The vaccine is safe; the induced infection is specifically restricted to the intestinal tract, and the vaccine virus is not transmitted from vaccinees to susceptible close contacts. Specific neutralizing antibody is noted in over 95% of vaccinated individuals 21 days after immunization. The new vaccines of the present invention which are specifically described are comprised of recombinant adenoviruses expressing hepatitis B surface antigen, LAV surface antigen, and rotavirus VP7 and are formulated and work in the same fashion as the present adenovirus vaccine except that antibody to hepatitis B surface antigen, LAV surface antigen or rotavirus VP7 is produced as well as antibody to adenovirus. In any of the embodiments of the invention, the administration of approximately 10 4 TCID 50 of recombinant virus, or even considerably less, will, of course, produce the desired immunogenic response. The determination of the optimum dosage will vary depending on the particular recombinant adenovirus employed; determination of this optimum is within the skill of the art.
EXAMPLE 5
Detailed example of a recombinant that expresses authentic HB S A g
As a detailed example of the construction of one adenovirus recombinant, the HB S A g gene of the adw subtype from 26 bp upstream of the HB S A g translation initiation codon and 131 bp downstream from the translation termination codon was flanked by upstream sequences from the Ad2 major late promoter (+33 to 400 bp; Solnick, D., Cell, 24, 135-143 (1981) and by downstream sequences from SV40 (2753 to 2516 bp; Tooze, J. (Ed.) Molecular Biology of Tumor Viruses, Cold Spring Harbor Laboratory pp. 801-829 (1980)). This plasmid is termed p6XH (see above). These sequences were inserted into the unique Xbal site plasmid pAC that contains an insert of Ad5 DNA extending from the Eco RI linker at the left end of the adenovirus genome to the Hind III site at Ad5 map coordinate 17.0 (Gluzman, Y., Reichl, H., and Solnick, D., 1982, in (Y. Gluzman, Ed.) Eukaryotic Viral Vectors, Cold Spring Harbor Laboratories, p. 187-192). The new plasmids (pACH-2 and pACH-9) with the cassette containing the Ad2 major late promoter--HB S A g gene--SV40 processing signals in either orientation, were cleaved with Hind III. The Hind III cleavage product of each was combined with the large Xbal fragment of the adenovirus mutant ΔEl extending from map coordinates 9.1 to 100 (Gluzman, Y., Reichl, H., and Solnick, D., 1982 in (Y. Gluzman, ed.) Eukaryotic Viral Vectors, Cold Spring Harbor Laboratories, pp. 187-192). This DNA mixture was transfected (Graham, F. L. and ven der Eb, A. J. Virology 52, 456-467 (1973)) onto 293 cells (Graham, F. L., Smiley, J., Russell, W. C., and Nairn, R., J. Gen. Virol., 36, 59-72 (1977)) and cells were overlaid with agar for plaque detection. Approximately 10-14 days later, 54 plaques were picked and virus stocks generated from each. These viruses were screened for the presence of HB S A g DNA by hybridization to a 32P-labeled HB S A g DNA probe. Positive plaques (49 out of 54) were next infected onto monolayers of 293 cells and the expression of authentic HB S A g was detected in cell lysates by both radioimmunoassay (AUSRIA, Abbott Laboratories, Inc. or NML-HB S A g RIA, Nuclear-Medical Laboratories) and by immunoprecipitation of 35S-radiolabeled HB S A g using a monoclonal antibody to HB S A g (anti-a subtype, Boehringer Mannheim Biochemicals).
In the specific example above, we use the Ad2 major late promoter extending only 33 nucleotides downstream from the transcriptional initiation site so that the first splice site is not included. This promoter contains only the first part of the tripartite leader of the adenoviral major late promoter. However, the major late promoter from other adenoviruses particularly types 3, 4, 5, or 7 can be used and the full tripartite leader of this promoter can be used. In the following example we describe the construction of two bacterial plasmids, pHM1 and pHM2 which contain cassettes composed of the Ad2 major late promoter and the leftmost 168 bp of the 200 bp Ad2 tripartite leader followed by the HB S A g gene and processing and polyadenylation signals from SV40 virus. These plasmids also contain adenovirus sequences flanking the cassette so that homologous recombination can be used to insert the cassette into the adenoviral genome. On the left the cassette is flanked by the leftmost 353 bp of the Ad5 genome-and on the right by map coordinates 8-15.5 of adenovirus 5. Plasmid pHM1 contains 19 bp of SV40 virus sequence (SV40 nucleotides 5173-5174) preceding the HB S A g gene. Plasmid pHM2 is identical to pHM1 except that it does not contain this sequence.
The cassettes from both pHM1 and pHM2 were placed at the E1 region of the adenovirus 5 genome by the technique of homologous recombination as described above. Each plasmid was linearized and combined with the large Xbal fragment of the adenovirus mutant ΔE1 extending from map coordinates 9.1 to 100 (Gluzman, Y., Reichl, H. and Solnick, D., 1982 in (Y. Gluzman, ed.) Eukaryotic Viral Vectors, Cold Spring Harbor Laboratories, pp. 187-192). Plaques were picked and stock viruses generated from each.
When these stock viruses (HM1 and HM2) were infected on a human embryonic kidney (293) cell line (Graham, F. L., Smiley, J., Russell, W. C. and Nairn, R. (1977) J. Gen. Virol. 36, 59-72) we found, after 40 h infection, approximately 1 μg HB S A g (based upon radioimmunoassay and comparison of cpm to NML-HB S A g kit positive control) per 5×106 infected cells were observed in culture supernatants of HM2 infected cells. HM1 virus yielded approximately 60% of this amount. We found that the HB S A g polypeptides produced by these viruses were glycosylated (P2) and non-glycosylated (P1) forms (Marion, P. L., Salazar, F. H., Alexander, J. J. and Robinson, W. (1979) J. Virol. 32, 796-802; Peterson D. L. (1981) J. Biol. Chem. 256, 6975-6983). At 40 h after infection most of the HB S A g (78%) was secreted from cells into the culture medium as a particle (density=1.20 g/ml) the same or nearly the same as the 22 nm particle (Gerin, J. L., Purcell, R. H., Hoggan, M. D., Holland, P. V. and Chanock, R. M. (1969) J. Virol. 4, 763-768; Gerin, J. L., Holland, P. V., and Purcell, R. H. (1971) J. Virol. 7, 569-576) observed in human serum. HM2 yielded approximately 40% more HB S A g than HM1. However, when HM2 was compared to the previously described hybrid adenovirus, ΔE1H, a 70-fold increase in HB S A g polypeptide was noted by HM2 virus.
Instead of the adenoviral major late promoter, any other suitable eukaryotic promoter can be used, such as human metallothionein promoter or the human dihydrofolate reductase promoter. In addition, in our examples, we have used adenovirus type 5 DNA as vector for foreign gene expression; however, other adenovirus types can be used as vector, and particularly useful are types 3, 4, and 7 that are presently in use as vaccines.
Also, we describe the use of processing and polyadenylation signals from SV40 DNA; however, any suitable processing and polyadenylation signals may be used. These may come from adenoviral DNA, particularly types 3, 4, and 7.
EXAMPLE 6
Recombinant Adenovirus Ad7HZ6-1
Example of a recombinant adenovirus type 7, Ad7HZ6-1, that contains hepatitis B virus DNA inserted into the E3 region of the adenovirus genome and that replicates in human cells, directing the expression of hepatitis B virus surface antigen.
Ad7HZ6-1 was assembled by transfecting A549 cells (ATCC CCL 185) with overlapping viral DNA fragments that recombined in vivo to generate a complete recombinant viral genome capable of replicating and of producing infectious recombinant adenovirus (Davis, A. R., et al., [1985. Proc. Natl. Acad. Sci. USA 82, 7560-7564). The majority of the recombinant viral genome was derived from the Eco RI "A" genomic fragment of adenovirus type 7 (strain 55142) DNA that extends from map unit 0 to map unit 87. The other viral DNA fragment was a cloned, recombinant fragment that extends from map unit 68 to map unit 100 and contains the hepatitis B virus DNA; it was constructed as described below by standard techniques of molecular biology (Maniatis, T., et at., [1982. Molecular Cloning: A Laboratory Manual, Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y.).
Adenovirus type 7 (strain 55142) DNA was cloned into the Eco RI site of pBR322 (Pharmacia Inc., Piscataway, N.J.) as described (Hanahan, D. and Gluzman, Y. [1984] Molecular and Cellular Biology 4, 302-309). This procedure yielded recombinant plasmid WypAd7RIA-17 which contains adenovirus viral DNA between map unit 0 and map unit 87 with some deletions between map unit 40 and map unit 65. Recombinant plasmid WypAd7RIB-10 that contains the Eco RI "B" fragment which extends from map unit 87 to map unit 100 was also recovered. Portions of these two plasmids were combined to create a plasmid that contains adenovirus DNA between map unit 68 and map unit 100 except that the Hind III "H" fragment (map units 80-84) is replaced by a chemically synthesized polylinker region.
WypAd7RIA-17 was digested with Sal I and religated to make ChpAd717E27w.t. which lacks the Sal I "A" fragment (map units 18-68). ChpAd717E27w.t. was digested with Eco RV, Sal I and Hind III. Three of the resultant fragments, pBR322 between the Eco RV site and the Sal I site, adenovirus between map unit G8 (Sal I) and map unit 80 (Hind III), and the recombinant fragment containing adenovirus between map unit 84 (Hind III) and map unit 87 (Eco RI) joined to pBR322 from the Eco RI site to the Eco RI site, were separated by gel electrophoresis, purified and ligated together in the presence of a synthetic polylinker (Pharmacia Inc., Piscataway, N.J.) with Hind III ends and an internal Xba I site. The plasmid ChpAd717E27HΔ was recovered from this ligation and digested with Sal I and Eco RI to obtain a cloned adenoviral DNA fragment extending from map unit 68 to map unit 87, with the Hind III "H" fragment replaced by a synthetic polylinker.
The Eco RI site added to the terminus of the viral genome at map unit 100 during cloning was replaced by a Sal I site in the following steps. WypAd7RIB-10 was digested with Eco RI, the Eco RI sites were filled-in with Klenow DNA polymerase, Sal I linkers were ligated to the filled-in ends, followed by digestion with Sal I and Bam HI. The adenoviral DNA fragment extending from the Bam HI site at map unit 92.5 to the synthetic Sal I site at map unit 100 was cloned into pUCl9 (Pharmacia Inc., Piscataway, N.J.). An adenoviral DNA fragment extending from map unit 87 (Eco RI) to map unit 92.5 (Bam HI) was prepared from WypAd7RIB-10 and added to this pUCl9 recombinant to make ChpAd73'RS.1. ChpAd73'RS.1 was digested with Eco RI and Sal I to obtain a cloned adenoviral DNA fragment extending from map unit 87 (Eco RI) to map unit 100 (Sal I).
The cloned adenoviral DNA fragment extending from map unit 68 to map unit 87 obtained from ChpAd717E27HΔ and the cloned adenoviral DNA fragment extending from map unit 87 to map unit 100 obtained from ChpAd73'RS.1 were ligated together and then inserted into the Sal I site of pBR328 (Soberon, X., et al., [1980] Gene 9, 287-305) to create ChpAd7SalBHΔ.
Hepatitis B virus DNA was obtained from a plasmid that contains hepatitis B virus genome cloned at the Eco RI sites. The numbering of the nucleotides in this hepatitis B virus genome is identical to that of Ono et al., [1983] Nucleic Acids Res., 11, 1747-1757. The fragment of the hepatitis B virus genome that contains the genetic code for hepatitis B virus major surface antigen, the major envelope protein, lies between an FnuD II site at nucleotide 131 and a Hpa I site at nucleotide 966. This DNA fragment was excised by digestion with FnuD II and Hpa I, Sal I linkers were added, and it was cloned into a pBR322 derivative to create the plasmid, pHMHS.3C. Hepatitis B virus DNA clones are readily available, for example ATCC 45020 from the American Type Culture Collection.
The DNA fragment that contains the genetic code for the hepatitis B virus major surface antigen was obtained from pHMHS.3C by Sal I digestion, the terminii were filled-in with Klenow DNA polymerase and Nhe I linkers were added, followed by Nhe I digestion. This fragment was inserted into the unique Xba I site of ChpAd7SalBHΔ, between adenovirus map unit 80 and map unit 84, to create pCAd7ΔHS1-5. In pCAd7ΔHS1-5, the hepatitis DNA fragment that contains the genetic code for the hepatitis B virus major surface antigen is oriented so that the translation initiation codon is proximal to the putative adenovirus E3 region promoter. Digestion of the Cla I site in the pBR328 portion yielded linear pCAd7ΔHS1-5; this cloned, recombinant viral DNA fragment extending from map unit 68 to map unit 100 was cotransfected into A549 cells with the Eco RI "A" genomic DNA fragment to generate the novel recombinant adenovirus Ad7HZ6-1.
Within 8 to 14 days after transfection, recombinant viruses were recovered as plaques on the A549 cell sheet. These viruses were screened for their ability to direct the production of hepatitis B virus major surface antigen in infected A549 cells by radioimmunoassay (Organon Teknika Corp., Irving, Tex.). After several rounds of plaque purification, Ad7HZ6-1 was amplified to high liter and genomic DNA was prepared and mapped with restriction endonucleases. This analysis confirmed the expected structure. A549 cells infected with Ad7HZ6-1 secreted approximately 1 μg of immunoreactive hepatitis B virus major surface antigen per 5 million cells within 48 hours (this corresponded to approximately 40,000 cpm per 100 μl sample of tissue culture supernatant using the radioimmunoassay). Ad7HZ6-1 has been deposited with the American Type Culture Collection and has been designated ATCC VR2167.
EXAMPLE 7
Recombinant Adenovirus Ad7HZ2-28
Ad7HZ2-28 was isolated after transfection of A549 cells with two overlapping Ad7 DNA fragments that recombined in transfected cells and produced a complete, infectious recombinant adenovirus. The two DNA fragments contributing to the recombination were (1) the EcoRI A fragment derived from genomic DNA map units 0 to 87; and (2) a cloned DNA fragment that extends from map units 68 to 100 and contains the hepatitis B virus surface antigen gene. The construction of the plasmid, pWyAd7E3HSB-C, for the second fragment is described below using standard techniques in molecular biology as summarized in (molecular cloning: A Laboratory Manual, Maniatis, T., et at. (1982) Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y.).
Adenovirus type 7 (strain 55142) ATCC VR2183 DNA fragment from map unit 68 to 87 was cloned in pBR322 after digestion with SalI and EcoRI to give the plasmid pWyAd768-87. Adenovirus DNA fragment from map unit 87 to 100 was cloned in pBR322 as described (Hananan D., and Gluzman, Y. (1984). Molec. and Cell. Biol. 4:302-309), to give the plasmid pWyAd7BN-10. In pWyAd7BN-10 an EcoRI site was added at map unit 100. pWyAd768-87 and pWyAd7BN-10 were used to construct pAd768-100 which contains Ad7 DNA extending from map 68 to 100 cloned as EcoRI to SalI fragment in pUC18.
In order to insert hepatitis B virus DNA that contains the gene for hepatitis B virus surface antigen into the E3 region, a fragment from pWyAd768-100 extending from map units 78.5 to 80.2 was isolated after SacII and NheI digestion. This fragment was cloned in a pBR322 derivative pBR322H-/S+. pBR322H-/S+ was prepared from pBR322 by HindIII digestion, fill-in of the HindIII site using Klenow DNA polymerase, addition of SAcII linkers, SAcll digestion and ligation. The fragment isolated from pWyAd768-100 (map units 78.5 to 80.2) was cloned into NheI and SacII digested pBR322H/S+ to yield the plasmid pBAd7Y2-7.
Hepatitis B virus DNA was obtained from a plasmid that contains the hepatitis B virus genome cloned at the Eco RI site. The numbering of the nucleotides in this hepatitis B virus genome is identical to that of Ono, et al. [1983] Nucleic Acids Res. 11. 1747-1757. The fragment of the hepatitis B virus genome that contains the genetic code for hepatitis B virus major surface antigen, the major envelope protein, lies between an FnuD II site at nucleotide 131 and a Hpa I site at nucleotide 966. This DNA fragment was excised by digestion with FnuD II and Hpa I, SalI linkers were added, and it was cloned into a pBR322 derivative to create the plasmid, pHMHS.3C. Hepatitis B virus clones are readily available, for example ATCC 45020 from the American Type Culture Collection.
The DNA fragment that contains the genetic code for the hepatitis B virus major surface antigen was obtained from pHMHS.3C by SalI digestion, the terminii were filled-in with Klenow DNA polymerase, HindIII linkers were added followed by HindIII digestion. This fragment was cloned into the unique HindIII site of pBAd7Y2-7 at adenovirus map unit 80, to create pBAd7YHS2-9. In pBAd7YHS2-9, the hepatitis B virus surface antigen gene is oriented so that the translation initiation codon is proximal to the adenovirus E3 promoter.
pBAd7YHS2-9 was digested with SacII and NheI and the adenovirus sequences from map unit 78.5 to 80.2 were joined to the large fragment of pWyAd768-100 that was also prepared by SacII and NheI digestion. This final plasmid construct, designated pWyAd7E3HSB-C contains adenovirus sequences from map units 68 to 100 and has the hepatitis B virus surface antigen gene sequence in the E3 region at map unit 80.
PvuI digestion at sites within the pUC18 portion of the plasmid gave linear pWyAd7E3HSB-C which was cotransfected into A549 cells with the adenovirus 7 EcoRI A fragment to generate the novel recombinant adenovirus Ad7HZ2-28.
Plaque purified Ad7HZ2-28 and A549 cells were examined for the production of hepatitis B virus surface antigen by radioimmunoassay (Organon Teknika Corp., Irving, Tex.).
Approximately 32,000 cpm per 100 μl sample of tissue culture media was found to be secreted within 48 hours postinfection. This corresponds to approximately 1 μg of HBSAg per 5 million cells. Preparation of genomic DNA from infected cells and analysis of the genomic recombinant DNA confirmed the structure as expected.
EXAMPLE 8
Recombinant Adenovirus Ad4HHXHS
Example of a recombinant adenovirus type 4, Ad4HH×HS, that contains the hepatitis B virus surface antigen gene with a synthetic splice acceptor sequence, which was inserted into the E3 region of adenovirus 4.
The recombinant adenovirus, Ad4HH×HS, contains 28 bp of middle surface antigen gene, 12 bp Ad5 hexon splice acceptor and the hepatitis B surface antigen gene inserted into the HpaI site of the E3 region of Ad4. The construction of Ad4HH×HS involved four steps:
1. subcloning of hepatitis B surface antigen gene.
2. cloning of the E3 region to the right-hand terminal region of Ad4.
3. subcloning of hexon splice acceptor and hepatitis B surface antigen.
4. generation of recombinant viruses by homologous recombination in vivo and identification of virus.
The hepatitis B virus major surface antigen gene (major envelope gene) was obtained from a plasmid, which contains HBV genome cloned at the Eco RI site. The numbering of the nucleotides in this HBV genome is identical to that of Ono et at., 11983] Nucleic Acids Res. 11, 1747-1757. Xho 1 linkers were added at the FnuDII site (nt. 131 ) and NheI linkers were added at the HpaI site (nt. 966). The fragment was subcloned at a constructed XhoI and NheI sites in a pBR322 derivative. The plasmid called pMPHSHpNh. The plasmid, Ad4E3, 71-100, contains the 29 mu fragment of Ad4 which extends from the HindIII site (71 mu) to the right-hand terminal end. The right-hand end of Ad4 was cloned by NaOH treatment followed by the addition of EcoRI linkers as described by Berkner and Sharp, (Nucl. Acids Res. 11, 6003 [1983]). The EcoRI C fragment (83 mu-100 mu) was cloned into pBR322. The XhoI EcoRI fragment (996.1-100mu) was subcloned into the pUC18 vector at the SalI and EcoRI sites. Ad4 DNA was prepared from Ad4 virus amplified in W138 cells. The HindIII to SalI fragment (71 mu-99.6mu) isolated from Ad4 viral DNA was subcloned into l;he pUC18, 96-100 plasmid at the SalI of Ad4 (99.6mu) and the HindIII site of pUC18 vector, resulting in the plasmid called pAd4E3, 71-100.
The plasmid, pAd4E3, 71-100, was modified in the following way so that the hepatitis surface antigen gene could be inserted at the HpaI site (76.3 map unit). In one isolate, Spe I linkers were added to the HpaI site. In a second isolate, the linkers below, called HHx, were added to the HpaI site and the plasmid digested with SalI:
5'ATTGCCTCTCACATCTCGTCAATCTCCGCCGCCAGAG 3'
3'TAACGGAGAGTGTAGAGCAGTTAGAGGCGGCGGTCTCAGCT 5'
The HBV surface antigen gene was inserted at the HpaI site by ligation of (a) the HBV XhoI to Nhe I fragment (nt. 131-966), (b) an Ad4 fragment from the 71 mu to 76.3 mu containing the HHx linker at 76.3 mu, i.e. the HindIII to SalI fragment and (c) Ad4-pUC18 fragment (76.3 mu-100 mu) from the SpeI site (76.3 mu) to the HindIII site of pUC18.
The recombinant adenovirus, Ad4E3HH×HS, was generated by cotransfection of 10 μg pAd4HpSpHS and 5 μg Bc1A fragment of Ad4 (0-87 mu) into A549 cells as described (Berkner and Sharp, [1983], Nucl. Acids Res. 11, 6003). Plaques were picked into 2 ml media, and 1 ml was amplified on A549 cells. The supernatants were screened for the secretion of HBV surface antigen by a radioimmunoassay (Organon Technika Corp., Irving, Tex.). The recombinant adenovirus, Ad4HH×HS, produces significant quantities of Hepatitis B surface antigen. Ad4HH×HS has been deposited with the American Type Culture Collection and has been designated ATCC VR 2210.
EXAMPLE 9
Recombinant Adenoviruses WyAd7H 6 and WyAd7H 7
Cloned DNA of the adenovirus type 7 strain 55142, was engineered by introducing an Xba I site at 159 base pairs from the right hand end of the adenovirus genome in the following manner. The EcoRI B fragment from adenovirus type 7 was cloned into pBR322, the plasmid was partially digested with Rsa 1 and Xba I linkers were ligated to the viral DNA. The resultant clones were screened and those with unique Xba I sites were selected and sequenced to assure that no deletions had occurred.
In order to express the major hepatitis B surface antigen (HB S A g ), it was necessary to introduce the major late promoter sequence and three pan leader sequence that is found on all adenovirus mRNAs. The major late promoter sequence was isolated by digesting with Xho I and Pvu II and subcloning the adenovirus DNA fragment from 5,643 to 5,934 base pairs. The three part leader sequence was selected from cDNA clones of adenovirus mRNA. The promoter sequence included from the Pvu II site at 5,934 base pairs to the Taq I site at 9,530 base pairs, where a SalI linked was added, with the intron sequences being deleted from the cDNA clones. The polyadenylation site consisted of the SV40 polyA site which included the fragment between the Bcl I site and BamH I sites from 2,770 base pairs to 2,533 base pairs of the SV40 genome. All three fragments (promoter, leader and polyA site) were introduced into the plasmid which contained the adenovirus EcoRI B fragment to produce the expression vector (pAd7BMTS-2).
Hepatitis B virus DNA was obtained from a plasmid that contains the hepatitis B virus genome cloned at the Eco RI site. The numbering of the nucleotides in this hepatitis B virus genome is identical to that of Ono, et al. [1983. Nucleic Acids Res. 11, 1747-1757. The fragment of the hepatitis B virus genome that contains the genetic code for hepatitis B virus major surface antigen, the major envelope protein, lies between an FnuD II site at nucleotide 131 and Hpa I site at nucleotide 966. This DNA fragment was excised by digestion with FnuD II and Hpa I, Sal I linkers were added, and it was cloned into a pBR322 derivative to create the plasmid, pHMHS.3C. Hepatitis B virus clones are readily available, for example ATCC 45020 from the American Type Culture Collection.
The HBSAg gene was removed from a plasmid (pHMHS.3C) by digesting with Sal I and ligated into the expression vector. The resultant plasmids (pAd7BMTHS-15 and pAd7BMTHS-26), which contained either one copy or two copies, respectively, of the HB S A g gene, were ligated to the EcoRI A fragment of adenovirus type 7 and transfected into A549 cells. Plaques were obtained, amplified on A549 cells and tested for the expression of HB S A g . Clones which were positive for surface antigen expression were passed again in A549 cells to make virus stocks and were also grown in W138 coils. The DNA of viruses WyAd7H 6 and WyAd7H 7, containing one copy or two copies of the HB S A g gene, were analyzed by restriction mapping and electrophoresis in agarose gels and were found to be nondefective and did not contain any deletions in the viral DNA.
EXAMPLE 10
Recombinant Adenoviruses WyAd7ChH1-16 and WyAd7ChH2-8
A different expression cassette was developed by Chiron and was introduced into the plasmid which- contained the adenovirus type 7 EcoRI B fragment with a unique XbaI site at 159 bp from the right hand end of the genome. Adenovirus DNA (from plasmid WyAdR1A-17) fragment XhoI (nucleotide 5643) to the HindIII site was cloned into pBR327. The tripartite leader was designed based on the published adenovirus type 7 sequence from the PvuII site (nucleotide 5934) within the first leader segment through the end of the first segment (nucleotide 5944), containing the second leader segment (nucleotide 6962-7033), and the third leader segment (nucleotide 9477-9563) and ending with a Hind III site. The poly A site for the hexon gene of adenovirus type 7, the major late promoter and the tripartite leader were cloned into the plasmid which contained viral DNA with a unique XbaI site near the inverted terminal repeat. The DNA constructions contained the promoter oriented in either the left hand orientation or the right hand orientation. The HBSAg gene was obtained from the pHMH5.3C plasmid as described in Example 9 and was cloned into the plasmid listed above.
The plasmids were ligated to the EcoRI A fragment and transfected into A549 cells. The plaques of virus that were obtained contained the surface antigen gene and the promoter sequence in a left-hand orientation (WyAd7ChH 1-16) or the right-hand orientation (WyAd7ChH 2-8). Both constructions expressed HB S A g and were nondefective.
EXAMPLE 11
Recombinant Adenovirus WyAd7IHH-I
The intron between the first and second part of the tripartite leader sequence was isolated from the adenovirus type 7 genome by digesting the adenovirus DNA with XhoI and purifying the fragment from agarose gels (5,643 to 8,168 base pairs on the adenovirus genome). The fragment was inserted by digestion with XbaI and ligation into a cassette which contained the major late promoter, the tripartite leader sequence and the SV40 poly A site. The leader sequence was joined by digestion with ScaI and ligation. The intron was further modified by treatment with BssHII which removed a fragment that corresponded to between 6,178 and 6,517 base pairs on the adenovirus genome DNA. The entire cassette was inserted into the XbaI site that had been constructed at 159 base pairs from the right-hand end of the adenovirus genome. The major HB S A g gene was obtained from pHMHS.3C as described in Example 9 and inserted into the SalI site. The hexon polyA site was substituted for the SV40 polyA site by digesting the plasmids with SpeI and exchanging fragments between pAd7ChHI-1 and pAd7ChHA-6 (left-hand orientation) as well as pAd7IChH3-10 and pAd7ChHB-31 (right-hand orientation). The SpeI sites were found near the right-hand end of the adenovirus genome and in the HB S A g gene. The plasmids were also treated with StuI and HindIII linkers were added to the blunt ends by ligation. After digestion with HindIII another fragment was removed from the intron which corresponded to between 6,135 and 6,819 base pairs of the adenovirus genome.
An additional modification was made to the clone which contained the major late promoter in the left-hand orientation.
A fragment of DNA which contained the adenovirus type 7 BamHI fragment that spanned from 70 map units to 90 map units of the adenovirus genome was cloned into the expression vector after digestion with BamHI. This fragment was obtained from the plasmid ChpAd7SalIBHΔ, and it contained a deletion in the E3 region that was made by the removal of a HindIII fragment from map units 80 to 84. The plasmid (pAd7ΔBH1-11) was subsequently digested with BglI to linearize the DNA and cotransfected with the adenovirus type 7 EcoRIA fragment into A549 cells. The plaque that was obtained after 21 days was amplified in A549 cells and the virus recombinant, WyAd7IHH-1, was positive for the expression of hepatitis B surface antigen.
EXAMPLE 12
Recombinant Adenovirus Ad4iHR
Recombinant virus Ad4iHR has a cassette for production of HB S A g positioned at a SalI site found in Ad4 138 bp from the extreme right-hand terminus. The cassette contains (1) the Ad4 major late promoter (MLP), (2) followed by the first leader of the Ad4 tripartite leader CFPL), (3) followed by the first intron of the tripartite leader (TL), followed by (4) the second two exons of the Ad4 TPL, followed by (5) the HB S A g gene, followed by (6) a processing and polyadenylation signal from SV40 virus. It was prepared and positioned in the rightward orientation at the unique SalI site as follows: Ad4 is known to have an XhoI site at 15.9 map units (Ginsberg, E. [ed], 1984, The Adenoviruses, Plenum Press, N.Y.), and it was determined by restriction enzyme mapping to have a ScaI site at 19.7 map units. DNA fragment 1 (approx. 1300 bp) from XhoI to ScaI contains the Ad4 major late promoter, the first leader of the TPL and the entire intron between the first and second exon of this TPL and one-half of the second exon.
DNA fragment 2 from this ScaI to a TaqI site 100 bp downstream of this ScaI site in Ad4 was obtained from a cDNA clone of the Ad4 TPL and was determined by DNA sequencing to contain the second-half of the second exon and two-thirds of the third exon for the TPL. This cDNA clone was obtained by standard methods (Maniatis, T. et al [1985], Molecular Cloning: A Laboratory, Cold Spring Harbor, N.Y.) with the use of the oligonucleotide 5'TCTFCAAGGGGGAACCCG3' as probe. Use of the oligonucleotide was based upon the published sequence in this region (exon 2 of the TPL in Ad7 DNA found in (Ginsberg et al. 1984 ibid)). In DNA fragment 2, this TagI site was converted to a SalI site by treatment with Klenow DNA polymerase 1 and ligation of a SalI linker. DNA fragment 3, the HB S A g gene, was obtained from pHMHS.3C by SalI digestion inserted into the SalI site of pBR328 (Soberon, X., et at. [1980], Gene 9, 287-305) to create ChpAd7SalBHΔ.
Hepatitis B virus DNA was obtained from a plasmid that contains the hepatitis B virus genome cloned at the Eco RI site. The numbering of the nucleotides in this hepatitis B virus genome is identical to that of Ono, et al [1983] Nucleic Acids Res. ˜, 1747-1757. The fragment of the hepatitis B virus genome that contains the genetic code for hepatitis B virus major surface antigen, the major envelope protein, lies between an FnuD II site at nucleotide 131 and a Hpa I site at nucleotide 966. This DNA fragment was excised by digestion with FnuD II and Hpa I, Sal I linkers were added, and it was cloned into a pBR322 derivative to create the plasmid, pHMHS.3C. DNA fragment 4 was the SV40 processing and polyadenylation signal, extending from 2753-2516 bp on the SV40 map (Tooze, I. [ed]), 1980 DNA Tumor Viruses, Cold Spring Harbor Laboratory, N.Y.) with a SalI site at 2,753 bp and a XhoI site at 2,516 pb.
Fragments 1 (Xhol-ScaI), 2 (ScaI-SalI), 3 (SalI-SalI) and 4 (SalI-XhoI) were assembled using standard manipulations (Maniatis, T. et al., 1982, ibid) in bacterial plasmid pBR322 (Bolivar et at. [19771, Gene 2.95) modified to contain an XhoI site at the junction of the BamHi (375 bp from the EcoRI site) and PvulI site (2,067 bp from the EcoRI site in BR322). Then the entire cassette was cloned (as an XhoI fragment) in either orientation at the unique SalI site of pAd4R1C-25. This plasmid contains the rightmost EcoRI fragment of Ad4 (Ad4EcoRIC) cloned at the EcoRI site of a pBR322 modified such that the SalI site (650 bp from the EcoRI site) is destroyed.
The Ad4EcoRI C fragment, prepared from Ad4 DNA, strain CL68578, was cloned by treatment of purified Ad4 DNA with NaOH to remove terminal protein complex followed by re-annealing, ligation of EcoRI linkers, and treatment with EcoRI as described in detail (Hanahan, D. and Gluzman, Y. [19843 Molecular and Cellular Biology 4, 302-309). The final plasmid, termed pAd4CMT(i)H-45 contained the above cassette cloned at the SalI site in the rightward orientation. Virus Ad4iHR was formed by co-transfection of the BclIA fragment of Ad4 DNA with pAd4CMT(i)H45 cloned with EcoRI. When A549 cells were infected with Ad4iHR, HB S A g activity was demonstrated using a commercial radioimmunoassay (Organon Technika Corp., Irving, Tex.).
EXAMPLE 13
Recombinant Adenoviruses Ad4(di)HR and Ad4(di)HL
Recombinant virus Ad4diHL and Ad4diHR were made in the same fashion as Ad4iHR except that the 1,000 bp intron between TPL exon 1 and TPL exon 2 was trimmed by deleting 500 bp from a StyI site approx. 500 bp from the 5' XhoI site to a SacII site approx. 1,000 bp from the 5' XhoI site. In addition, both orientations of this DNA fragment (rightward and leftward) were used. When Ad549 cells were infected with suspensions of Ad4(di)HR and Ad4(di)HL, HB S A g activity was demonstrated in both cases.
EXAMPLE 14
Recombinant Adenoviruses Ad4XiHR, Ad4X(di)HR
Recombinant viruses Ad4XiHR and Ad4X(di)HR were made in exactly the same fashion as Ad4iHR and Ad4(di)HR except that a synthetic 112 bp Ad4 hexon processing and polyadenylation signal on a SalI to XhoI DNA fragment replaced the SV40 polyadenylation signal. The DNA sequence used for this signal was determined by DNA sequence analysis of the published sequence of the Ad2 hexon polyA site (LeMoullec, J. M. et al [1983], J. Virol. 48: 127) and DNA sequence analysis of the corresponding region in Ad4. By comparing the two sequences, one was able to determine which elements appear to be necessary for function. When A549 cells were infected with a plaque suspension of Ad4XiHR and Ad4X(di)HR, HB S A g activity was demonstrated in both instances.
EXAMPLE 15
Recombinant Antivirus WyAd7LAV# 17
This is an example of a recombinant adenovirus type 7, WyAd7LAV#17, that contains lymphadenopathy associated virus DNA within an expression cassette inserted between the E4 region and the right ITR of the adenovirus genome and that replicates in human cells, directing the expression of LAV envelope protein.
WyAdLAV#17 is similar to WyAd7H#6 and many of the plasmids used to construct WyAd7H#6 were also used to construct WyAd7LAV# 17. WyAd7LAV#17 was assembled in vitro by ligating together the Eco RI "A" genomic fragment of adenovirus type 7 (strain 55142) DNA and a cloned, recombinant derivative of the adenovirus type 7 Eco RI "B" fragment that contains the LAV DNA inserted into a genetically engineered expression cassette driven by a copy of the adenovirus type 7 major late promoter. The ligated viral DNA was transfected into A549 cells (ATCC CCL 185) from which recombinant virus was subsequently recovered (Davis, A. R., et at., [1985] Proc. Natl. Acad. Sc. USA 82, 7560-7564).
A description of the procedures used to clone adenovirus type 7 DNA and to construct the expression cassette is given in Example 9. Standard techniques of molecular biology were utilized to create a recombinant plasmid, pAd7BMTS-2, that contains the Eco RI "B" fragment extending from map unit 87 to a synthetic Eco RI site at map unit 100. An expression cassette containing the adenovirus major late promoter followed by a cDNA copy of the tripartite leader, a synthetic SalI site and the SV40 early polyadenylation signal was inserted into a synthetic Xba I site at map unit 99.6 The major late promoter within the expression cassette was oriented in the same direction as the endogenous major late promoter at map unit 16, and transcription should proceed toward map unit 100. Cloned DNA fragments which encode vital antigens can be inserted at the synthetic SalI site within the cassette and can be expressed during the course of virus infection.
Lymphadenopathy associated virus DNA was subcloned from a subgenomic clone of LAV inserted into the SacI site of pUC18, pUC18LAV, (Wain-Hobson, [1985] Cell 40, 9-17). A549 cells infected with WyAd7LAV#17 express immunologically reactive LAV envelope protein. This LAV antigen can be detected by cytoimmunofluorescence staining using either mouse monoclonal antibody directed against the gp 120K portion of the LAV envelope protein (Biotech Research Labs, Rockville, Md.) or human polyelonal antibodies from patients with AIDS ! (Cellular Products Inc., Buffalo, N.Y.). Electrophoretic analysis of metabolically radiolabeled LAV envelope protein that was immunoprecipitated by monoclonal antibody from A549 cells infected with WyAd7LAV#17 indicates that the LAV envelope protein is of the expected molecular weight, approximately 120 Kilodaltons, and that it is secreted into the media. WyAd76AV#17 has been filed with the American Type Culture Collection and has been designated ATCC VR 2185.
EXAMPLE 16
Recombinant Adenoviruses AD5 HBsAg78.5 and Ad5 HBsAG E3
Adenovirus type S (Ad5) (ATCC VR-5) was cloned into the Bam HI site of the bacterial plasmid pBR322 (Pharmacia Inc., catalog 27-4902-01) as described (Berkner, K. L., and Sharp, P. A., Nucleic Acids Res. 11, 6003 [1983]) except that Bam HI linkers (GGGATCCC, Pharmacia lnc.) were used instead of Eco Rl linkers. The resulting plasmid, p60W-43, was modified by excision of the Xba 1 fragment between adenovirus map unit (MU) 78.5 and MU 84.7 from p60W-43 grown in a Dem E. coli strain (NEB208, available from New England Biolabs). The Xba 1 fragment was separated from the modified plasmid, p60W E3 by electrophoresis in a low melting agarose gel and the modified plasmid was recovered, ligated, and propagated in E. coli (general techniques of the art are described in Maniatis, T., Fritsch, E. F., Sambrook, J., [1982J Molecular Cloning: A Laboratory Manual, Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y.). These recombinant adenovirus plasmids, p60W-43 and p60W E3-6, are prepared for insertion of heterologous DNA by digesting plasmid DNA grown in a Dam + strain of E. coli (New England Biolabs) with Xba 1 and treating the digested DNA with alkaline phosphatase.
The hepatitis B virus (HBV), ADW strain, major surface antigen coding sequence (HS) was excised from the recombinant plasmid pHM1-11 (Davis, A. R., et alia, Proc. Natl. Acad. Sci. USA 82, 7560 [1985]; another plasmid which includes HS is freely available, ATCC 45020, Moriarty et alia, Proc. Natl. Acad. Sci. USA 78, 2606 [1981] with SalI. The overhanging ends were filled in with Klenow polymerase, the HS was purified from a low temperature agarose electrophoresis gel and Nhe 1 linkers (CGCTAGCG, Pharmacia) were ligated to HS, followed by digestion with Nhe 1 and a second round of gel purification to yield pure HS fragment with overhanging Nhe 1 linkers.
The HS with overhanging Nhe 1 linkers was ligated to each of the prepared recombinant plasmids, p60W-43 and p60W E3-6, to construct the recombinant plasmids p60WHBsAgII-3 and p60W E3HBsAgII-12. These plasmids were digested with BamHI and transfected into the 293 cell line (ATCC CRL 1573), together with the Eco RI "A" fragment of genomic Ad5 DNA which extends from Mu 0 to Mu 76, as described (Davis, A. R., et alia, ibid). Homologous recombination occurs in vivo between the adenovirus DNA segments common to both the genomic DNA fragment and the cloned DNA fragment, Mu 60 to Mu 76, to generate full length recombinant viruses recovered as plaques on the 293 cell sheet (Stow, N. D. J. Virol. 37, 171 [19811). Recombinant viruses were screened for their ability to direct the production of HBV major surface antigen (S) in infected 293 cells by radioimmunoassay (Organon Teknika Corp., Irving, Tex.; Abbott Laboratories, N. Chicago, Ill.). Recombinant viruses which scored positive for S production were plaque purified, amplified to high titer, further purified by isopycnic centrifugation and the viral DNA was isolated as described (Davis, A. R., et alia, ibid). Analysis of vital DNA confirmed the expected structures. HS is inserted downstream of the E3 region promoter, within the second E3 intron, approximately 100 base pairs (bp) downstream of the Y leader (FIG. I) (Cladaras, C., et alia, Virol.140, 28 [1985]; Cladaras, C., et alia, ibid., p44).
In the recombinant Ad5 HBsAg78.5, no Ad5 DNA is deleted and the HS is approximately 150 pb upstream of the initiation codon for the vital glycoprotein gp 19K. In the recombinant Ad5HBsAG E3, the Mu 78.5 to Mu 84.7 Xba 1 "D" fragment is replaced by HS. WyAd5 HBsAg E3 has been deposited with the American Type Culture Collection and has been designated ATCC VR 2211.
Both recombinants are nondefective and can be propagated in a cell line appropriate for pharmaceutical use, W138 (ATCC CCL 75) as well as the transformed cell line, A549 (ATCC CCL 185) or the adenovirus transformed cell line, 293 (ATCC CRL 1573). Cells infected with 10 plaque forming units of either recombinant virus per cell should secrete at least 1 $g of immunoreactive S into the medium per 5 million cells within 48 hr. S secreted by these viruses is of the correct molecular weights corresponding to both unglycosylated and glycosylated protein (Heermann, K. H., et alia, J. Virol. 52, 396 [1984]) as determined by electrophoretic analysis of immunoprecipitated proteins (Mason, B. B., et alia, J. Virol. 33, 1111 [1980]).
Recombinant adenoviruses with similar structures can be constructed by using these same techniques applied to Adenovirus type 4 (ATCC VR-4) and Adenovirus type 7 (ATCC VR-7). ATCC catalog numbers refer to the American Type Culture Collection, Catalogue of Cell Lines and Catalogue of Animal Viruses, Rockville, Md.
EXAMPLE 17
Recombinant Adenovirus WyAd7IHH-3
Adenovirus vector was further modified by the addition of an EcoRI site at 80 map units. This site was produced by digesting with Stul and the ligation of EcoRI linkers. After digesting with EcoRI and religation, a fragment of adenovirus DNA was deleted which was from 84 to 87 map units.
The resultant plasmid, pAd7AHEH-3, was transfected into A549 cells and plaques were isolated which expressed HB S A g (Ad71HH-3). An analysis of the viral DNA from these recombinants confirmed that a deletion existed in the adenovirus DNA between 80 and 87 map units. WyAd7IHH-3 has been deposited with the American Type Culture Collection, and has been designated ATCC VR 2221.
EXAMPLE 18
Recombinant Adenoviruses WyAd7IHENV-4, 11, and 42
Constructs which contained the envelope gene from the AIDS virus were made by removing the HBsAg gene from other cassettes (pAd7 HEH-3, pAd7HRHL-5 and pAd7IHH-11) by digestion with SalI and ligation with the LAV-ENV gene which had been purified from pUCLenv.8. The envelope gene was the same as was used in the preparation of WyAd7LAV#17.
After isolation of the envelope gene, the DNA fragment was ligated into a plasmid which contained the adenovirus expression cassette with an intron and either a 1.6 or 2.6 kilobase deletion in the E3 region (80-84 map units and 80-87 map units respectively). Plasmids called pAd7IHENV-4 and pAd7IHENV-42 contained the expression cassette in either the right or left hand orientation, respectively, and a 2.6 KB deletion. The plasmid denoted pAd7IHENV-11 contained the expression cassette in the right-hand orientation and a 1.6 kilobase deletion. These three plasmids were linearized with BglI and transfected into A549 along with the adenovirus EcoRI "A" fragment. After 2-3 weeks, plaques were picked and amplified on A549 cells. The presence of the envelope gene was confirmed by performing a Hirt extraction on infected cells and an analyzing restriction enzyme digest on agarose gels.
The viruses were named according to which plasmid they originated from (WyAd7IHENV-4, 11 and 42). The production of the AIDS envelope antigen was determined by immunoprecipitation with a monoclonal which reacted with gp120/160. The identity of the precipitated protein was further confirmed by analysis on polyacrylamide gels. WyAd7IHENV-4 and WyAd7IHENV-42 have been deposited with the American Type Culture Collection and have been designated ATCC VR 2222 and ATCC VR 2220, respectively.
EXAMPLE 19
Recombinant Adenovirus WyAd7IHART-4
WyAd7IHART-4 was isolated by transfecting A549 cells with two overlapping DNA fragments that recombined in vivo to generate a complete recombinant vital genome capable of replicating and producing infectious recombinant adenovirus (Davis, A. R. et al. [1985] Proc. Natl. Acad. Sci. 82, 7560-7564). The two DNA fragments used for recombination were (1) the EcoRI "A" fragment derived from adenovirus type 7 genomic DNA that extends from map units (m.u.) 0 to 87 and (2) a cloned Ad7 DNA fragment that extends from m.u. 70 to 100 and contains REV(ART/TRS) gene. The construction of the plasmid, WyAd7 BH1-11.ART-4 for the second fragment is described below using standard techniques in molecular biology as summarized in (molecular cloning: A Laboratory Manual, Maniaties, T., et al. (1982) Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y.).
REV(ART/TRS) gene which was constructed as described below was inserted in the expression cassette WyAd7BH1-11 that contains the HBsAg between the E4 region and the inverted terminal repeat (ITR). HBsAg was removed by SalI digestion and the ART gene was inserted at the SalI site to generate the plasmid WyAd7 BH1-11.ART-4.
The expression cassette consisted of the adenovirus major late promoter (MLP), the tripartite leader sequence (TPL) and the hexon polyadenylation site. The major late promoter within the expression cassette was oriented in the same direction as the endogenous major late promoter at map unit 16, and transcription should proceed toward map unit 100.
The construction of REV(ART/TRS) involved the following steps: ART gene consists of two exons. The first part of the entire exon containing a Sacl-HindIII-SalI linker in front of ATG codon of ART gene and a part of the second exon up to AvaI site (Position 7950 on LAV genome; Wain-Hobson, (1985) Cell 40, 9-17) was synthesized chemically. The rest portion of the second exon including the termination codon was derived from AvaI (7950)-Xhol (8454) fragment of puc18 Lenv.8, a subgenomic clone of lymphadenopathy associated virus (LAV). These two fragments were then ligated to pTZ18R at the SacI-SalI site to generate a plasmid called pTZ18R.ART-3. This plasmid was then digested with HindIII and the HindIII fragment containing the ART gene was then cloned in pUC19 at the HindIII site. One of the resultant plasmids designated as pUC19.ART.d3-15 was digested with SalI and the SalI fragment containing the ART gene was isolated. This fragment was then inserted into the synthetic SalI site within the expression cassette.
Approximately (11-18) days after transfection, the recombinant adenovirus was recovered as plaques on the A549 cell sheet. Following plaque purification, WyAd71HART-4 DNA was extracted by Hirt's extraction procedure and then analyzed with restriction endonucleases. This analysis confirmed the expected structure. The effect of ART gene on the HIV envelope was then analyzed by infecting A549 cells with both WyAd71HART-4 and WyAd71HENV-42 viruses. WyAd71HENV-42 contains HIV env gene in the terminal cassette and has been described in Example 18. The total cell lysate was prepared at different time points (24, 30, 48, and 72 hr.) and the amount of HIV envelope gene was measured by antigen capture/ELISA assay. Approximately 50-70 fold increased envelope gene production was observed in the presence of ART gene. Electrophoretic analysis of metabolically radiolabeled cells infected with both viruses indicate the presence of gp160 and gp120, the products of HIV envelope gene. gp41 was also detected by using western blot analysis with inactivated human sera from AIDS patients. Immunoprecipitation with monoclonal antibody also confirmed the presence of gp160 and gp120. WyAd71 HART-4 has been deposited with the American Type Culture Collection and has been designated ATCC VR 2226.
EXAMPLE 20
Recombinant Adenovirus WyAd71HART-5,ENV-42
Recombinant adenovirus type 7, WyAd71HART-5.ENV-42 that contains REV(ART/TRS) gene in the deleted (80-87 m.u.) E3 region and ENV gene in the cassette that was inserted between the E4 and ITR region was isolated by transfecting A549 cells with two overlapping DNA fragments that recombined in vivo to generate a complete recombinant viral genome capable of replicating and producing infectious recombinant adenovirus. The two DNA fragments used for recombination were (1) The EcoRI "A" fragment derived from adenovirus type 7 genomic DNA that extends from map units (m.u.) 0 to 87 and (2) a cloned DNA fragment that extends from 70 to 100 m.u. which contains both REV and ENV gene. The construction of the plasmid, WyAd71HART-5.ENV-42 is described below. The plasmid pAd7 HEH-3 which contains HBsAg in the terminal cassette was digested with SalI to remove HBsAg and then ligated to (SalI-Xhol) fragment obtained from pUCLenv.8 which contained the HIV ENV gene to generate the plasmid, WyAd71HENV-42. The plasmid pAd7 HEH-3 contains 80-87 m.u. E3 deletion with a EcoRI site in it. The plasmid, WyAd71HENV.42 was then digested with EcoRI and then ligated to EcoRI fragments of ART gene which was derived from plasmid, pTZ18RART4.R1 which contains the ART gene flanked by EcoRI restriction sites.
Approximately (11-18) days after transfection, the recombinant adenovirus was obtained as plaques on A549 cell sheet. Following plaque purification, the recombinant adenoviruses were analyzed by restriction enzymes on Hirt extract DNA. Most of the plaques had deletion except one which had the expected structure. This plaque has been purified 2 times and a couple of plaques were analyzed on random basis by Hirt DNA analysis and by ELISA during each plaque purification. All of them had the expected structure and produced large amount of HIV ENV antigen WyAd71HART-5.ENV-42 has been deposited with the American Type Culture Collection, and has been designated ATCC VR 2241.
In practicing the method of this invention, where the foreign gene is inserted in deleted early region 3 of the adenovirus, the recombinant virus remains infective, and the vaccination requires nothing more than delivery of the recombinant virus to the gut. On the other hand, early region 1 is essential to adenovirus infectivity. Therefore, if the foreign gene is inserted in deleted early region 1, helper virus must be co-administered. This helper virus is conveniently unmodified, infectious adenovirus. Also, the helper virus can itself be a defective virus with a deletion which can be complemented by the recombinant virus. In this fashion virus growth and foreign antigen production would be elicited only in cells infected with both viruses. This defective helper virus can be of the same or of different subtype as the recombinant virus. If of differing subtype (e.g. if recombinant virus was Ad4 subtype and the defective virus of Ad7 subtype), formation of wild type virus though recombination should be minimized. Propagation of virus for vaccine production can be accomplished either through co-cultivation of both viruses in human diploid fibroblasts or cultivation of viruses separately in cell lines known to complement each of the defects.
In addition to the E 1 and E3 regions, there are several other regions of the viral genome where the cassette containing promoter, tripartite leader, foreign gene, and processing and polyadenylation signals may be inserted. These include a region between Ela and Elb, regions at the left and right ends of the genome, and at the E4 region, and between L5 and E4 regions. Some examples are given below:
Ad5 contains an Eta promoter at map coordinate 1.4 and an Elb promoter at map coordinate 4.7. The polyadenylation site for Ela is at map coordinate 4.6, nucleotide 1631, at nucleotide 1671 is the TATA box for the Elb promoter. At nucleotide 1572 there is a unique Hpal site (GTTAAC). This site can be utilized for placement of the adenovirus type 2 major late promoter and hepatitis B surface antigen and use of the Ela polyadenylation site. Polyadenylation of Ela can be provided by placement of a polyadenylation signal from SV40 viral DNA behind Eta or from the L4 region of the virus. The additional DNA in the genome in the above construct may be compensated by removal of DNA determined non-essential in the E3 region.
Other insertion points are the extreme left and right ends of the genome. At the left end the position will be between the 116 bp inverted terminal repeat and the TATA box of the E4 promoter. In Ad2 there is an Mbo II site at 99.3 map units. This is 191 bp from the extreme right end of the viral DNA. In Ad5 there is a Thai (FnU4DII) site 240 bp from the left end of the genome. This region is between the ITR and upstream of the E4 TATA box. Again, if necessary, insertion will be made into an E3 deletion mutant to accommodate the extra DNA.
In each case these same regions can be used as insertion points for the cassette of the adenovirus major late promoter, adenovirus tripartite leader, foreign gene and processing and polyadenylation signals in adenovirus type 4 and type 7 strains that are used for the presently marketed adenovirus vaccines.
Although this specification specifically refers to adenovirus of types 4, 5, or 7, live, infectious adenovirus of any type may be employed in this invention. Adenovirus of types 4 or 7 are preferred since these are the types presently employed in commercial adenovirus vaccines. Similarly, although specific reference has been made to vaccines producing antibodies to hepatitis-B, rotavirus, and HIV, our invention provides oral vaccines against any infectious agent containing an antigen to which a warm-blooded animal will produce antibodies or cell mediated immunity, and which antigen is coded for by a gene composed of up to about 3000 base pairs. Thus, for example, included within the scope of the invention are immunization against such diseases as influenza, parainfluenza, respiratory synctial virus disease, hepatitis A, acquired immunodeficiency syndrome (AIDS), cholera, E. coli, pertussis, diphtheria, tetanus, shigellosis, gonorrhea, mycoplasma pneumonia, and so on.
EXAMPLE 21
Recombinant Adenovirus WyAd7ΔE3 r80-88)TPL-S-35: (WyAd7delE3H)
This is an example of a recombinant adenovirus type 7, that contains synthetic WyAd7 cDNA copy of TPL and HBsAg DNA inserted within endogenous E3 mRNAs having a large deletion and produces high level of HBsAg protein mediated by the internal TPL sequences positioned immediately upstream to HBsAg gene. The E3 region protein coding sequences downstream to the HBsAg insertion site has been completely deleted in this recombinant. The recombinant virus isolation was carried out by recombining in vivo two overlapping WyAd7 DNA fragments transfected into A549 cells (Berkner, K. L. and Sharp, P., Nucleic Acids Res. 11:6003, 1983; and Davis, A. R., et at., Proc. Natl. Acad. Sci. USA, 82:7560, 1985). One of the DNA fragments was purified from WyAd7 vaccine strain (55142) as EcoRI A fragment spanning map units 0-87 portion of the viral genome. The second fragment was ClaI digested recombinant plasmid pAd7 SalIB (ΔE3 80-88) TPL-S-35. This contains a DNA segment of synthetic WyAd7 TPL appended to HBsAg gene and WyAd7 DNA between m.u. 68 to 100 as SalIB fragment, but without most of the E3 region sequences between m.u. 80-88. The construction of this recombinant plasmid involved the standard molecular cloning techniques (Molecular Cloning: A Laboratory Manual, Eds. Maniatis, T., et al. [1982] Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y.) and the details are as follows:
(a) Construction of WyAd7 TPL and HBsAg coding gene. A pBR327 derivative plasmid pAd7ChHA2-3 contained HBsAg coding DNA fragment between nucleotides 131 and 966 (Ono, et al., Nucleic Acids Res. 11:1747) as synthetic SalI fragment that was cloned into the synthetic SalI site located immediately downstream to the end of the synthetic cDNA copy of WyAd7 TPL-third leader. By site directed mutagenesis, a restriction site NheI was introduced immediately upstream to the 5' end of TPL and just downstream to the stop codon of HBsAg gene at nt 840 and resulted in plasmid pAd7ChHA2-318R-8 that was renamed as pAd7NCTPLH18R-7, from which the TPLHBsAg sequences can be isolated as NheI-NheI DNA fragment.
(b) Generation of a plasmid with large deletion (m.u. 80-88) in E3 Region of WyAd7: From a pBR328 vector plasmid that contained WyAd7 SalI B DNA (m.u. 68-m.u. 100) fragment with the 80-84 m.u. deletion in E3 region a derivative was constructed. This was called pAd7SalIB (68-100)ΔE3 (80-84)-12, in which the HindIII, BamHI, NheI sites of pBR328 were deleted. Then the Ad7 E3 region sequence between the StuI site present in a linker at 80 m.u. and the ApaLI site (located upstream to Ad7 E3B polyadenylation signal) at ˜88 m.u. was deleted to yield pAd7SalIB (68-100)ΔE3 (80-88)-78.
(c) Generation of Ad7-TPL-HBsAg-recombinant plasmid: The Ad7TPL-HBsAg containing DNA fragment was isolated as NheI/NheI fragment from above-mentioned pAd7NCTPLH 18R-7, and cloned into the synthetic XbaI site present at 80 m.u. in pAd7SalIB (68-100)ΔE3 (80-88)-78 to yield pAd7SalIBΔE3 (80-88)-TP-S-35. This plasmid contained TPL-HBsAg sequence at 80 m.u. in E3 region and provided the rest of Ad7 genome with 80-88 m.u. deletion for the generation of recombinant virus that produced high level of HBsAg protein as detected by radioimmuno assay using AUSRIA test kit of Abbot Labs.
WyAd7ΔE3 (80-88) TPL-S-35 (WyAd7delE3H) was deposited with the American Type Culture Collection and has been designated ATCC VR2295.
EXAMPLE 22
Recombinant Adenovirus WyAd4(3.11)ΔE3TPLH (WyAd4delE3H)
The recombinant virus construction strategy is similar to that in example 21, except that the WyAd4 synthetic TPL was appended to HBsAg gene and placed within a 3.11 kilo base pair deletion in E3 region of Ad4 genome. The steps involved in the construction are as follows:
(a) Construction of Ad4TPL-HBsAg containing plasmid: A synthetic cDNA copy of WyAd4 TPL containing DNA was isolated as a SmaI-EcoRI fragment and cloned into SmaI-EcoRI sites of pTZ18R (Pharmacia) vector to yield a plasmid pAd4TPL-MLP18R-12. By site directed mutagenesis, NheI and SalI sites were created at 5' and 3' ends of Ad4TPL sequences respectively to generate pAd4TPL-18R-21. The Ad4 TPL containing NheI-SalI DNA fragment was isolated from pAd4TPL-18R-21 and subcloned into NheI-SalI polylinker sites of pTZ18RD, to obtain pAd4TPL18RD-38 The HBsAg coding DNA fragment was isolated from pAd7NH18R-2, that was derived from pAd7ChHA2-3 mentioned under Example 21, Section (a). The HBsAg coding sequence was inserted downstream to Ad4TPL sequence present in pAd4TPL-18RD38 to yield pAd4TPLH. 18RD-47.
(b) Generation of Ad4-TPL-HBsAg recombinant plasmid: The Ad4TPL-HBsAg sequence containing DNA in pAd4.TPLH.18RD-47 was isolated as XbaI-NheI fragment and inserted at the synthetic SpeI site located within the 3.11 kb deletion (between 77 m.u. -86 m.u.) present in Ad4E3 region clone pAd4SDΔE3.8.12. The resulting recombinant plasmid clone which also contained the rest of Ad4 genome between m.u. 71 to m.u. 100, is called pAd4SDΔE3TPLH 142-423.
(c) Isolation of recombinant virus: The Ad4TPL-HBsAg containing recombinant plasmid pAd4SDΔE3TPLH142-423 was linearized with EcoRI and transfected into A549 cells along with the purified Ad4 BclI A fragment containing 0-87 map units of WyAd4 genome. The overlapping region recombination between the above mentioned two DNA fragments yielded the recombinant WyAd4(3.11 )ΔE3TPLH, producing abundant quantities of HBsAg protein as detected by radioimmuno assay using AUSRIA kit of Abbott Labs. The recombinant has been renamed as WyAd4delE3H.
WyAd4(3.11)ΔE3TPLH (WyAd4delE3H) was deposited with the American Type Culture Collection and bears the designation ATCC VR2303.
EXAMPLE 23
Recombinant Adenovirus WyAd7H
Ad7-HBsAg recombinant with complete E3 region: The recombinant contains the HBsAg and regulatory sequences inserted at the 3' end non-coding E3B region and retains all the E3 protein coding region as they are in vaccine strain WyAd7. The construction of this recombinant involved the following steps:
(a) Creating a new site of insertion at 3' non-coding part of E3B region: A synthetic SpeI linder/adapter was inserted at the BspMI site located between Ad7E3 region last open-reading frame stop codon and the E3B polyadenylation signal sequence in a subclone of E3b/L5 region and called pGEM3Zf(+) (Ad7E3BSpeI). The sequence of Ad7E3B region it contains is between SacI (˜88 m.u.) and HpaI (˜90 m.u.) that was subcloned into pGEM3Zf(+) vector from a plasmid containing m.u. 60-m.u. 100 of WyAd7DNA. The SpeI linker/adapter also provides stop condons in all the three reading frames and duplicates 10 bp of E3B sequences on either side of SpeI site to retain possible E3B polyadenylation functions.
(b) Source of HBsAg sequence and the regulatory elements as a cassette: The cassette containing-XbaI site, BamHI site, synthetic Ad7 hexon related splice acceptor, hexon leader, HBsAg coding sequence, SalI site, Ad7 hexon polyadenylation signal sequence and XbaI site was isolated as a DNA fragment with XbaI sites at both of the ends from a parent plasmid, pAd7SHLHPAΔX-7. The internal XbaI site within the HBsAg coding sequence was removed by site-directed mutagenesis of plasmid pAd7SAH×HPA-18R-10, while the coding amino acid remained unaltered. The pAd7SAH×HPA-18R-10 plasmid was assembled in pTZ18R vector, to contain synthetic Ad7 hexon like splice acceptor, hexon leader, HBsAg coding region and Ad7 synthetic hexon polyadenylation signal sequences, that were obtained from pAd7SAH×TPLH-50 and pAd7TPLHBsAg-52. In these plasmids the HBsAg (adw) coding sequence was originated from pAd7TP-HS-11, wherein a SalI site was added immediately downstream to stop codon of HBsAg open reading frame. The prior source of adw type HBsAg sequence and synthetic Ad7 hexon polyadenylation signal sequences were from pAd7HEH18R-153-4, while it was a derivative of pAd7NCTPLH 18R-7.
(c) Insertion of HBsAg sequence as a cassette into the new site at 3' non-coding part of E3B region: The cassette containing Ad7 hexon related splice acceptor, hexon leader, HBsAg and hexon polyadenylation signal sequence with XbaI sites at both of the ends was isolated from the plasmid pAd7SHLHPAΔX-7 (described above, Section -b). It was cloned into the synthetic SpeI site of pGEM3Zf(+) (Ad7E3BSpeI) and yielded the plasmid p3Zf(+) (Ad7E3B-xsa-xl-S-xpa)T3. From this plasmid, the SaclHincII DNA fragment containing E3B region (˜88 and ˜90 m.u.) and the HBsAg cassette sequences was cloned into SacI-HpaI sites (˜88 and ˜90 m.u.) of a plasmid[Ad7(84-100)]5a6, that contained Ad7 genome between map units 84 and 100. The resulting recombinant plasmid was called p18R [Ad7(84100)E3B-S]-G14. The pUC18R[Ad7(84-100)]5a6 was a derivative of pAd7SalIB(68-100) clone, that contains WyAd7 genome from 68 m.u. to 100 m.u. in pUC18R vector.
(d) Generation of recombinant virus: The recombinant plasmid p18R [Ad7 (84100)E3B-S]G14 was digested with BglI enzyme and co-transfected with agarose gel purified WyAd7 EcoRI A fragment of 0-87 m.u. The recombinant virus isolated produced high levels of HBsAg protein as tested by radioimmuno assay using AUSRIA test kit of Abbott Labs. The recombinant has been named WyAd7H.
EXAMPLE 24
Recombinant Adenovirus WyAd4H
This is an example of Ad4-HBsAg recombinant with complete E3 region.
The recombinant contains the TPL-HBsAg sequences inserted at the 3' end non-coding E3B region as in WyAd7H (Example 23) and retains all the E3 protein coding region as they are in vaccine strain WyAd4. The construction of this recombinant involved the following steps:
(a) Creating a new site of insertion at 3' non-coding part of Ad4E3B region: A synthetic linker/adapter with NheI and XbaI sites at 5' end and SpeI at 3' end was inserted into the SpeI site created between the stop codon of last E3 region protein (14.7K) open reading frame and the E3 B polyadenylation signal sequences in a subclone called pAd4 (86.7-91.5/SpeI)-65. The SpeI site that is located immediately downstream to Ad4 14.7K stop codon was created by site-directed mutagenesis of plasmid pAd4 (86.7-91.5). This in turn was obtained by subcloning the SacI (86.7 m.u.)- SphI (91.5 m.u.) DNA fragment of Ad4E3B region into pTZ19R. The SacVSphI fragment was isolated from the plasmid pAd4MPRIC-25 that contains EcoRI-C fragment (m.u. 83-m.u. 100) of WyAd4 MP vaccine strain that was cloned into pBR322 vector.
Once the linder/adapter NheI-XbaI-SpeI was inserted into the SpeI site in plasmid pAd4 (86.7-91.5/SpeI)-65, it generated two cloning sites namely XbaI at 5' end of the linker followed by E3B repeated synthetic sequences and the SpeI site at the 3' end of the linker. This new plasmid was called p19R(Ad4E3B)326-A4.
(b) Construction of Ad4TPL-HBsAg cassette containing plasmid-pAdTPLHx-SHpA-10: The cassette containing NheI site, Ad4TPL, Ad4 hexon leader, SalI site, HBsAg, SalI site, XbaI site, Ad4 hexon polyadenylation signal and NheI site has been put together by several steps of subcloning into pTZ18RD vector. In summary (i) the NheI site, Ad4TPL, Ad4 hexon leader--were obtained by plasmids namely pAd4TPLA HBsAg-64 (derived from pAd4TPLH- 18RD-47, pAd4TPL- 18RD-38, and pAd7NH- 18R-2) and pAd4TPLHxL-5. (ii) The HBsAg sequence was obtained from pAdSTPLS-8 and pAd7TPL-HS-HpA-52 (derived from pAd7TPLHS-11 and pAd7HEH18R-153-4). The HBsAg sequence was edited such that SalI site is created immediately upstream to AUG start codon and another SalI site is brought immediately downstream to TAA stop codon of HBsAg. (iii) The Ad4 hexon polyadenylation signal was obtained from pAd4TPLH×L-S-HpA- 13, 15 (derivative of Ad4TPL-S-HpA-42, and pAd4TPLHpA-38).
(c) Insertion of TPL-HBsAg sequence as a cassette into the new SpeI site at 3' noncoding part of E3B region: The cassette containing NheI site, Ad4TPL, Ad4 hexon leader, SalI site, HBsAg, SalI site, Xbal site, Ad4 hexon polyadenylation signal and Nhei site was isolated from the plasmid mentioned above -pAd4TPLHx-S-HpA-10. The cassette was isolated as NheI/NheI DNA fragment by gel purification and inserted into the new SpeI site present in p18R(Ad4E3B)326A4. The resulting Ad4E3BHBsAg recombinant plasmid is called p18R(Ad4E3B-TPL xl-S-xpA)32812.
(d) Generation of Ad4-TPL-HBsAg recombinant plasmid: The TPL-HBsAg cassette within Ad4E3B region fragment SacI and SphI was purified as BclI (87.1 m.u.)cassette-BclI (˜87.4 m.u.)DNA fragment from the above plasmid p18R(Ad4E3B-TPL-xl-S-xpA)32812. This fragment was cloned into the BclI (˜87.1 m.u./BclI (˜87.4 m.u.) sites of large plasmid pAd4 (71-100) 25.4 that contained HindIII (m.u. ˜71) - EcoRI (m.u. 100) fragment of WyAd4 vaccine strain. The resulting recombinant large plasmid is called pAd4 (77-100) TPL-S-412G1.
(e) Isolation of recombinant virus: The recombinant plasmid pAd4 [(77-100) TPL-xl-S-xpA]412G1 was digested with HindIII enzyme and co-transfected into A549 cells along with agarose gel purified Ad4 viral DNA (BclI A fragment) containing 0-87 map units of WyAd4 genome. The overlapping homologous region recombination between the transfected two DNA fragments yielded the viral plaques. These were amplified, plaque purified and identified by Hirt DNA analysis for the expected structure. As predicted they also produced abundant quantities of HBsAg protein as detected by radioimmuno assay using AUSRIA kit of Abbott labs. The recombinant has been named WyAd4H.
EXAMPLE 25
Ad7-eny MN
The construction of recombinant adenoviruses containing the coding sequence of the env (gp 160) gene of MN strain of HIV-1 is described briefly as follows: The 125 bp (6243 to 6367) fragment of the amino (NH 2 ) terminus of the env (gp160) gene including the initiation codon (ATG) as well as consensus Kozak sequence was amplified by polymerase chain reaction (PCR) from the clone pMNST 1-8-9. This fragment was then cloned in pGEM vector and the resultant clone was designated as pGEMMNenv. The following fragments of DNA were isolated by digesting with the restriction enzymes KpnI and XbaI from the clone PAd5tpl MN env 223 (6367 bp to 8816 bp), XhoI+KpnI fragment from PGEMenv and salI+XbaI fragment from pAd7tpl 18RD. All of these fragments were ligated together and the resultant clone was designated as pAd7tpl MN env. This plasmid was then digested with XbaI and treated with calf intestine alkaline phosphatase (CIAP). The NheI+XbaI fragment of Hrev gene was then isolated from the plasmid, pAd7tplHrev 18RD. The clone that was obtained after ligating these two fragments together was designated as pAD7tpl MN envtplHrev. This plasmid was then digested with NheI+XbaI and then ligated to the E3 deletion plasmid of Ad7, pAd7ΔE3 (68 m.u. to 100 m.u. deletion) that was also digested with XbaI and then treated with CIAP. The resultant plasmid was designated as pAD7ΔE3tpl MN envtpl MN Hrev. This plasmid was digested with EcoRI and mixed with the EcoRI (0-87 m.u.) fragment of the Ad7 genomic DNA. A549 cells were then transfected with these DNAs. Recombinant plaques obtained from in vivo recombination were identified by the appropriate restriction digestion analyses of the Hirt DNA. The plaques were also identified by the production of gp160, gp120, and gp41 using appropriate antibodies on Western blots.
EXAMPLE 26
Ad4-env MN and Ad5-eny MN
The construction of Ad4 and Ad5 recombinants are the same as that of Ad7-env MN except that for Ad4, EcoRI digested DNA from pAd4ΔE3tpl MN envtplHrev was combined with the BclI (0-87 m.u.) fragment from the Ad4 genomic DNA to produce the recombinant Ad4 virus. Similarly for Ad5, MluI-digested DNA from pAd5ΔE3tpl MN envtplHrev was combined with the SpeI (0-75 m.u.) fragment of Ad5 genomic DNA to produce the recombinant Ad5 adenovirus. Like Ad7, both Ad4 and Ad5 recombinants were obtained from A549 cells.
Measurement of Replication and Antigen Expression
Human A549 cells were infected (MOI 10:1 ) with recombinant adenovirus types 4, 5, and 7 that contained either the LAV or MN env genes. At 34 hours post-infection, virus titer and env antigen expression was determined in duplicate samples. One dish of infected cells was subjected to 3 cycles of freeze thawing and the cell lysate was tested for the presence of infectious virus by plaque assay. The second culture dish was washed, detergent solubilized, and an aliquot of the cell lysate was loaded on to a 10% polyacrylamide gel. Following electrophoresis, the separated proteins were transferred to nitrocellulose by a Western blot apparatus. The transferred proteins were immunostained with anti-env reagents. A known standard, recombinant gp160, was added prior to electrophoresis. The resulting immunoblot was scanned by a densitometer and the amount of recombinant env determined. There were no significant differences seen between wild type adenoviruses and the recombinant adenoviruses expressing either the LAV or MN env gene. Both types of recombinant adenoviruses, LAV or MN, produced similar amounts of env antigen. Therefore, both types of Ad-env recombinants, LAV and MN, were able to grow in human A549 cells as well as their corresponding wild type adenovirus, and were able to express recombinant env antigen. These results therefore demonstrate that both the LAV and MN adenovirus recombinants are capable of generating cell mediated, humoral, and secretory immunity in a mammal. The data obtained are summarized in the table below.
ADENOVIRUS REPLICATION AND ANTIGEN EXPRESSION
______________________________________Adenovirus pfu/cell × 10.sup.2 μg env/10.sup.6 cells______________________________________Ad4 wild type 5.4 0Ad4-env 9.1 2.1Ad4-env.sub.MN 6.8 2.7Ad5 wild type 22 0Ad5-env 86 5.4Ad5-env.sub.MN 18 5.7Ad7 wild type 18 0Ad7-env 11 3.1Ad7-env.sub.MN 7.8 3.6______________________________________ | Methods and vaccines for the production of antibodies to infectious organisms are described. Live recombinant adenovirus containing a foreign gene coding for an antigen produced by another infectious organism is delivered to the intestine of a warm-blooded animal in an enteric-coated dosage form, whereupon the virus infects the gut wall and induces the production of antibodies or cell mediated immunity to both adenovirus and the other infectious organism. | 2 |
This application is a continuation of application Ser. No. 163,259, filed 3/2/88, now U.S. Pat. No. 4,858,613.
BACKGROUND OF THE INVENTION
The present invention relates in general to the treatment of disease, tumors, etc., by the use of ultrasound. More particularly the present invention relates to a combined visualization and treatment device using ultrasound for both functions. Treatment is achieved by ablation of tissue representing the disease entity.
A large number of diseases manifest themselves in whole or in part in a focal manner. These include, for example, diseases of or in the brain, breast, liver and prostate. While surgical procedures have traditionally been employed when medicinal approaches were not suitable or effective, surgery still represents a significant risk to the patient and a chance that the entirety of the disease entity will not be completely removed.
There is no dispute as to the value of noninvasive treatment as such as producing volume lesions with focused ultrasound. One difficulty though with ultrasound treatment procedures is the need to visualize the disease entity and thereby determine the size, shape and location. While this concern does not normally exist with invasive techniques such as surgery, it is of critical concern in noninvasive procedures.
In our pending application entitled ULTRASOUND BRAIN LESIONING SYSTEM, filed on even date herewith, a visualization technique is described for volume lesioning treatment of a brain tumor. The technique involves a use of ultrasound or CT or MRI scan transparencies whose data is digitized into a computer and the landmark references from a skull fixation apparatus are used to preprogram the drive system for the transducer. By computer control, the brain tumors are located and the transducer automatically programmed for positioning such that the focused ultrasound beam is directed at each tumor and the dosage set to produce volume lesions.
An alternative to this position translation technique for brain tumors is to use ultrasound to visualize the disease entity. Since brain lesioning is somewhat unique due to the CT or MRI scans and the skull fixation apparatus, the visualization technique of our co-pending application may not be the most appropriate technique for ablation of other focal disease sites.
Since some of these other disease sites may be most effectively treated by the use of ultrasound in either a transcutaneous or intraoperative mode, there is a need to insure that the transducer components which are designed and the materials selected be such so as to be suitable for steam autoclaving.
The present invention provides an ultrasound localization and therapy system which is designed with both a visualization transducer and a therapy transducer. Those portions of the structure which must be sterilized are constructed from selected materials which are steam autoclavable.
Another concern with the treatment of disease in a transcutaneous mode by ultrasound is the physical size and shape of the probe. Since the transducer design of the co-pending application is used external to the patient, size and packaging considerations are not substantial. However, with the modes of examination and treatment such as transrectal, transesophogeal, etc., the probe design is critical. While the specifics of our co-pending transducer design may be used in some embodiments of the present invention, it will require some scaling down in size. Further, if the transducer assembly is going to be steam autoclavable, certain material changes are advisable in order to provide a finished product which will withstand the high autoclaving temperatures.
In a related embodiment the concept of utilizing a visualization transducer in combination with a treatment transducer is disclosed for treatment of the prostate. This particular configuration is adaptable for use in other body cavities. The therapy treatment from within such body cavities by ultrasound, where ultrasound is also used for imaging of the area to be treated, has not heretofore been done.
SUMMARY OF THE INVENTION
A visualization and treatment transducer for producing lesions in diseased tissue sites according to one embodiment of the present invention comprises a transducer housing having a main section and a detachable enclosure, movable visualization transducer means disposed within the detachable enclosure, movable treatment transducer means disposed within the detachable enclosure, first drive means providing rotary motion to the visualization transducer means in two degrees of freedom, second drive means providing rotary motion to the treatment transducer means in two degrees of freedom, the visualization transducer means and treatment transducer means having generally coaxial focal axes and the first and second drive means being operable independently of each other.
A transrectal or other body cavity visualization and treatment transducer assembly for ultrasonic visualization and treatment by producing lesions in diseased tissue sites according to another embodiment of the present invention comprises a fluid-filled, flexible-walled enclosure, a movable visualization transducer disposed within the enclosure, a movable treatment transducer disposed within the enclosure, a reflective scanner disposed within the enclosure and aligned with the treatment transducer for changing the direction of the focused ultrasound beam from the treatment transducer, first drive means providing rotary motion to the treatment transducer, second drive means providing linear motion to the visualization transducer, the first and second drive means being operable independently of each other, and third drive means providing rotary motion to the visualization transducer and the treatment transducer concurrently.
One object of the present invention is to provide an improved transducer assembly including both a visualization transducer and a cooperating treatment transducer.
Related objects and advantages of the present invention will be apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic illustration of an ultrasound treatment apparatus according to a typical embodiment of the present invention.
FIG. 2 is a side elevation, diagrammatic illustration of a transducer assembly which is suitable for use in the FIG. 1 apparatus.
FIG. 3 is a front elevation, diagrammatic illustration in full section of a transducer design suitable for use in the FIG. 2 transducer assembly.
FIG. 4 is a perspective, diagrammatic illustration of an ultrasonic probe for prostate visualization and treatment.
FIG. 5 is a side elevation, diagrammatic illustration of the FIG. 4 ultrasonic probe.
FIG. 6 is a lateral section view of the FIG. 4 ultrasonic probe detailing the configuration and support of a reflective scanner.
FIG. 7 is a lateral section view of the ultrasonic probe detailing the arrangement and support of the treatment transducer.
FIG. 8 is a side elevation, diagrammatic illustration in full section of a control unit which is coupled to the FIG. 4 probe for imaging and treatment control.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
Referring to FIG. 1, there is illustrated an ultrasound treatment system generally in block diagram form with the patient 20 lying on an appropriate table 21 with the transducer housing 22 diaphragm 23 in contact with the patient. A suitable coupling medium is used between the diaphragm and patient and the therapy transducer 24 is disposed in a volume of degassed water 25. In an intraoperative mode, sterile housing 22 with its diaphragm 23 is brought into contact with sterile fluid overlying on the internal organ or tissue directly. Guidance to the tissue or organ site is provided by ultrasound visualization element 28 located inside housing 22. The relative sizes and positional relationships of therapy transducer 24 and visualization element 28 which is an imaging transducer is best illustrated in FIG. 2.
Housing 22 is manually placed in position by the operator while being guided by transducer 28 with the ultrasound image displayed on monitor 29. Housing 22 is supported by articulating arms 30 and 31 with rotation axes as shown by the rotary arrows. Vertical motion is shown emanating from base support 32. Once the system is appropriately located for treatment, the articulating arms and rotation axes are locked in place. From the scanning of visualization transducer 28, the treatment volume is defined and stored in computer 35. The spatial position of the treatment volume is also defined with respect to depth and orientation to surrounding tissues. By interacting with the tissue and organs displayed on monitor 36, the treatment spatial regimen is computed. Dosage parameters of sound intensity and time-on period are entered into computer 35.
Once the treatment regimen is established, the system automatically progresses through the treatment volume by placing individual focal ablative lesions. Power amplifier 37 provides the drive energy to therapy transducer 24 for each focal site under control of computer 35. Degassed water system 38 provides degassed water to the interior of transducer housing 22 and temperature control system 39 keeps this degassed water at a constant temperature during the therapy procedure. The procedure can be interrupted at any time by the operator and restarted at the last stopped position, if that is desired.
In the event the operating and control electronics are remote from the patient, which would be the typical case, local keyboard control 42 is provided for at-site interfacing with the computer 35. Also interfacing with computer 35 are the ultrasound guidance and site placement system 43 and the motion drive and control apparatus 44.
Referring to FIG. 2, transducer assembly 27 is illustrated. Assembly 27 includes visualization transducer 28 which is a spherical ceramic piezoelectric element mounted in a metal ring. Hollow metal rod 47 attaches to this metal ring and runs through O-ring seal 48 in metal housing 49. Housing 49 is attached to metal housing 50 which runs through plate 51 and is sealed by O-ring 52. Transducer 28 is mechanically rotated (as shown by arrow) in a sector motion by rotation of rod 47 which is driven through bevel gears 55 and 56. Gear 55 is attached to rod (shaft) 47 and gear 56 is attached to drive shaft 57. Shaft 57 is driven in a rotary fashion by motor 58 which incorporates an encoder so that the angular position of transducer 28 is known. Knowing the angular position of transducer 28 provides angular information for the sector format (visualization) display. Electrical driving pulses and receiving pulses to transducer 28 go through wire lead 59 which attaches to the piezoelectric element in transducer 28 through the center hollow portion of rod 47. Transducer 28 is rotated in a plane normal to the plane of the paper from beneath transducer 22 by rotating tubular housing 50 using attached gear 62 which meshes with gear 63 driven by stepping motor 64 which has an encoder to establish the position of transducer 28 in this particular plane of rotary motion.
Transducer 24 is rotated on axis elements 67. This rotation is accomplished through sprocket gear 68 driven by belt 69 which in turn is driven by sprocket 70. Sprocket 70 is driven by shaft 71 which in turn is driven in a rotary manner by meshed bevel gears 72 and 73. Bevel gear 73 is attached to and driven by shaft 74. Shaft 74 is rotatable through O-ring seal 75 in top plate 76 which is attached to tubular housing 77. Transducers 28 and 24 are positioned so that their respective ultrasound beam focal axes are substantially coaxial to each other.
Tubular housing 77 is movable up and down relative to plate 51 through O-ring seal 80. Plate 51 is rotatable in ring 81 through ring gear 82 mounted to plate 51 and running entirely around the apparatus (360° circle). The parts including and below plate 51 and ring 81 are detachable from ring 83 for autoclaving. Ring 83a is illustrated as a separate piece but is in fact rigidly attached to ring 83. These components remain with the support (articulating) arms during the autoclaving procedure for the parts which are detached. Similarly, gear 85 is not removed for autoclaving. For autoclaving top plate 76 is removed with housing 77 and plate 51.
After autoclaving plate 51 and ring gear 82 are inserted in ring 83 and attached by a plurality of pins 84 positioned around the periphery of ring 83a. Rotation of plate 51 is accomplished through circular ring gear 82 driven by gear 85 attached to stepping motor 86 which includes an encoder. When plate 51 rotates all attached members including transducer 24 rotate concurrently. Plate 76 meshes with tube 89 on insertion of plate 51 and ring 81. When plate 76 meshes, drive shaft 74 meshes with shaft 90 which is attached to stepper motor 91 which includes an encoder.
Electrical drive power to transducer 24 is also coupled as is pressure system 92 when plate 51 and ring 81 are inserted. Vertical motion of transducer 24 is accomplished through ring 95 attached to tube 89 which links with plate 76. Ring 95 can rotate freely in element 96 which is driven up and down by gear rack 97 attached to element 96. Element 96 is constrained by slide system 98. Gear rack 97 is driven by gear 99 which is attached to stepper motor 100 and includes an encoder which is supported off the top surface 101 of ring 83 by member 102. Filling of chamber 103 with degassed water 25 is accomplished through tubing member 104 which is coupled through O-rings 105 to ring 81. Bath temperature in 103 is maintained by coils which circulate controlled-temperature fluid introduced through tubing 104.
Therapy transducer 24 is provided with three degrees of freedom. The unit can be rotated about axis 106, it can be moved up and down as shown by arrow 107, and it can be rotated about axis 108. Use of these motions permits volume lesions to be made after unit 27 is locked in position.
Referring to FIG. 3, internal details of therapy transducer 24 are illustrated in greater detail. It should be noted that this illustration does not include axis elements 67 and the power cable which is diagrammatically shown in FIG. 2 as a coiled wire connecting to the transducer is, in the FIG. 3 illustration a coaxial cable. While FIG. 2 discloses an air pressure system 92 for some of the interior spaces, FIG. 3 further includes a similar air pressure system 188 and an air pressure system 196 for controlling the silicone oil pressure for other interior spaces within transducer 24.
Referring to FIG. 3, transducer 24 is configured with several unique features which are provided in order for a stable acoustic output to be obtained at all preselected driving levels. These driving levels are required in order to produce controlled focal lesions. In order to achieve this necessary objective, it is necessary to have a stable sound-producing source such as generally circular (disc) quartz plate 161 which is used in this particular embodiment. The quartz plate 161 is able to be maintained flat and parallel to generally circular, plano-concave lens 162 by the structure which will be described hereinafter. Lens 162 is a hard anodized aluminum lens with an elliptic concave surface for minimizing the half-intensity length of the beam at the focus. In order to maintain flatness and parallelism of plate 161 and lens 162 with a fixed spacing distance therebetween, the aluminum flat side of the lens is precisely machine flat with at least one 1/8 inch diameter rod 163 machined on the surface to extend a distance above the lens surface equal to a 1/4 wave length in the silicone oil which is disposed in space 165.
In order to maintain this 1/4 wave length spacing to within plus or minus 0.0001 inches, it is required that the outer peripheral lip 162a of aluminum lens 162 provide unanodized surfaces (flat top and bottom surfaces and outer edge surface) which rest directly in contact with the flat machined surface of housing 164 and end plate 164a. Housing 164 includes an inwardly and upwardly directed lip 164b, of an annular ring configuration, whose underside abuts against the top surface of lip 162a and whose top surface supports plate 161. The height of this lip is precisely machined since it is the means to fix the 1/4 wave length separation between the plate 161 and lens 162. Rod 163 provides center stabilizing for the plate due to its span between peripheral edge supports and the pressure differential between the top and bottom surfaces of the quartz plate. The space 165 between the plate 161 and lens 162 (the 1/4 wave length spacing) is filled with silicone oil 166 which is freely exchanged through radially open channels in lip 164b. A suitable silicone oil for this application is Dow Corning 710 fluid. Gasket 164c seals the oil in space 165.
One gold-plated and polished electrode, electrically connected to quartz plate 161, rests in direct contact with the top machined surface of lip 164b and provides the electrical ground contact for the quartz plate.
In order to keep plate 161 in pressure contact with housing 164, a flat, flexible gasket 171 is firmly pressed against plate 161 through metal member 172. In order to provide electrical contact for power to plate 161 an electrode 173 fabricated of an approximate 0.001 thick soft metal foil (gold, brass, silver) extends part-way under compression gasket 171, while the remainder of gasket 171 acts as a seal for the silicone oil. The power and ground electrodes on plate 161 do not extend to the edge of plate 161 and the silicone oil provides insulation around the edge. The foil electrode 173 is attached to metal member 172 with a series of metal screws 174.
To provide RF power to drive quartz plate 161 a coaxial cable 179, with metal sheath 180 drawn back and clamped under plate 181 to metal plate 182, is provided. The coaxial cable has an end plug 184 which side pressure contacts plate (metal member) 172 through a central hole. Space 185 is an air space so that the quartz plate 161 is not back acoustically loaded thereby directing all its acoustic output through the interspace 165 and lens 162 into the fluid which is in front of lens 162. To insure flatness of quartz plate 161 and parallelism with the flat surface of lens 162, the air space 185 and all other air spaces in the transducer housing 164 are pressurized through tube 186 into element 187. This air pressure holds quartz plate 161 against machined rod 163 to maintain the necessary parallelism. Pressure is applied from source 188.
In order to maintain a positive differential pressure in space 185 relative to the pressure in interspace 165, flow communication is provided from interspace 165 via flow access channels 189 into column 190 and well 191. These areas are all silicone oil filled and in pressure equilibrium is a thin flexible diaphragm 192 which covers well 191. Above diaphragm 192, the air space 193 is exhausted through flexible tubing 194 and rigid tube 195 to the outside atmosphere.
A further feature to suppress cavitation in the oil in space 165 between the quartz plate 161 and lens 162 when the system is run at the highest acoustic output power is provided by pressure system 196 providing greater-than-atmospheric pressure to space 193. Typically this pressure will be that which prevents any cavitation in space 165 (of the order of 40-50 pounds per square inch). This pressure in space 193 is readily transmitted through diaphragm 192 to the silicone oil in well 191 and hence through column 190 into space 165. The pressure provided by source 188 is in the order of 2 pounds per square inch higher than the pressure in system 196 in order to keep plate 161 flat and held against lens 162 through rod 163.
Element 199 in the transducer assembly is an insulating member to which element 172 is bolted by screw(s) 200. Gasket 201 keeps the silicone oil contained in column 190 from reaching the coaxial cable 179. Metal plate 182 is bolted to housing 164 around the outer periphery of plate 182. Oil is kept in column 190 and well 191 by the use of O-ring seal 203 positioned between housing 164 and plate 182 and by gasket 205. Member 206 is bolted and sealed to plate 182. Top metal plate 207 is bolted by screws 203 to housing 164 and sealed thereto through O-rings 209. Metal tube 195 is sealed to element 187 through seal 210. The coaxial cable 179 is water-tight and sealed to top plate 207 through member 211 and O-ring 212.
In order to accomplish the task of producing lesions of any complex size or shape with intense focused ultrasound it is necessary to provide for ultrasound dosage conditions which produce individual focal lesions (from which the complex volume can be generated), which do not compromise tissue outside the intended focal lesions side and permit subsequent individual focal lesions in a contiguous manner. When transducer 24 is used for the treatment of brain tumors by creating lesions in deep brain sites in both gray and white matter and abnormal brain tissue, it is necessary to inhibit the production of microbubble formation at the primary focal site so that there can be no vascular dispersion of such microbubbles away from the primary focal site which microbubbles could initiate off primary site lesion production and hemorrage due to ultrasound passage through microbubble comprised tissue.
In order to accomplish this task while being able to accomplish primary site lesions, it is necessary to derive these sound intensities as a function of frequency which will not produce microbubbles at the primary lesion site. This requires that for a 1 MHz sound frequency (a frequency necessary to achieve deep penetration into the human brain), the primary site sound intensity must not exceed 300 watts per square centimeter. At this intensity and for lower intensities, gray and white matter lesions on a multiplicity of individual contiguous sites can be produced without undesirable side effects (microbubbles). As the frequency is increased above 1 MHz, the primary site sound intensity can be increased and produce no microbubbles but the penetration capability in brain tissue returns as the sound frequency is increased. At 4 MHz frequency which is the upper frequency which can be considered for more superficial brain lesion production, the intensity which will not lead to microbubble formation is at least 2100 watts per square centimeter. At these intensity limits, the time-on period of sound irradiation at each individual site can be extended to as many seconds as is needed to ablate the tissue at the focal site without microbubble formation.
In order to constrict the individual lesion sites so that the boundaries of desired volume lesions can be constrained, the transducer configuration used will give a half intensity length at the lesion focal region in the order of 15 mm at 1 MHz operating frequency. This length of half intensity is consistent with the necessity of constraining lesions in the human brain so that the extending of individual lesions into white matter (white matter is more sensitive than gray matter) can also be constrained.
Still referring to FIG. 3, in order to make the transducer assembly 27 capable of being steam autoclaved, gasket 171 needs to be made from fluorosilicone in order to take the high autoclave temperature and resist the uptake of the silicone oil which is used within the assembly. A suitable silicone oil for this application is Dow Corning 710 fluid which has the necessary high temperature resistance. All gaskets in contact with the Dow Corning 710 fluid must be made of fluorosilicone. All other O-rings and gaskets not in contact with the Dow Corning 710 fluid can be made of silicone. Insulator 199 must be a high-temperature plastic, such as, for example, General Electric's Ultem. Coaxial cable 179 must also include high-temperature materials such as Teflon insulation. The volume expansion chamber (well) 191 requires a fluorosilicone membrane 192 which must be capable of taking the volumetric expansion of the silicone oil during the autoclaving procedure. The system design requires that all differential expansions be accounted for when the steam autoclaving is performed.
As previously pointed out, one of the primary concerns with transcutaneous and intraoperative modes of ultrasound treatment is the need to design the transducer assembly so that those portions that need to be autoclaved can be steam autoclaved. Recognizing that the entirety of the assembly will not be contaminated by use in the prior treatment procedure, only selected components need to be autoclaved and these are detachable as previously described. Another concern is the ability to visualize the area for treatment. In order to guide and manuever the therapy (treatment) transducer to the appropriate ablation sites within the body, some visualization means must be employed. In the disclosed embodiment of FIGS. 1-3, the visualization means is the visualization transducer 28. Yet another concern with a transcutaneous mode of treatment is the size and shape of the probe (transducer assembly and housing). Transcutaneous modes may include transrectal or transesophogeal, for example.
Localization and treatment (tissue destruction) of the prostate by way of a transrectal route requires both the ability to localize the treatment volume and then to apply the treatment regimen in that identified volume. One configuration to accomplish this particular task is described in FIGS. 4-8.
In the FIG. 4 embodiment, ultrasound probe 240 is illustrated as inserted into the rectum and positioned for visualization and treatment of the prostate 241. Also illustrated and positioned in FIG. 4 are the urinary bladder 242 and rectum 243. Diagrammatically illustrated is a cross-section area of the tapered stem of probe 240 in order to show the entry diameter 244. The probe is inserted by way of the rectal entry region 245.
Referring to FIG. 5, the internal features and components of probe 240 are diagrammatically illustrated. In answer to concerns previously mentioned, probe 240 includes a focused transducer 248 for delivering the therapy (abalation) which is supported by and movable relative to arm elements 249 positioned within flexible envelope 250. Envelope 250 is filled with water so as to expand to contact the rectal wall, but by removal of some water and some rotation of transducer 248 and mirror 256, the size is reduced to make entry easier. Arm elements are curved so that when the unit is in the rectum, the diameter at the entry of the probe is smaller than the remainder.
Visualization element 253 includes in its interior space transducer 254 which is operable to generate ultrasound imaging beam 255 in the direction of the prostate. Transducer 248 is movable in a rotary manner relative to elements 249 and has a focused beam directed at circular (disc) mirror 256 which is adapted to bend and redirect beam 257 toward the desired region of the prostate. The movement of transducer 248 relative to mirror 256 is used to affect the depth of the beam (focused spot) into the prostate. Since the transducer beam has a fixed focus, the less of the beam length used between the transducer and mirror, the longer the beam length reflected from the mirror. Transducer 248 is also movable linearly with mirror 256 along the longitudinal axis of probe 240. The entire probe portion is rotatable by external means as illustrated in FIG. 8.
Referring to FIG. 6, the support of mirror 256 by arm elements 249 and related components is illustrated in greater detail. As previously described, elements 249 which support transducer 248 and by means of rotary and sliding extensions 260 also support mirror 256. Arm elements 249 are thin-walled, hollow, flexible tubes open at their proximal end for the exiting of elements 262 and 263 (FIG. 7) and bands 273 and 274 (FIG. 7). Extensions 260 rigidly attach to mirror 256 and extend through slot 267 so that linear movement of the mirror relative to elements 249 can be affected. Extensions 260 fit within elements 262 for rotary motion and elements 262 travel in top and bottom tracks 268 formed as part of the interior wall surface of element 249. Referring to FIG. 7, the extension of elements 249 and their coupling to transducer 248 is illustrated. Both FIGS. 6 and 7 should be regarded as lateral sections looking along the longitudinal axis of the ultrasonic probe 240 with the mirror and transducer oriented so as to reveal their full disc (circular) configuration. The structure of FIG. 7 is virtually the same as FIG. 6 with one main difference. The rotational and linear travel linkage made up of elements 263, 270, 272 and 274 for transducer 248 is outward, relative to element 249, from elements 262, 269, 271 and 273 for the mirror. This allows the linear travel of the mirror to be separately controlled as well as the rotation relative to element 263, without interference between the transducer and mirror and their linkages.
Referring now additionally to FIG. 8, control unit 261 which attaches to the reduced diameter end of probe 240 is illustrated. The linear movements on both transducer 248 and mirror 256 are accomplished by the linear translation of elements 262 and 263 which are flexible strips or bands so that they are able to accommodate the configurational bend in arm elements 249. Elements 262 and 263 are coupled to linear actuators and encoders, all of which are represented by block 264 through couplers 265 and 266. This arrangement permits coordinate linear translation of the therapy transducer and reflective mirror with respect to the visualization element 253 and the beam 255 generated by transducer 254. Rotation of focused transducer 248 and reflective mirror 256 is accomplished by crank arms 269 and 270. The crank arms with pins 271 and 272 are in turn driven by bands 273 and 274. These bands are connected to the linear actuators and encoders represented by block 264 by way of couplers 275 and 276. This particular arrangement permits the coordination of linear translation and/or relative translations to rotate the focused transducer 248 and reflective mirror 256.
On insertion of ultrasonic probe 240 into the rectal area, the focused transducer and reflective mirror are rotated so as to reduce as much as possible the overall outside contour of the probe upon entry into the patient. The mirror may be rotated on axis, i.e., relative to elements 249 in order to gain additional space within the probe for movement of the visualization transducer 254. Except for these two instances of mirror rotation, it remains rotationally fixed.
When visualizing the prostate elements, the focused transducer and reflective mirror are translated as shown so that free visualization of the prostate can be accomplished and then the transducer 248 and reflective mirror 256 positioned in order to place beam 257 at the positions delineated by beam 255. These position determinations are made through encoder determinations arrived at by computer computations. Visualization element 253 is linearly translated and encoded by rack 279, pinion 280, shaft 281, and drive motor with encoder 282.
In order to provide rotary motion in the rectum, the entire system including control unit 261 can be rotated through ring gear 285 driven by pinion or drive gear 286 and motor encoder 287.
Filling (and emptying) of the unit with degassed water is done through tubes 288 and 289 so that the entire system is water-filled and means for removing trapped air bubbles provided. This arrangement avoids sliding seals at the juncture between the insertable elements and the exterior elements. Flexible envelope 250 is attached to control unit 261 by slipping band 290 over the outer surface of envelope 250.
All electrical leads, some of which are shown diagrammatically, pass through water-tight seals in control unit 261. Electrical power to the focused transducer 248 is provided by an electrical lead which travels along arm element 249.
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. | A transducer assembly for visualization and treatment of transcutaneous and intraoperative sites includes in combination a visualization transducer and a treatment transducer, each of which are movable with both linear and rotary degrees of freedom. Movement of each transducer is by various motor and geared drive arrangements wherein certain degrees of freedom for one transducer are separate and independent from the degrees of freedom for the other transducer. At least one degree of freedom for each transducer is common and the transducers are moved concurrently.
One arrangement of the transducer combination is for prostate treatment and includes a specific shape and configuration for anatomical considerations and a control unit which is operable external to the patient to control both transducers and a reflective scanner which are inserted into the patient as part of the ultrasound probe. | 0 |
FIELD OF THE INVENTION
The present invention relates to improved anti-hunt logic for an automated vehicular change-gear transmission. In particular, the present invention relates to a control system/method for an automated transmission having logic rules whereby certain sensed vehicle operating conditions and/or operator actions will be determined as indicative of operator desire for rapid shifting, and the control logic will be modified to minimize or eliminate the effectiveness of normally implemented anti-hunt routines.
DESCRIPTION OF THE PRIOR ART
Partially automated vehicular transmission systems requiring manual shifting in the lower ratios and having a control for automated shifting in the upper ratios are known in the prior art, as may be seen by reference to U.S. Pat. Nos. 4,722,248; 4,850,236; 5,038,627; 5,393,276; 5,393,277 and 5,498,195, the disclosures of which are incorporated herein by reference.
Splitter and combined range and splitter-type compound vehicular transmissions requiring manual splitter shifting are well known in the prior art, as may be seen by reference to U.S. Pat. Nos. 3,799,002; 4,754,665; 4,974,468; 5,000,060; 5,370,013 and 5,390,561, the disclosures of which are incorporated herein by reference.
Fully automated mechanical transmission systems are known in the prior art, as may be seen by reference to U.S. Pat. Nos. 4,361,060 and 4,595,986, the disclosures of which are incorporated herein by reference. Automated transmissions utilizing anti-hunt logic whereby shift points are offset after a shift to prevent rapid upshifting/downshifting cycles also are known in the prior art, as may be seen by reference to aforementioned U.S. Pat. Nos. 4,361,060. While the prior art anti-hunt routines are effective in most situations to prevent undesirable shift cycling or "hunting," in certain situations, the result of the anti-hunting routines was less frequent shifting than desired by the operator.
SUMMARY OF THE INVENTION
In accordance with the present invention, a new and improved automated change-gear shift control, including improved anti-hunt logic, is provided.
The foregoing is accomplished by providing logic rules whereby, under certain operating conditions and/or operator actions, the effect of the normally applied anti-hunt logic is minimized or eliminated. By way of example, after a downshift, if throttle is reduced to below a reference, or decreased and then increased, the normally instituted upshift shift point offset is minimized or canceled. By way of further example, after an upshift, if throttle is at a maximum value, the normally instituted downshift shift point offset is minimized or canceled.
Accordingly, it is an object of the present invention to provide a new and improved automated change-gear transmission shift control system/method.
This and other objects and advantages of the present invention will become apparent from a reading of the following description of the preferred embodiment taken in connection with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 1A are sectional views of a typical splitter or combined splitter and range-type compound transmission.
FIG. 2 is a schematic illustration of the manual shift pattern and ratio steps for the transmission of FIGS. 1 and 1A.
FIG. 3 is a schematic illustration of a partially automated vehicular mechanical transmission system having both manual and automatic splitter shifting and utilizing the control of the present invention.
FIG. 4 is a valve table for the control valve assembly utilized in the system of FIG. 3.
FIG. 5 is a schematic illustration, similar to FIG. 2, of the shift pattern and ratio steps for the transmission system of FIG. 3.
FIG. 6 is a graphical representation of the disengagement confirmation logic of the system of FIG. 3.
FIG. 7 is a graphical representation of a prior art shift point profile including anti-hunt offsets.
FIG. 8 is a schematic representation, in flow chart format, of the control logic of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1, 1A and 2 illustrate a typical combined splitter and range-type compound mechanical transmission 10 of the type advantageously utilized in connection with the control of the present invention.
Transmission 10 comprises a main transmission section 12 connected in series with an auxiliary transmission section 14 having both range and splitter-type gearing. Typically, transmission 10 is housed within a single multi-piece housing 16 and includes an input shaft 18 driven by a prime mover (such as a diesel engine) through a selectively disengaged, normally engaged friction master clutch.
In the main transmission section 12, the input shaft 18 carries an input gear 20 for driving at least one countershaft assembly 22. Preferably, as is well known in the prior art and as is illustrated in U.S. Pat. Nos. 3,105,395 and 3,335,616, the disclosures of which are hereby incorporated by reference, input gear 20 simultaneously drives a plurality of substantially identical main section countershaft assemblies at substantially identical rotational speeds. Each of the main section countershaft assemblies comprises a main section countershaft 24 supported by bearings 26 and 28 in housing 16 and is provided with main section countershaft gears 30, 32, 34, 36 and 38 fixed thereto. A plurality of main section drive or main shaft gears 40, 42 and 44 surround the transmission main shaft 46 and are selectively clutchable, one at a time, to the main shaft 46 for rotation therewith by sliding clutch collars 48 and 50, as is well known in the art. Clutch collar 48 may also be utilized to clutch input gear 20 to the main shaft 46 to provide a direct drive relationship between the input shaft 18 and the main shaft 46. Preferably, each of the main section main shaft gears encircles the main shaft 46 and is in continuous meshing engagement with and is floatingly supported by the associated countershaft gear groups, which mounting means and special advantages resulting therefrom are explained in greater detail in aforementioned U.S. Pat. Nos. 3,105,395 and 3,335,616. Typically, clutch collars 48 and 50 are axially positioned by means of shift forks or yokes 52 and 54, respectively, associated with a shift bar housing assembly 56 of the type illustrated in U.S. Pat. Nos. 4,920,815 and 5,000,060. Clutch collars 48 and 50 are, in the preferred embodiment, of the well-known, non-synchronized, double-acting jaw clutch type.
Main section main shaft gear 44 is the reverse gear and is in continuous meshing engagement with countershaft gears 38 by means of conventional intermediate idler gears 57 (see FIG. 1A). Main section countershaft gear 32 is provided for powering power takeoff devices and the like. Jaw clutches 48 and 50 are 3-position clutches in that they may be positioned in a centered axially non-displaced, non-engaged position as illustrated or in a fully rightwardly engaged or fully leftwardly engaged position.
Auxiliary transmission section 14 is connected in series with main transmission section 12 and is of the 3-layer, 4-speed combined splitter/range type, as illustrated in above-mentioned U.S. Pat. No. 4,754,665. Main shaft 46 extends into the auxiliary section 14 and is journaled in the inward end of the output shaft 58 which extends from the rearward end of the transmission.
Auxiliary transmission section 14 includes, in the preferred embodiment thereof, a plurality of substantially identical auxiliary countershaft assemblies 60 (see FIG. 1A), each comprising an auxiliary countershaft 62 supported by bearings 64 and 66 in housing 16 and carrying three auxiliary section countershaft gears 68, 70 and 72 fixed for rotation therewith. Auxiliary countershaft gears 68 are constantly meshed with and support auxiliary section splitter gear 74. Auxiliary countershaft gears 70 are constantly meshed with and support auxiliary section splitter/range gear 76 which surrounds the output shaft 58 at the end thereof adjacent the coaxial inner end of main shaft 46. Auxiliary section countershaft gears 72 constantly mesh with and support auxiliary section range gear 78, which surrounds the output shaft 58. Accordingly, auxiliary section countershaft gears 68 and splitter gear 74 define a first gear layer, auxiliary section countershaft gears 70 and splitter/range gear 76 define a second gear layer and auxiliary section countershaft gears 72 and range gear 78 define a third layer, or gear group, of the combined splitter and range-type auxiliary transmission section 14.
A sliding 2-position jaw clutch collar 80 is utilized to selectively couple either the splitter gear 74 or the splitter/range gear 76 to the main shaft 46, while a 2-position synchronized clutch assembly 82 is utilized to selectively couple the splitter/range gear 76 or the range gear 78 to the output shaft 58.
The splitter jaw clutch 80 is a 2-position clutch assembly which may be selectively positioned in the rightwardmost or leftwardmost positions for engaging either gear 76 or gear 74, respectively, to the main shaft 46. Splitter jaw clutch 80 is axially positioned by means of a shift fork 84 controlled by a 2-position piston actuator 86, which normally is operable by a driver selection switch such as a button or the like on the shift knob, as is known in the prior art. Two-position synchronized range clutch assembly 82 is also a 2-position clutch which may be selectively positioned in either the rightwardmost or leftwardmost positions thereof for selectively clutching either gear 78 or 76, respectively, to output shaft 58. Clutch assembly 82 is positioned by means of a shift fork 88 operated by means of a 2-position piston device 90, the actuation and control of which is described in greater detail in aforementioned U.S. Pat. No. 4,974,468.
As may be seen by reference to FIGS. 1-2, by selectively axially positioning both the splitter clutch 80 and the range clutch 82 in the forward and rearward axial positions thereof, four distinct ratios of main shaft rotation to output shaft rotation may be provided. Accordingly, auxiliary transmission section 14 is a 3-layer auxiliary section of the combined range and splitter type providing four selectable speeds or drive ratios between the input (main shaft 46) and output (output shaft 58) thereof. The main section 12 provides a reverse and three potentially selectable forward speeds. However, one of the selectable main section forward gear ratios, the low speed gear ratios associated with main shaft gear 42, is not utilized in the high range. Thus, transmission 10 is properly designated as a "(2+1)×(2×2)" type transmission providing nine or ten selectable forward speeds, depending upon the desirability and practicality of splitting the low gear ratio.
While clutch 82 (the range clutch) should be a synchronized clutch, double-acting clutch collar 80 (the splitter clutch) is not required to be synchronized. The shift pattern for manually shifting transmission 10 is schematically illustrated in FIG. 2. Divisions in the vertical direction at each gear lever position signify splitter shifts, while movement in the horizontal direction from the 3/4 and 5/6 leg of the H pattern to the 7/8 and 9/10 leg of the H pattern signifies a shift from the low range to the high range of the transmission. As discussed above, manual splitter shifting is accomplished in the usual manner by means of a vehicle operator-actuated splitter button or the like, usually a button located at the shift lever knob, while operation of the range clutch shifting assembly is an automatic response to movement of the gear shift lever between the central and rightwardmost legs of the shift pattern, as illustrated in FIG. 2. Range shift devices of this general type are known in the prior art and may be seen by reference to U.S. Pat. Nos. 3,429,202; 4,455,883; 4,561,325 and 4,663,725, the disclosures of which are incorporated herein by reference. Manually operated splitter and range shift actuators are known in the prior art and may be seen by reference to U.S. Pat. Nos. 5,193,410; 5,199,314 and 5,329,826, the disclosures of which are incorporated herein by reference.
A partially automated vehicular mechanical transmission system 92 utilizing the control system of the present invention is illustrated in FIG. 3. Partially automated system 92 is of the type requiring manual shifting in the lower gear ratios (first through eighth) and, after initial manual selection of one of the upper two ratios, providing automatic shifting in the upper gear ratios (ninth and tenth), as described in aforementioned U.S. Pat. Nos. 4,722,248; 4,850,236; 5,038,027 and 5,393,276. The shift pattern for partially automated operation of the system 92 is schematically illustrated in FIG. 5.
The system includes a splitter control valve assembly 94 and a prime mover (such as diesel engine 96) driving the input shaft 18 of transmission 10 through a master friction clutch 98. The transmission 10 includes a shift lever 100 having a shift knob 102, which is associated with the shift bar housing 56 for manually shifting main section 12 and the range clutch 82 of auxiliary section 14.
A manually operated splitter valve 104, having a selector lever or button 106, is provided, usually on or integral with the shift knob, for manually shifting the splitter clutch 80. Splitter valve 104 is a 2-position, 3-way manually operated valve effective to selectively connect a first pilot conduit 108 to exhaust ("E x ") or to pilot pressure, respectively, to manually select either the high or low splitter ratio. The pilot pressure may be equal to supply pressure ("S") or to a lower value. In a typical onboard pneumatic system, supply is filtered, regulated air at about 60 to 80 psi.
The first pilot conduit 108 may fluidly communicate with a second pilot conduit 110 in series through the control valve assembly 94 of the present invention. The second pilot conduit 110 is effective to act on a 2-position, 3-way pilot valve 112, which is effective to normally vent or selectively pressurize a control chamber 114 of the splitter piston/cylinder actuator assembly 86. Chamber 114 is exposed to the larger area face 116 of a differential area piston 118 having a smaller area face 120 constantly exposed to supply pressure in biasing chamber 122. As is known, a spring may be utilized in place of or in combination with smaller area piston face 120 to bias piston 118 rightwardly, as seen in FIG. 3.
As may be seen, when pilot conduit 110 is exhausted, pilot valve 112 will connect control chamber 114 to exhaust, and supply pressure acting on smaller area face 120 will cause shift fork 84 to move splitter clutch 80 to engage gear 76 for the low splitter ratio, and when pilot conduit 110 is pressurized, valve 112 will move against a bias to a position for pressurizing control chamber 114, causing the piston 118 to move leftwardly to cause splitter clutch 80 to engage gear 74 for the high splitter ratio.
Except for interposing the control valve assembly 94 in series between pilot conduits 108 and 110, the above-described components are structurally and functionally equivalent to components utilized to shift the manually shifted transmission of FIGS. 1, 1A and 2.
To provide the partially automated operation of system 92, a controller 124, preferably a microprocessor-based controller, is provided for receiving input signals 126 and for processing same according to predetermined logic rules to issue command output signals 128 to various system actuators, such as an engine fuel control 130 and a solenoid driver and fault detection unit 132. Controllers of this type may be seen by reference to U.S. Pat. Nos. 4,361,060 and 4,595,986, the disclosures of which are incorporated herein by reference. The program for controller 124 is stored on a computer-usable medium such as a floppy disk, hard drive, CD-rom, tape or other external or internal storage medium. The program for controller 124 is stored on a computer-usable medium such as a floppy disk, hard drive, CD-rom, tape or other external or internal storage medium.
Sensors for sensing engine speed (ES) and/or input shaft speed (IS) and output shaft speed (OS) may be provided, as well as sensors for sensing engine fueling THL and solenoid faults SF, all of which provide input signals indicative thereof to the controller 124. With the clutch 98 engaged, input shaft speed may be assumed to equal engine speed.
As is known, the engine 96 may have a built-in controller 96A and/or may communicate with controller 124 by an electronic data link of the type conforming to SAE J-1922, SAE J-1939, ISO 11898 or the like. All or a portion of controller 124 may be defined by hardware and/or software associated with engine controller 96A. A sensor may be provided for providing a signal (GR) indicative of engaged gear ratio or gear ratio may be calculated and confirmed by dividing input shaft speed or engine speed by output shaft speed (GR=((IS or ES)/OS)±error?).
The control valve assembly 94 of the present invention is interposed in series between the standard manual splitter shift selection valve 104 and the standard pilot valve 112/splitter actuator 86 and is operated in response to command output signals from controller 124. The assembly includes, in series, a first 2-position, 3-way solenoid-controlled valve 134 and a second 2-position, 3-way solenoid-controlled valve 136 and a solenoid driver and fault detection unit 132 operating in response to command output signals from the controller.
Valve 134 has an inlet 138 connected to pilot conduit 108 and two outlets 140 (connected to one inlet 142 of valve 136) and 144 (connected to exhaust). Valve 134 has a first normal or default position wherein inlet 138 is connected to outlet 140, and thus, to inlet 142 of valve 136, while outlet 144 of valve 134 is blocked. Valve 134 has a second or actuated position upon energizing the first solenoid S#1 wherein outlet 140 is connected to exhaust at outlet 144 and inlet 138 is blocked.
Valve 136 has two inlets 142 (connected to the outlet 140 of valve 134) and 146 (connected to the source of pressurized fluid) and an outlet 148 connected to the second pilot conduit 110 controlling the pilot valve 112. Valve 136 has a first normal or default position wherein inlet 142 is connected to outlet 148 and the inlet 146 from source pressure is blocked, and a second actuated position upon energizing the second solenoid S#2 wherein inlet 142 is blocked and source pressure at inlet 146 communicates with outlet 148 and pilot conduit 110.
The valve table for operation of the solenoid-operated valves is set forth in FIG. 4.
The controller 124 senses a manual splitter operation mode by sensing a shift bar condition GR other than AUTO (see FIG. 5). In this mode (i.e., gear ratios 1-8), the solenoid driver is commanded to de-energize both of the solenoids, and the valves 134 and 136 will assume the default positions thereof. Pilot conduit 108 will communicate with pilot conduit 110 through the valves 134 and 136, and the actuator 86 will be under the manual control of selector valve 104.
AUTO or not-AUTO mode conditions may be sensed by position sensors or by processing the ES and OS signals according to predetermined logic rules.
Upon sensing a manual shift to the AUTO position, the controller will cause the solenoid driver 132 to energize the first solenoid S#1 to create an automatic-only splitter situation, as valve 134 moves to its second position, wherein the pilot conduit 108 controlled by manual selector valve 104 is blocked at inlet 138, and thus, the series connection through port 140 to the pilot valve 112 is blocked. With valve 134 in the second or actuated position thereof, the manual selector 104 is ineffective to control pilot valve 112 or splitter actuator 86.
In the current example, ninth and tenth speeds are the AUTO mode gear ratios, while eighth speed is the "entry gear ratio." A shift or intent to shift into the AUTO mode is confirmed when either:
(1) gear ratio is the entry gear ratio, and
(2) vehicle speed exceeds a first reference value (REF 1 ), followed by
(3) a shift into neutral;
OR
(1) vehicle speed exceeds the first reference value, and
(2) gear ratio is one of the AUTO mode ratios.
The first reference value (REF 1 ) is an output shaft speed at which a manual upshift from the entry gear is expected to occur, usually about the minimum output shaft speed at which an upshift from the entry gear is expected to occur.
When in the AUTO mode of operation, manual control 104 is bypassed and, based upon vehicle speed as indicated by the output shaft speed OS and/or the other sensed parameters, the control 124 will automatically determine if an automatic upshift from ninth to tenth or an automatic downshift from tenth to ninth is required, and will control engine fueling and the second solenoid-controlled valve 136 to implement same. With valve 134 actuated and valve 136 in its normal or default position, pilot conduit 110 is exhausted at port 144 of valve 134, and pilot valve 112 will exhaust the control chamber 114 of the piston/cylinder assembly 86, causing the piston to urge the splitter clutch in the low splitter ratio direction. With the second solenoid-controlled valve 136 actuated, pilot conduit 110 is connected to source pressure through inlet 146 and outlet 148 of valve 136, regardless of the position of valve 134, and pilot valve 112 will cause control chamber 114 to be pressurized, causing the piston 118 to urge the splitter clutch in the high splitter ratio direction. Valve 134 may be deactivated whenever valve 136 is energized to reduce heat generation.
In addition to causing the splitter clutch to be properly positioned in the AUTO mode, controller 124 will also cause the engine to be properly fueled to disengage the existing splitter ratio and synchronized for engaging the target splitter ratio. Upon sensing an eighth-to-ninth upshift into AUTO mode, the engine will be caused to synchronize for the required main and splitter clutch engagement.
In the current example, continuing operation in the AUTO mode is confirmed when either:
(1) the confirmed gear ratio is an AUTO mode ratio (i.e., ninth or tenth), and
(2) vehicle speed exceeds the first reference value (OS*GR ENTRY ≧ the expected manual upshift RPM from the entry gear);
OR
an AUTO mode shift (ninth-tenth, tenth-ninth) is in progress.
Upon sensing that a shift from AUTO mode has occurred, the controller 124 will cause solenoid driver 132 to deactivate both solenoids to return splitter control to the operator. In the current example, a not-AUTO mode condition is confirmed when either:
(1) an AUTO mode shift is not in progress, and
(2) vehicle speed is less than a second reference value (REF 2 ), followed by
(3) a shift into neutral;
OR
(1) an AUTO shift is in progress, and
(2) after a given period of time, engagement in an AUTO mode ratio cannot be confirmed;
OR
engagement in a non-AUTO mode ratio is confirmed.
The first, immediately preceding example involves a downshift out of AUTO mode, while the second example involves an apparent operator shift to main section neutral during an AUTO mode shift event.
In causing synchronous conditions for engagement of a target gear ratio, the engine is commanded to assume a rotational speed equal to true synchronous speed (ES=OS*GR T ) plus or minus an offset value X equal to about 30 to 50 RPM. Accordingly, the engine is alternately commanded to a speed (ES=(OS+X)*GR T ), and then a speed (ES=(OS-X)*GR T ).
To confirm engagement/non-engagement, the value of ES/OS is compared over a period of time to known gear ratios plus or minus a given percent Y (such as 0.5 to 1.5%). Thus, by way of example, over a period of time, if ES/OS=GR*(1±Y%), then confirmation of engagement of GR is true. The offset X and the percentage error Y are selected so that at ES=(OS+X)*GR T , or at ES=(OS-X)*GR T , ES/OS will not equal GR*(1±Y%).
The foregoing, as discussed in aforementioned co-pending U.S. patent application Ser. No. 08/649,829, allows the use of speed signals to confirm engaged and neutral conditions without false readings due to engine synchronizing.
To confirm disengagement (of the entry gear ratio or of one of the AUTO mode ratios), the quotient of ES/OS is compared to the numerical value of the disengaging gear, plus or minus a disengaging gear error value, which may exceed the magnitude of the gear error value used to confirm engagement. For example, the disengaging gear error value may equal 1.5%, while the engaging gear error value may equal 1%.
Additionally, the gear error value used for confirming disengagement may be set larger on the positive side of synchronous of the disengaging gear than on the negative side to minimize false indications of neutral. Speed separations while still in gear tend to be higher on the positive side of synchronous due to the higher driving torque (the engine driving the vehicle tends to produce a greater positive torque magnitude than the negative torque produced when coasting with the vehicle driving the engine). Providing a larger Pos 13 Disengage Gear 13 Error and a smaller Neg 13 Disengage 13 Gear 13 Error allows for protection against false indications of neutral on the positive side caused by aggressive throttle application, while still providing for a quick confirmation of neutral in the negative direction (the direction in which neutral is confirmed on most shifts).
In the preferred embodiment, the calculated gear ratio, ES/OS, is compared to an expanding window of error values and will be confirmed as disengaged only if it continues to remain outside the window. In the current example (see FIG. 6), the calculated gear ratio must fall outside a range from:
Engaged GR*(1-(40* Counter*Loop 13 Time*Ne 13 Disengage 13 Gear 13 Error))!
to
Engaged GR*(1+(40*Counter*Loop 13 Time*Pos 13 Disengage 13 Gear 13 Error))!,
where Counter is incremented by one each time this is true and decremented each time this is not true (minimizing at a value of 1). Disengagement is confirmed when the Counter reaches or exceeds a value equal to (Synch 13 Disengage 13 Time/Loop 13 Time). In the preferred embodiment, the values of Neg 13 Disengage 13 Gear 13 Error=1%, Pos 13 Disengage 13 Gear 13 Error=1.5%, and the maximum value of (40*Counter*Loop 13 Time)=6.
The advantage of this "expanding window" over a fixed error band (prior art) is that it allows disengagement confirmation to start sooner (using the relatively small initial error window) while simultaneously providing better protection against false confirmations of neutal (using the relatively large, fully expanded window before confirming). If the calculated gear ratios fall back within the window during the disengagement confirmation process, the window will decrement to the next smaller value (or to the smallest window) and upon the calculated gear ratio falling outside the window, the disengagement process will continue. The advantage gained with this "contracting window" over immediately resetting to the smallest error window is that it maintains a quick confirmation of true disengagement even if one data point falls inside the expanding error bounds, while preventing false neutral confirmation with transient speed separations induced by large torque oscillations.
Upon an electrical power failure, the solenoid-controlled valves will return to the open positions thereof, fluidly connecting conduits 108 and 110, and allowing manual selection of all ten forward ratios. Upon the solenoid driver detecting conditions indicative of a failure at one or both solenoids, the controller will cause both solenoids to be de-energized again, causing the two valves 134 and 136 to assume the open positions thereof, and allow manual selection of all ten forward ratios.
The control valve assembly 94, thus, provides a control allowing both manual and automatic splitter shifting, provides a favorable failure mode and as a module requires only four additional fluid connections (conduit 108 to port 138, conduit 110 to port 148, source S to port 146 and exhaust E x to port 144) to the normally utilized manual splitter control.
As used herein, "main section" ratio positions will include the 1/2, 2/3, 3/4, 5/6, 7/8 and 9/10(A) ratio positions, and the range section is considered a portion of the manually shifted main section.
When in the AUTO mode of operation, shift profiles are utilized to determine if an automatic upshift (ninth-tenth) or an automatic downshift (tenth-ninth) is required (see, for example, aforementioned U.S. Pat. No. 4,361,060). Referring to FIG. 7, by way of a simplified example, under most conditions, if in tenth ratio and output shaft speed falls below 1250 RPM, a tenth-ninth downshift is required, and if in ninth ratio and output shaft speed exceeds 1680 RPM, a ninth-tenth upshift is required. These speeds become 1300 RPM and 2000 RPM, respectively, if the engine brake is active.
To prevent "hunting," i.e., rapid upshift/downshift cycling, anti-hunt logic is typically utilized whereby, after an upshift, the downshift RPM is temporarily decreased, and after a downshift the upshift RPM is temporarily increased. Typically, these offsets are deleted based upon elapsed time since the last shift and/or achieving a predetermined vehicle performance.
Still referring to FIG. 7, immediately after an upshift, the downshift point is offset from 1250 RPM to 1050 RPM. After four seconds, the offset is reduced and the downshift point will be 1200 RPM. The downshift point will remain at 1200 RPM until output shaft speed exceeds 1350 RPM, when the normal 1250 RPM downshift point becomes effective. Immediately after a downshift, the upshfit shift point is offset from 1680 RPM to 1900 RPM. After four seconds, the offset is reduced and the upshift point becomes 1800 RPM and remains so until output shaft speed falls below 1550 RPM, at which point the normal 1680 RPM upshift point becomes effective.
While the foregoing shift strategy is satisfactory for most purposes, it has been found that under certain operating conditions, quicker shifting is required and/or it may be desirable that the operator be provided with a means to request faster shifting (i.e., to wholly or partially cancel the anti-hunt offsets, regardless of elapsed time or vehicle performance).
Should an operator require faster shifting after a downshift, the logic allows the operator to request a decrease or cancellation of the offset by decreasing throttle demand to a relatively low value (about 20% of full throttle displacement). Thus, by quickly releasing and then reapplying the throttle after a downshift, the operator may request a cancellation of the upshift anti-hunt offset. Similarly, if after an upshift throttle remains at about 100% displacement, this indicates that the operator is requesting performance and that a performance downshift should not be delayed by the downshift anti-hunt offset. Accordingly, after an upshift, if throttle remains at a high value (about 100% of full displacement), the downshift anti-hunt offset will be minimized or canceled, regardless of elapsed time since the shift or of vehicle performance
FIG. 8 is a flow chart representation of the control logic of the present invention.
Accordingly, it may be seen that an improved compound transmission and shift control unit has been provided.
Although the present invention has been described with a certain degree of particularity, it is understood that the description of the preferred embodiment is by way of example only and that numerous changes to form and detail are possible without departing from the spirit and scope of the invention as hereinafter claimed. | An automated mechanical transmission system (92) including anti-hunt logic (FIG. 7) and logic allowing the operator to reduce or cancel the anti-hunt logic offsets by post-shift throttle pedal (THL) manipulation. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to a diene polymer having a superior heat resistance, and a process for producing the diene polymer.
BACKGROUND OF THE INVENTION
[0002] There cannot be obtained diene polymers having a superior balance between a heat resistance and workability, by means of polymerizing non-conjugated diene compounds such as 2,2-dially-1,3-cyclopentanedione represented by the hereinafter-mentioned formula (3) having two carbon-to-carbon double bonds, in the presence of a commonly-used addition polymerization catalyst. The reason is that one of the two carbon-to-carbon double bonds is involved in not an addition polymerization reaction but an undesirable reaction such as a cross-linking reaction, although another carbon-to-carbon double bond is involved in an addition polymerization reaction, and as a result, there is obtained only a polymer, which (i) has no cyclic structure in its main chain contributing to a heat resistance, and (ii) is not necessarily a thermoplastic polymer contributing to workability.
[0003] On the other hand, Macromolecules, Vol. 35, pages 9640-9647 (2002) discloses a preparation method of an ethylene-cyclopentane alternating copolymer having a superior heat resistance due to a cyclic structure contained in its main chain, the method comprising the steps of (a) copolymerizing ethylene with cyclopentene by coordination ring-opening polymerization, thereby obtaining an alternating copolymer having carbon-to-carbon double bonds in its main chain, and (b) hydrogenating those carbon-to-carbon double bonds, thereby obtaining an ethylene-cyclopentane alternating copolymer. However, the above-mentioned preparation method has a problem in that (i) it is not easy to synthesize a monomer for preparing a target substituent-carrying alternating copolymer, and (ii) even if such a monomer can be synthesized, the above-mentioned hydrogenation step (b) may unfavorably hydrogenate also those substituents in an alternating copolymer obtained in the above-mentioned copolymerization step (a).
SUMMARY OF THE INVENTION
[0004] In view of the above-mentioned circumstances, the present invention has an object to provide a diene polymer having a superior heat resistance, and a process for producing the diene polymer.
[0005] The present invention is a polymer containing units represented by the following formula (1):
[0000]
[0000] wherein X 1 and X 2 are independently of each other an atom of Group 16 in the Periodic Table of the elements; Y 1 and Y 2 are independently of each other a hydrogen atom, an alkyl group, an aralkyl group, an aryl group, or a silyl group, and Y 1 and Y 2 may be linked with each other to form a ring; A 1 , A 2 , A 3 , A 4 , A 5 , A 6 , A 7 , A 8 , A 9 and A 10 are independently of one another a hydrogen atom, a halogen atom, a hydroxyl group, a nitrile group, an aldehyde group, an alkyl group, an aralkyl group, an aryl group, a silyl group, a siloxy group, an alkoxy group, an aralkyloxy group, an aryloxy group, an amino group, an amide group, an imide group, or a hydrocarbylthio group; m is 0 or 1; and n is an integer of 1 to 20.
[0006] Also, the present invention is a process for producing a polymer containing units represented by the above formula (1), which comprises the step of polymerizing a compound represented by the following formula (3):
[0000]
[0000] wherein Z is a group of —(CH 2 ) n-1 —(CA 9 A 10 ) m H; two wavy lines displayed in the upper right of the formula (3) mean variety in their configuration; and X 1 , X 2 , Y 1 , Y 2 , A 1 to A 10 , n and m are the same as those defined in the formula (1).
[0007] In the present invention, the term “unit” contained in the above-mentioned “units represented by the formula (1)” means a polymerization unit of a monomer such as a compound represented by the formula (3).
DETAILED DESCRIPTION OF THE INVENTION
[0008] Examples of X 1 and X 2 in the above formulas are an oxygen atom, a sulfur atom and a selenium atom. Among them, preferred is an oxygen atom.
[0009] Examples of the alkyl group of Y 1 and Y 2 in the above formulas are linear alkyl groups such as a methyl group, an ethyl group, and a n-butyl group; branched alkyl groups such as an isopropyl group, an isobutyl group, a tert-butyl group, and a neopentyl group; and cyclic alkyl groups such as a cyclohexyl group and a cyclooctyl group.
[0010] Examples of the aralkyl group of Y 1 and Y 2 in the above formulas are a benzyl group, a triphenylmethyl group, a 1-naphthylmethyl group, a 2-naphthylmethyl group, and a 9-fluorenylmethyl group.
[0011] Examples of the aryl group of Y 1 and Y 2 in the above formulas are a phenyl group, a 1-naphthyl group, a 2-naphthyl group, a 1-anthracenyl group, a 2-anthracenyl group, a 5-anthracenyl group, a 1-phenanthryl group, a 2-phenanthryl group, a 3-phenanthryl group, a 4-phenanthryl group, a 9-phenanthryl group, a 1-fluorenyl group, a 2-fluorenyl group, a 3-fluorenyl group, a 4-fluorenyl group, a 9-fluorenyl group, a 1-indenyl group, a 2-indenyl group, a 3-indenyl group, a 4-indenyl group, a 5-indenyl group, a 1-biphenyl group, a 2-biphenyl group, a 3-biphenyl group, a 2-pyridyl group, a 3-pyridyl group, a 4-pyridyl group, a 2-quinolinyl group, a 3-quinolinyl group, a 4-quinolinyl group, a 5-quinolinyl group, a 6-quinolinyl group, a 2-pyrrolyl group, a 3-pyrrolyl group, a 2-furanyl group, a 3-furanyl group, a 2-thiophenyl group, and a 3-thiophenyl group. The aryl group may have a substituent such as a halogen atom, a hydrocarbyloxy group, a nitro group, a sulfonate group, and a cyano group.
[0012] Examples of the silyl group of Y 1 and Y 2 in the above formulas are mono-substituted silyl groups such as a methylsilyl group, an ethylsilyl group, and a phenylsilyl group; di-substituted silyl groups such as a dimethylsilyl group, a diethylsilyl group, and a diphenylsilyl group; and tri-substituted silyl groups such as a trimethylsilyl group, a trimethoxysilyl group, a dimethylmethoxysilyl group, a methyldimethoxysilyl group, a triethylsilyl group, a triethoxysilyl group, a tri-n-propylsilyl group, a triisopropylsilyl group, a tri-n-butylsilyl group, a tri-sec-butylsilyl group, a tert-butyldimethylsilyl group, a triisobutylsilyl group, a tert-butyldiphenylsilyl group, a cyclohexyldimethylsilyl group, a tricyclohexylsilyl group, and a triphenylsilyl group. Among them, preferred is a tri-substituted silyl group, and further preferred is a trimethylsilyl group, a triethylsilyl group, a triphenylsilyl group, a tert-butyldimethylsilyl group, a tert-butyldiphenylsilyl group, a cyclohexyldimethylsilyl group, or a triisopropylsilyl group. The silyl group may have a substituent such as a halogen atom, a hydrocarbyloxy group, a nitro group, a sulfonate group, and a cyano group.
[0013] Examples of the siloxy group of Y 1 and Y 2 in the above formulas are a trimethylsiloxy group, a trimethoxysiloxy group, a dimethylmethoxysiloxy group, a methyldimethoxysiloxy group, a triethylsiloxy group, a triethoxysiloxy group, a tri-n-propylsiloxy group, a triisopropylsiloxy group, a tri-n-butylsiloxy group, a tri-sec-butylsiloxy group, a tert-butyldimethylsiloxy group, a triisobutylsiloxy group, a tert-butyldiphenylsiloxy group, a cyclohexyldimethylsiloxy group, a tricyclohexylsiloxy group, and a triphenylsiloxy group. Among them, preferred is a trimethylsiloxy group, a triethylsiloxy group, a triphenylsiloxy group, a tert-butyldimethylsiloxy group, a tert-butyldiphenylsiloxy group, a cyclohexyldimethylsiloxy group, or a triisopropylsiloxy group. The siloxy group may have a substituent such as a halogen atom, a hydrocarbyloxy group, a nitro group, a sulfonate group, and a cyano group.
[0014] When Y 1 and Y 2 in the above formulas are linked to each other to form a ring, examples of the ring are aliphatic rings and aromatic rings. Examples of a divalent group formed by a linkage between Y 1 and Y 2 in the aliphatic ring are a methylene group, an isopropylidene group, a 1,2-ethylene group, a 1,2-cyclohexylene group, a 1,3-cyclohexylene group, a 1,4-cyclohexylene group, a 1,2-norbornene group, a 2,3-butene group, a 2,3-dimethyl-2,3-butene group, and a 2,4-pentene group. Among them, preferred is a methylene group, an isopropylidene group, a 2,3-butene group, or a 2,3-dimethyl-2,3-butene group. Examples of a divalent group formed by a linkage between Y 1 and Y 2 in the aromatic ring are a 1,2-phenylene group, a 1,3-phenylene group, a 1,2-naphthylene group, a 1,3-naphthylene group, a 1,8-naphthylene group, a 2,3-naphthylene group, a 2,4-naphthylene group, a 2,2′-biphenylene group, a 1,2-dimethylenephnyl group, a 1,3-dimethylenephnyl group, a 1,4-dimethylenephnyl group, a 1,2-diethylenephnyl group, a 1,3-diethylenephnyl group, and a 1,4-diethylenephnyl group. Those rings may have a substituent such as a halogen atom, a hydrocarbyloxy group, a nitro group, a sulfonate group, and a cyano group.
[0015] Among them, Y 1 and Y 2 are preferably an alkyl group, more preferably a linear alkyl group, and further preferably a methyl group, an ethyl group or a n-butyl group.
[0016] Examples of the halogen atom of A 1 to A 10 in the above formulas are a fluorine atom, a chlorine atom, a bromine atom, and an iodine atom. Among them, preferred is a fluorine atom.
[0017] Examples of the alkyl group of A 1 to A 10 in the above formulas are linear alkyl groups such as a methyl group, an ethyl group, and a n-butyl group; branched alkyl groups such as an isopropyl group, an isobutyl group, a tert-butyl group, and a neopentyl group; and cyclic alkyl groups such as a cyclohexyl group and a cyclooctyl group. The alkyl group may have a substituent such as a halogen atom, a hydrocarbyloxy group, a nitro group, a sulfonate group, a silyl group, and a cyano group.
[0018] Examples of the aralkyl group of A 1 to A 10 in the above formulas are a benzyl group, a phenethyl group, a 2-methylbenzyl group, a 3-methylbenzyl group, a 4-methylbenzyl group, a 2,6-dimethylbenzyl group, and a 3,5-dimethylbenzyl group. The aralkyl group may have a substituent such as a halogen atom, a hydrocarbyloxy group, a nitro group, a sulfonate group, a silyl group, and a cyano group.
[0019] Examples of the aryl group of A 1 to A 10 in the above formulas are a phenyl group, a 2-tolyl group, a 3-tolyl group, a 4-tolyl group, a 1-naphthyl group, a 2-naphthyl group, a 1-anthracenyl group, a 2-anthracenyl group, a 5-anthracenyl group, a 1-phenanthryl group, a 2-phenanthryl group, a 3-phenanthryl group, a 4-phenanthryl group, a 9-phenanthryl group, a 1-fluorenyl group, a 2-fluorenyl group, a 3-fluorenyl group, a 4-fluorenyl group, a 9-fluorenyl group, a 1-indenyl group, a 2-indenyl group, a 3-indenyl group, a 4-indenyl group, a 5-indenyl group, a 1-biphenyl group, a 2-biphenyl group, a 3-biphenyl group, a 2-pyridyl group, a 3-pyridyl group, a 4-pyridyl group, a 2-quinolinyl group, a 3-quinolinyl group, a 4-quinolinyl group, a 5-quinolinyl group, a 6-quinolinyl group, a 2-pyrrolyl group, a 3-pyrrolyl group, a 2-furanyl group, a 3-furanyl group, a 2-thiophenyl group, a 3-thiophenyl group, and a mesityl group. The aryl group may have a substituent such as a halogen atom, a hydrocarbyloxy group, a nitro group, a sulfonate group, a silyl group, and a cyano group.
[0020] Examples of the silyl group of A 1 to A 10 in the above formulas are mono-substituted silyl groups such as a methylsilyl group, an ethylsilyl group, and a phenylsilyl group; di-substituted silyl groups such as a dimethylsilyl group, a diethylsilyl group, and a diphenylsilyl group; and tri-substituted silyl groups such as a trimethylsilyl group, a trimethoxysilyl group, a dimethylmethoxysilyl group, a methyldimethoxysilyl group, a triethylsilyl group, a triethoxysilyl group, a tri-n-propylsilyl group, a triisopropylsilyl group, a tri-n-butylsilyl group, a tri-sec-butylsilyl group, a tert-butyldimethylsilyl group, a triisobutylsilyl group, a tert-butyldiphenylsilyl group, a cyclohexyldimethylsilyl group, a tricyclohexylsilyl group, and a triphenylsilyl group. The silyl group may have a substituent such as a halogen atom, a hydrocarbyloxy group, a nitro group, a sulfonate group, and a cyano group.
[0021] Examples of the siloxy group of A 1 to A 10 in the above formulas are a trimethylsiloxy group, a trimethoxysiloxy group, a dimethylmethoxysiloxy group, a methyldimethoxysiloxy group, a triethylsiloxy group, a triethoxysiloxy group, a tri-n-propylsiloxy group, a triisopropylsiloxy group, a tri-n-butylsiloxy group, a tri-sec-butylsiloxy group, a tert-butyldimethylsiloxy group, a triisobutylsiloxy group, a tert-butyldiphenylsiloxy group, a cyclohexyldimethylsiloxy group, a tricyclohexylsiloxy group, and a triphenylsiloxy group. The siloxy group may have a substituent such as a halogen atom, a hydrocarbyloxy group, a nitro group, a sulfonate group, and a cyano group.
[0022] Examples of the alkoxy group of A 1 to A 10 in the above formulas are linear alkoxy groups such as a methoxy group, an ethoxy group, and a n-butoxy group; branched alkoxy groups such as an isopropoxy group, an isobutoxy group, a tert-butoxy group, and a neopentoxy group; and cyclic alkoxy groups such as a cyclohexyloxy group and a cyclooctyloxy group. The alkoxy group may have a substituent such as a halogen atom, a hydrocarbyloxy group, a nitro group, a sulfonate group, a silyl group, and a cyano group.
[0023] Examples of the aralkyloxy group of A 1 to A 10 in the above formulas are a benzyloxy group, a phenethyloxy group, a 2-methylbenzyloxy group, a 3-methylbenzyloxy group, a 4-methylbenzyloxy group, a 2,6-dimethylbenzyloxy group, and a 3,5-dimethylbenzyloxy group. The aralkyloxy group may have a substituent such as a halogen atom, a hydrocarbyloxy group, a nitro group, a sulfonate group, a silyl group, and a cyano group.
[0024] Examples of the aryloxy group of A 1 to A 10 in the above formulas are a phenoxy group, a 2-methylphenoxy group, a 2-ethylphenoxy group, a 2-n-propylphenoxy group, a 2-isopropylphenoxy group, a 2-n-butylphenoxy group, a 2-isobutylphenoxy group, a 2-tert-butylphenoxy group, a 3-methylphenoxy group, a 3-isopropylphenoxy group, a 3-n-butylphenoxy group, a 3-tert-butylphenoxy group, a 4-methylphenoxy group, a 4-isopropylphenoxy group, a 4-n-butylphenoxy group, a 4-tert-butylphenoxy group, a 2,3-dimethylphenoxy group, a 2,4-dimethylphenoxy group, a 2,5-dimethylphenoxy group, a 2,6-dimethylphenoxy group, a 3,5-dimethylphenoxy group, a 2,6-diisopropylphenoxy group, a 2,6-di-tert-butylphenoxy group, and a naphthoxy group. The aryloxy group may have a substituent such as a halogen atom, a hydrocarbyloxy group, a nitro group, a sulfonate group, a silyl group, and a cyano group.
[0025] Examples of the amino group of A 1 to A 10 in the above formulas are linear alkylamino groups such as an N-methylamino group, an N-ethylamino group, an N-n-butylamino group, an N,N-dimethylamino group, an N,N-diethylamino group, and an N,N-di-n-butylamino group; branched alkylamino groups such as an N,N-diisopropylamino group, an N,N-diisobutylamino group, an N,N-di-tert-butylamino group, and an N,N-dineopentylamino group; and cyclic alkylamino groups such as an N,N-dicyclohexylamino group and an N,N-dicyclooctylamino group. The amino group may have a substituent such as a halogen atom, a hydrocarbyloxy group, a nitro group, a sulfonate group, a silyl group, and a cyano group.
[0026] Examples of the amide group of A 1 to A 10 in the above formulas are an ethanamide group, an N-n-butylethanamide group, an N-methylethanamide group, an N-ethylethanamide group, an N-n-butylhexanamide group, an isopropanamide group, an isobutanamide group, a tert-butanamide group, a neopentanamide group, a cyclohexanamide group, and a cyclooctanamide group. The amide group may have a substituent such as a halogen atom, a hydrocarbyloxy group, a nitro group, a sulfonate group, a silyl group, and a cyano group.
[0027] Examples of the imide group of A 1 to A 10 in the above formulas are a succinimide group, a maleimide group, and a phthalimide group. The imide group may have a substituent such as a halogen atom, a hydrocarbyloxy group, a nitro group, a sulfonate group, a silyl group, and a cyano group.
[0028] Examples of the hydrocarbylthio group of A 1 to A 10 in the above formulas are linear alkylthio groups such as a methylthio group, an ethylthio group, and a n-butylthio group; branched alkylthio groups such as an isopropylthio group, an isobutylthio group, a tert-butylthio group, and a neopentylthio group; and cyclic alkylthio groups such as a cyclohexylthio group and a cyclooctylthio group. The hydrocarbylthio group may have a substituent such as a halogen atom, a hydrocarbyloxy group, a nitro group, a sulfonate group, a silyl group, and a cyano group.
[0029] Among them, A 1 to A 10 are preferably a hydrogen atom, a halogen atom, or an alkyl group having 1 to 10 carbon atoms; more preferably a hydrogen atom or a methyl group; and further preferably a hydrogen atom.
[0030] A 3 and A 4 , or A 5 and A 6 may be linked with each other to form a ring. Examples of the ring are aliphatic rings such as a cyclobutane ring, a cyclopentane ring and a cyclohexane ring, and aromatic rings. Those rings may have a substituent such as a halogen atom, a hydrocarbyloxy group, a nitro group, a sulfonate group, a silyl group, and a cyano group.
[0031] A relative configuration between A 7 and A 8 in the formula (1) is not particularly limited. The configuration is preferably a trans-form represented by the following formula (2), in order to improve a heat resistance of the diene polymer of the present invention; and from a viewpoint of an excellent heat resistance of the diene polymer, the unit represented by the formula (2) is contained in the diene polymer in an amount of preferably 50% by mol or larger, and more preferably 95% by mol or larger, the total amount of the unit represented by the formula (1) being 100% by mol:
[0000]
[0000] wherein all the symbols contained in the formula (2) are the same as those defined in the formula (1).
[0032] A proportion of the above-mentioned trans-form is measured with a 13 C-NMR spectrum, which is obtained using a chloroform-d 1 solution of the polymer of the present invention. A peak (i) appearing at 45 to 48 ppm in the 13 C-NMR spectrum is assigned to carbon atoms having a trans-form configuration, and a peak (ii) appearing at 39 to 42 ppm therein is assigned to carbon atoms having a cis-form configuration, provided that a peak assigned to chloroform-d 1 appears at 77 ppm. Therefore, the proportion (% by mol) of the trans-form is obtained from the following formula:
[0000] proportion (% by mol) of trans-form=area of peak ( i )×100/[area of peak ( i )+area of peak (ii)].
[0033] Stereoregularity of the polymer of the present invention is determined by an absolute configuration of the two asymmetric carbon atoms, which are linked to A 7 and A 8 , respectively, and exist in the main chain of the polymer having the unit represented by the formula (1). There are four kinds of polymers in view of said stereoregularity, (a) an erythrodiisotactic polymer, (b) an erythrodisyndiotactic polymer, (c) a threodiisotactic polymer, and (d) a threodisyndiotactic polymer, as shown in the following formulas:
[0000]
[0000] wherein C 1 means a carbon atom linked to A 3 and A 4 in the formula (1); C 2 means a carbon atom linked to A 5 and A 6 therein; a curved line between C 1 and C 2 corresponds to the tree bonds existing between the carbon atom linked to A 3 and A 4 and the carbon atom linked to A 5 and A 6 ; and other carbon atoms and other substituents contained in the unit represented by the formula (1) are abbreviated.
[0034] The above-mentioned four kinds of polymers are defined in Encyclopedia of Polymer Science and Engineering (USA), 2nd Ed., Vol. 10, pages 191-203, John Wiley & Sons, 1987.
[0035] Stereoregularity of the polymer of the present invention is not particularly limited. From a viewpoint of production of a polymer excellent in its heat resistance, the polymer of the present invention is (i) a polymer having an erythrodiisotactic triad or a threodiisotactic triad in an amount of preferably more than 25% by mol, more preferably 30% by mol or more, and further preferably 50% by mol or more, the total amount of the unit represented by the formula (1) being 100% by mol, or (ii) a polymer having an erythrodisyndiotactic triad or a threodisyndiotactic triad in an amount of preferably more than 25% by mol, more preferably 30% by mol or more, and further preferably 50% by mol or more, the total amount of the unit represented by the formula (1) being 100% by mol.
[0036] The above-mentioned stereoregularity is determined with a 13 C-NMR spectrum obtained by use of a solution of the polymer of the present invention in chloroform-d 1 . A peak (iii) appearing at 46.2 to 46.6 ppm in the 13 C-NMR spectrum is assigned to carbon atoms derived from a threodiisotactic triad, and a peak (iv) appearing at 46.9 to 47.3 ppm therein is assigned to carbon atoms derived from a threodisyndiotactic triad, provided that a peak assigned to chloroform-d 1 appears at 77 ppm.
[0037] Therefore, a proportion (%) of the above-mentioned threodiisotactic triad is derived form the following formula:
[0000] Proportion (%) of threodiisotactic triad=area of peak ( iii )×100/[area of peak ( iii )+area of peak ( iv )];
[0000] and
a proportion (%) of the above-mentioned threodisyndiotactic triad is derived form the following formula:
[0000] Proportion (%) of threodisyndiotactic triad=area of peak ( iv )×100/[area of peak ( iii )+area of peak ( iv )].
[0038] Z in the formula (3) is preferably a hydrogen atom (m=0 and n=1), or an alkyl group having 1 to 20 carbon atoms (m=1, n=1 to 20, A 9 =H, and A 10 =H).
[0039] Compounds represented by the formula (3) may be known in the art. Preferable examples thereof are
2,2-diallylcyclobutan-1,3-dione, 2,2-diallylcyclopentan-1,3-dione, 2,2-diallylcyclohexan-1,3-dione, 2,2-diallylcycloheptan-1,3-dione, 2,2-diallylcyclooctan-1,3-dione, 2,2-diallylcyclononan-1,3-dione, 2-allyl-2-((2E)-2-butenyl)cyclohexan-1,3-dione, 2-allyl-2-((2E)-2-pentenyl)cyclohexan-1,3-dione, 2-allyl-2-((2E)-2-hexenyl)cyclohexan-1,3-dione, 2-allyl-2-((2E)-2-heptenyl)cyclohexan-1,3-dione, 2-allyl-2-((2E)-2-octenyl)cyclohexan-1,3-dione, 2-allyl-2-((2E)-2-nonenyl)cyclohexan-1,3-dione, 2-allyl-2-((2E)-2-decenyl)cyclohexan-1,3-dione, 2-allyl-2-((2E)-2-undecenyl)cyclohexan-1,3-dione, 2-allyl-2-((2E)-2-dodecenyl)cyclohexan-1,3-dione, 2-allyl-2-((2E)-2-tridecenyl)cyclohexan-1,3-dione, 2-allyl-2-((2E)-2-tetradecenyl)cyclohexan-1,3-dione, 2-allyl-2-((2E)-2-hexadecenyl)cyclohexan-1,3-dione, 2,2-diallylindan-1,3-dione, 2-allyl-2-((2E)-2-butenyl)indan-1,3-dione, 2-allyl-2-((2E)-2-pentenyl)indan-1,3-dione, 2-allyl-2-((2E)-2-hexenyl)indan-1,3-dione, 2-allyl-2-((2E)-2-heptenyl)indan-1,3-dione, 2-allyl-2-((2E)-2-octenyl)indan-1,3-dione, 2-allyl-2-((2E)-2-nonenyl)indan-1,3-dione, 2-allyl-2-((2E)-2-decenyl)indan-1,3-dione, 2-allyl-2-((2E)-2-undecenyl)indan-1,3-dione, 2-allyl-2-((2E)-2-dodecenyl)indan-1,3-dione, 2-allyl-2-((2E)-2-tridecenyl)indan-1,3-dione, 2-allyl-2-((2E)-2-tetradecenyl)indan-1,3-dione, and 2-allyl-2-((2E)-2-hexadecenyl)indan-1,3-dione.
[0071] Examples of the polymer of the present invention are homopolymers obtained by homopolymerizing each of the above-mentioned compounds. Representative examples of the homopolymer are poly-2,2-diallylcyclopentan-1,3-dione, poly-2,2-diallylcyclohexan-1,3-dione, and poly-2,2-diallylindan-1,3-dione.
[0072] The polymer of the present invention can be prepared by polymerizing the compound represented by the formula (3). The polymerization is preferably carried out in the presence of a polymerization catalyst formed by contacting a transition metal compound with an organoaluminum compound and/or boron compound.
[0073] The transition metal compound is not particularly limited as long as it has an addition polymerization activity, and may be a compound known in the art. Among them, preferred is a transition metal compound having a transition metal of Groups 4 to 10 or lanthanide series in the Periodic Table of the elements. Examples of the transition metal compound are those represented by the following formula (4), and a μ-oxo transition metal compound, which is a dimmer obtained by reacting the transition metal compound with water:
[0000] L a M 1 X 1 b (4)
[0000] wherein M 1 is a transition metal atom of Groups 4 to 10 or lanthanide series of the Periodic Table of the elements (IUPAC 1985); L is a cyclopentadiene-containing anionic group or a hetero atom-having group, and when plural Ls exist, they may be linked with one another directly or through a group having a carbon atom, a silicon atom, a nitrogen atom, an oxygen atom, a sulfur atom or a phosphor atom; X 1 is a halogen atom or a hydrocarbyl group having 1 to 20 carbon atoms; a is a number satisfying 0<a≦8; and b is a number satisfying 0<a≦8.
[0074] Examples of M 1 are a titanium atom, a zirconium atom, a hafnium atom, a vanadium atom, a niobium atom, a tantalum atom, a chromium atom, an iron atom, a ruthenium atom, a cobalt atom, a rhodium atom, a nickel atom, a palladium atom, a samarium atom, and an ytterbium atom.
[0075] Examples of the above-mentioned cyclopentadiene-containing anionic group of L are a cyclopentadienyl group, a substituent-having cyclopentadienyl group, an indenyl group, a substituent-having indenyl group, a fluorenyl group, and a substituent-having fluorenyl group.
[0076] Specific examples of the cyclopentadiene-containing anionic group are an η 5 -cyclopentadienyl group, an η 5 -methylcyclopentadienyl group, an η 5 -tert-butylcyclopentadienyl group, an η 5 -1,2-dimethylcyclopentadienyl group, an η 5 -1,3-dimethylcyclopentadienyl group, an η 5 -1-tert-butyl-2-methylcyclopentadienyl group, an η 5 -1-tert-butyl-3-methylcyclopentadienyl group, an η 5 -1-methyl-2-isopropylcyclopentadienyl group, an η 5 -1-methyl-3-isopropylcyclopentadienyl group, an η 5 -1,2,3-trimethylcyclopentadienyl group, an η 5 -1,2,4-trimethylcyclopentadienyl group, an η 5 -tetramethylcyclopentadienyl group, an η 5 -pentamethylcyclopentadienyl group, an 5-indenyl group, an η 5 -4,5,6,7-tetrahydroindenyl group, an η 5 -2-methylindenyl group, an η 5 -3-methylindenyl group, an η 5 -4-methylindenyl group, an η 5 -5-methylindenyl group, an η 5 -6-methylindenyl group, an η 5 -7-methylindenyl group, an η 5 -2-tert-butylindenyl group, an η 5 -3-tert-butylindenyl group, an η 5 -4-tert-butylindenyl group, an η 5 -5-tert-butylindenyl group, an η 5 -6-tert-butylindenyl group, an η 5 -7-tert-butylindenyl group, an η 5 -2,3-dimethylindenyl group, an η 5 -4,7-dimethylindenyl group, an η 5 -2,4,7-trimethylindenyl group, an η 5 -2-methyl-4-isopropylindenyl group, an η 5 -4,5-benzindenyl group, an η 5 -2-methyl-4,5-benzindenyl group, an η 5 -4-phenylindenyl group, an η 5 -2-methyl-5-phenylindenyl group, an η 5 -2-methyl-4-phenylindenyl group, an η 5 -2-methyl-4-naphthylindenyl group, an η 5 -fluorenyl group, an η 5 -2,7-dimethylfluorenyl group, and an η 5 -2,7-di-tert-butylfluorenyl group.
[0077] Examples of the hetero atom in the above-mentioned hetero atom-having group of L are an oxygen atom, a sulfur atom, a nitrogen atom, and a phosphorus atom. Examples of the hetero atom-having group are an alkoxy group; an aryloxy group; a thioalkoxy group; a thioaryloxy group; an alkylamino group; an arylamino group; an alkylphosphino group; an arylphosphino group; an aromatic or aliphatic heterocyclic group containing in its ring at least one atom selected from the group consisting of an oxygen atom, a sulfur atom, a nitrogen atom and a phosphorus atom; and a chelating ligand.
[0078] Examples of the hetero atom-having group are an alkoxy group such as a methoxy group, an ethoxy group, a propoxy group, and a butoxy group; an aryloxy group such as a phenoxy group, a 2-methylphenoxy group, a 2,6-dimethylphenoxy group, a 2,4,6-trimethylphenoxy group, a 2-ethylphenoxy group, a 4-n-propylphenoxy group, a 2-isopropylphenoxy group, a 2,6-diisopropylphenoxy group, a 4-sec-butylphenoxy group, a 4-tert-butylphenoxy group, a 2,6-di-sec-butylphenoxy group, a 2-tert-butyl-4-methylphenoxy group, and a 2,6-di-tert-butylphenoxy group; a substituent-having aryloxy group such as a 4-methoxyphenoxy group, a 2,6-dimethoxyphenoxy group, a 3,5-dimethoxyphenoxy group, a 2-chlorophenoxy group, a 4-nitrosophenoxy group, a 4-nitrophenoxy group, a 2-aminophenoxy group, a 3-aminophenoxy group, a 4-aminothiophenoxy group, a 2,3,6-trichlorophenoxy group, and a 2,4,6-trifluorophenoxy group; a thioalkoxy group such as a thiomethoxy group; an alkylamino group such as a dimethylamino group, a diethylamino group, a dipropylamino group, an isopropylamino group, and a tert-butylamino group; an arylamino group such as a diphenylamino group; a pyrrolyl group; a phosphino group such as a dimethylphosphino group; and a aryldioxy group such as a 2-(2-oxy-1-propyl)phenoxy group, a catecholato group, a resorcinolate group, a 4-isopropylcatecholato group, a 3-methoxycatecholato group, a 1,8-dihydroxynahpthyl group, a 1,2-dihydroxynahpthyl group, a 2,2′-biphenyldiol group, a 1,1′-bi-2-naphthol group, a 2,2′-dihydroxy-6,6′-dimethylbiphenyl group, a 4,4′,6,6′-tetra-tert-butyl-2,2′-methylenediphenoxy group, and a 4,4′,6,6′-tetramethyl-2,2′-isobutylidenediphenoxy group.
[0079] The above-mentioned chelating ligand in the examples of the hetero atom-having group means a ligand having plural coordinating positions. Examples thereof are acetylacetonate, diimine, oxazoline, bisoxazoline, terpyridine, acylhydrazone, diethylenetriamine, triethylenetetramine, porphyrin, crown ether and cryptate.
[0080] As mentioned above, when plural Ls exist, they may be linked (namely, plural cyclopentadiene-containing anionic groups may be linked; plural hetero atom-having groups may be linked; or the cyclopentadiene-containing anionic group and the hetero atom-having group may be linked) with one another directly or through a group having a carbon atom, a silicon atom, a nitrogen atom, an oxygen atom, a sulfur atom or a phosphor atom. Examples of the group having a carbon atom, a silicon atom, a nitrogen atom, an oxygen atom, a sulfur atom or a phosphor atom are an alkylene group such as an ethylene group and a propylene group; a substituent-having alkylene group such as a dimethylmethylene group (an isopropylidene group) and a diphenylmethylene group; a silylene group; a substituent-having silylene group such as a dimethylsilylene group, a diphenylsilylene group, and a tetramethyldisilylene group; and a hetero-atom such as a nitrogen atom, an oxygen atom, a sulfur atom and a phosphorus atom.
[0081] Examples of the halogen atom of X 1 in formula (4) are a fluorine atom, a chlorine atom, a bromine atom and an iodine atom, and examples of the hydrocarbyl group having 1 to 20 carbon atoms of X 1 therein are a methyl group, an ethyl group, a n-propyl group, an isopropyl group, a n-butyl group, a phenyl group, and a benzyl group.
[0082] Each number of “a” and “b” in formula (4) is determined so that the charge of the transition metal compound represented by formula (4) is neutral, taking account of each valence of M 1 , L and X 1 .
[0083] Examples of the transition metal compound represented by formula (4), wherein M 1 is a titanium atom, are bis(cyclopentadienyl)titanium dichloride, bis(methylcyclopentadienyl)titanium dichloride, bis(n-butylcyclopentadienyl)titanium dichloride, bis(dimethylcyclopentadienyl)titanium dichloride, bis(ethylmethylcyclopentadienyl)titanium dichloride, bis(trimethylcyclopentadienyl)titanium dichloride, bis(tetramethylcyclopentadienyl)titanium dichloride, bis(pentamethylcyclopentadienyl)titanium dichloride, bis(indenyl)titanium dichloride, bis(4,5,6,7-tetrahydroindenyl)titanium dichloride, bis(fluorenyl)titanium dichloride, cyclopentadienyl(pentamethylcyclopentadienyl) titanium dichloride, cyclopentadienyl(indenyl)titanium dichloride, cyclopentadienyl(fluorenyl)titanium dichloride, indenyl(fluorenyl)titanium dichloride, pentamethylcyclopentadienyl(indenyl)titanium dichloride, pentamethylcyclopentadienyl(fluorenyl)titanium dichloride, ethylenebis(cyclopentadienyl)titanium dichloride, ethylenebis(2-methylcyclopentadienyl)titanium dichloride, ethylenebis(3-methylcyclopentadienyl)titanium dichloride, ethylenebis(2-n-butylcyclopentadienyl)titanium dichloride, ethylenebis(3-n-butylcyclopentadienyl)titanium dichloride, ethylenebis(2,3-dimethylcyclopentadienyl)titanium dichloride, ethylenebis(2,4-dimethylcyclopentadienyl)titanium dichloride, ethylenebis(2,5-dimethylcyclopentadienyl)titanium dichloride, ethylenebis(3,4-dimethylcyclopentadienyl)titanium dichloride, ethylenebis(2-ethyl-3-methylcyclopentadienyl)titanium dichloride, ethylenebis(2-ethyl-4-methylcyclopentadienyl)titanium dichloride, ethylenebis(2-ethyl-5-methylcyclopentadienyl)titanium dichloride, ethylenebis(3-ethyl-5-methylcyclopentadienyl)titanium dichloride, ethylenebis(2,3,4-trimethylcyclopentadienyl)titanium dichloride, ethylenebis(2,3,5-trimethylcyclopentadienyl)titanium dichloride, ethylenebis(tetramethylcyclopentadienyl)titanium dichloride, ethylenebis(indenyl)titanium dichloride, ethylenebis(4,5,6,7-tetrahydroindenyl)titanium dichloride, ethylenebis(2-phenylindenyl)titanium dichloride, ethylenebis(2-methylindenyl)titanium dichloride, ethylenebis(2-methyl-4-phenylindenyl)titanium dichloride, ethylenebis(2-methyl-4-naphthylindenyl)titanium dichloride, ethylenebis(2-methyl-4,5-benzoindenyl)titanium dichloride, ethylenebis(fluorenyl)titanium dichloride, ethylene(cyclopentadienyl)(pentamethylcyclopentadienyl)titanium dichloride, ethylene(cyclopentadienyl)(indenyl)titanium dichloride, ethylene (methylcyclopentadienyl)(indenyl)titanium dichloride, ethylene(n-butylcyclopentadienyl)(indenyl)titanium dichloride, ethylene(tetramethylcyclopentadienyl)(indenyl)titanium dichloride, ethylene(cyclopentadienyl)(fluorenyl)titanium dichloride, ethylene(methylcyclopentadienyl)(fluorenyl)titanium dichloride, ethylene (pentamethylcyclopentadienyl)(fluorenyl)titanium dichloride, ethylene(n-butylcyclopentadienyl)(fluorenyl)titanium dichloride, ethylene (tetramethylpentadienyl)(fluorenyl)titanium dichloride, ethylene(indenyl)(fluorenyl)titanium dichloride, isopropylidenebis(cyclopentadienyl)titanium dichloride, isopropylidenebis(2-methylcyclopentadienyl)titanium dichloride, isopropylidenebis(3-methylcyclopentadienyl)titanium dichloride, isopropylidenebis(2-n-butylcyclopentadienyl)titanium dichloride, isopropylidenebis(3-n-butylcyclopentadienyl)titanium dichloride, isopropylidenebis(2,3-dimethylcyclopentadienyl)titanium dichloride, isopropylidenebis(2,4-dimethylcyclopentadienyl)titanium dichloride, isopropylidenebis(2,5-dimethylcyclopentadienyl)titanium dichloride, isopropylidenebis(3,4-dimethylcyclopentadienyl)titanium dichloride, isopropylidenebis(2-ethyl-3-methylcyclopentadienyl)titanium dichloride, isopropylidenebis(2-ethyl-4-methylcyclopentadienyl)titanium chloride, isopropylidenebis(2-ethyl-5-methylcyclopentadienyl)titanium dichloride, isopropylidenebis(3-ethyl-5-methylcyclopentadienyl)titanium dichloride, isopropylidenebis(2,3,4-trimethylcyclopentadienyl)titanium dichloride, isopropylidenebis(2,3,5-trimethylcyclopentadienyl)titanium dichloride, isopropylidenebis(tetramethylcyclopentadienyl)titanium dichloride, isopropylidenebis(indenyl)titanium dichloride, isopropylidenebis(4,5,6,7-tetrahydroindenyl)titanium dichloride, isopropylidenebis(2-phenylindenyl)titanium dichloride, isopropylidenebis(2-methylindenyl)titanium dichloride, isopropylidenebis(2-methyl-4-phenylindenyl)titanium dichloride, isopropylidenebis(2-methyl-4-naphthylindenyl)titanium dichloride, isopropylidenebis(2-methyl-4,5-benzoindenyl)titanium dichloride, isopropylidenebis(fluorenyl)titanium dichloride, isopropylidene(cyclopentadienyl)(tetramethylcyclopentadienyl)titanium dichloride, isopropylidene(cyclopentadienyl)(indenyl)titanium dichloride, isopropylidene(methylcyclopentadienyl)(indenyl)titanium dichloride, isopropylidene(n-butylcyclopentadienyl)(indenyl)titanium dichloride, isopropylidene(tetramethylcyclopentadienyl)(indenyl)titanium dichloride, isopropylidene (cyclopentadienyl)(fluorenyl)titanium dichloride, isopropylidene(methylcyclopentadienyl)(fluorenyl)titanium dichloride, isopropylidene(n-butylcyclopentadienyl)(fluorenyl)titanium dichloride, isopropylidene(tetramethylcyclopentadienyl)(fluorenyl)titanium dichloride, isopropylidene (indenyl)(fluorenyl)titanium dichloride, dimethylsilylenebis(cyclopentadienyl)titanium dichloride, dimethylsilylenebis(2-methylcyclopentadienyl)titanium dichloride, dimethylsilylenebis(3-methylcyclopentadienyl)titanium dichloride, dimethylsilylenebis(2-n-butylcyclopentadienyl)titanium dichloride, dimethylsilylenebis(3-n-butylcyclopentadienyl)titanium dichloride, dimethylsilylenebis(2,3-dimethylcyclopentadienyl)titanium dichloride, dimethylsilylenebis(2,4-dimethylcyclopentadienyl)titanium dichloride, dimethylsilylenebis(2,5-dimethylcyclopentadienyl)titanium dichloride, dimethylsilylenebis(3,4-dimethylcyclopentadienyl)titanium dichloride, dimethylsilylenebis(2-ethyl-3-methylcyclopentadienyl)titanium dichloride, dimethylsilylenebis(2-ethyl-4-methylcyclopentadienyl)titanium dichloride, dimethylsilylenebis(2-ethyl-5-methylcyclopentadienyl)titanium dichloride, dimethylsilylenebis(3-ethyl-5-methylcyclopentadienyl)titanium dichloride, dimethylsilylenebis(2,3,4-trimethylcyclopentadienyl)titanium dichloride, dimethylsilylenebis(2,3,5-trimethylcyclopentadienyl) titanium dichloride, dimethylsilylenebis(tetramethylcyclopentadienyl)titanium dichloride, dimethylsilylenebis(indenyl)titanium dichloride, dimethylsilylenebis(4,5,6,7-tetrahydroindenyl)titanium dichloride, dimethylsilylenebis(2-phenylindenyl)titanium dichloride, dimethylsilylenebis(2-methylindenyl)titanium dichloride, dimethylsilylenebis(2-methyl-4-phenylindenyl)titanium dichloride, dimethylsilylenebis(2-methyl-4-naphthylindenyl)titanium dichloride, dimethylsilylenebis(2-methyl-4,5-benzoindenyl)titanium dichloride, dimethylsilylene(cyclopentadienyl)(indenyl)titanium dichloride, dimethylsilylene(methylcyclopentadienyl)(indenyl)titanium dichloride, dimethylsilylene(n-butylcyclopentadienyl)(indenyl)titanium dichloride, dimethylsilylene(tetramethylcyclopentadienyl)(indenyl)titanium dichloride, dimethylsilylene(cyclopentadienyl)(fluorenyl)titanium dichloride, dimethylsilylene(methylcyclopentadienyl)(fluorenyl)titanium dichloride, dimethylsilylene(n-butylcyclopentadienyl)(fluorenyl)titanium dichloride, dimethylsilylene(tetramethylcyclopentadienyl)(indenyl)titanium dichloride, dimethylsilylene(indenyl)(fluorenyl)titanium dichloride, cyclopentadienylitanium trichloride, pentamethylcyclopentadienyltitanium trichloride, cyclopentadienyl(dimethylamido)titanium dichloride, cyclopentadienyl(phenoxy)titanium dichloride, cyclopentadienyl(2,6-dimethylphenyl)titanium dichloride, cyclopentadienyl(2,6-diisopropylphenyl)titanium dichloride, cyclopentadienyl(2,6-di-tert-butylphenyl)titanium dichloride, pentamethylcyclopentadienyl(2,6-dimethylphenyl)titanium dichloride, pentamethylcyclopentadienyl(2,6-diisopropylphenyl)titanium dichloride, pentamethylcyclopentadienyl(2,6-di-tert-butylphenyl)titanium dichloride, indenyl(2,6-diisopropylphenyl)titanium dichloride, fluorenyl (2,6-diisopropylphenyl)titanium dichloride, methylene(cyclopentadienyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, methylene(cyclopentadienyl)(3-tert-butyl-2-phenoxy)titanium dichloride, methylene(cyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, methylene(cyclopentadienyl)(3-phenyl-2-phenoxy)titanium dichloride, methylene(cyclopentadienyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, methylene(cyclopentadienyl)(3-trimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, methylene(cyclopentadienyl)(3-tert-butyl-5-methoxy-2-phenoxy) titanium dichloride, methylene(cyclopentadienyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, methylene(methylcyclopentadienyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, methylene(methylcyclopentadienyl)(3-tert-butyl-2-phenoxy)titanium dichloride, methylene(methylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, methylene(methylcyclopentadienyl)(3-phenyl-2-phenoxy)titanium dichloride, methylene(methylcyclopentadienyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, methylene(methylcyclopentadienyl)(3-trimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, methylene(methylcyclopentadienyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, methylene(methylcyclopentadienyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, methylene(tert-butylcyclopentadienyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, methylene(tert-butylcyclopentadienyl)(3-tert-butyl-2-phenoxy)titanium dichloride, methylene(tert-butylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, methylene(tert-butylcyclopentadienyl)(3-phenyl-2-phenoxy)titanium dichloride, methylene(tert-butylcyclopentadienyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, methylene(tert-butylcyclopentadienyl)(3-trimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, methylene(tert-butylcyclopentadienyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, methylene(tert-butylcyclopentadienyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, methylene(tetramethylcyclopentadienyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, methylene(tetramethylcyclopentadienyl)(3-tert-butyl-2-phenoxy)titanium dichloride, methylene(tetramethylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, methylene(tetramethylcyclopentadienyl)(3-phenyl-2-phenoxy)titanium dichloride, methylene(tetramethylcyclopentadienyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, methylene(tetramethylcyclopentadienyl) (3-trimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, methylene(tetramethylcyclopentadienyl) (3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, methylene(tetramethylcyclopentadienyl) (3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, methylene(trimethylsilylcyclopentadienyl) (3,5-dimethyl-2-phenoxy)titanium dichloride, methylene(trimethylsilylcyclopentadienyl) (3-tert-butyl-2-phenoxy)titanium dichloride, methylene(trimethylsilylcyclopentadienyl) (3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, methylene(trimethylsilylcyclopentadienyl) (3-phenyl-2-phenoxy)titanium dichloride, methylene(trimethylsilylcyclopentadienyl) (3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, methylene(trimethylsilylcyclopentadienyl) (3-trimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, methylene(trimethylsilylcyclopentadienyl) (3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, methylene(trimethylsilylcyclopentadienyl) (3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, methylene(fluorenyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, methylene(fluorenyl)(3-tert-butyl-2-phenoxy)titanium dichloride, methylene(fluorenyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, methylene(fluorenyl)(3-phenyl-2-phenoxy)titanium dichloride, methylene(fluorenyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, methylene(fluorenyl)(3-trimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, methylene(fluorenyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, methylene(fluorenyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, isopropylidene(cyclopentadienyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, isopropylidene(cyclopentadienyl)(3-tert-butyl-2-phenoxy)titanium dichloride, isopropylidene(cyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, isopropylidene(cyclopentadienyl)(3-phenyl-2-phenoxy)titanium dichloride, isopropylidene(cyclopentadienyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, isopropylidene(cyclopentadienyl)(3-trimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, isopropylidene(cyclopentadienyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, isopropylidene(cyclopentadienyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, isopropylidene(methylcyclopentadienyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, isopropylidene(methylcyclopentadienyl)(3-tert-butyl-2-phenoxy)titanium dichloride, isopropylidene(methylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, isopropylidene(methylcyclopentadienyl)(3-phenyl-2-phenoxy)titanium dichloride, isopropylidene(methylcyclopentadienyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, isopropylidene(methylcyclopentadienyl)(3-trimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, isopropylidene(methylcyclopentadienyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, isopropylidene(methylcyclopentadienyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, isopropylidene(tert-butylcyclopentadienyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, isopropylidene(tert-butylcyclopentadienyl)(3-tert-butyl-2-phenoxy)titanium dichloride, isopropylidene(tert-butylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, isopropylidene(tert-butylcyclopentadienyl)(3-phenyl-2-phenoxy)titanium dichloride, isopropylidene(tert-butylcyclopentadienyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, isopropylidene(tert-butylcyclopentadienyl)(3-trimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, isopropylidene(tert-butylcyclopentadienyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, isopropylidene(tert-butylcyclopentadienyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, isopropylidene(tetramethylcyclopentadienyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, isopropylidene(tetramethylcyclopentadienyl)(3-tert-butyl-2-phenoxy)titanium dichloride, isopropylidene(tetramethylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, isopropylidene(tetramethylcyclopentadienyl)(3-phenyl-2-phenoxy)titanium dichloride, isopropylidene(tetramethylcyclopentadienyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, isopropylidene(tetramethylcyclopentadienyl)(3-trimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, isopropylidene(tetramethylcyclopentadienyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, isopropylidene(tetramethylcyclopentadienyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, isopropylidene(trimethylsilylcyclopentadienyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, isopropylidene(trimethylsilylcyclopentadienyl)(3-tert-butyl-2-phenoxy)titanium dichloride, isopropylidene(trimethylsilylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, isopropylidene(trimethylsilylcyclopentadienyl)(3-phenyl-2-phenoxy)titanium dichloride, isopropylidene(trimethylsilylcyclopentadienyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, isopropylidene(trimethylsilylcyclopentadienyl)(3-trimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, isopropylidene(trimethylsilylcyclopentadienyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, isopropylidene(trimethylsilylcyclopentadienyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, isopropylidene(fluorenyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, isopropylidene(fluorenyl)(3-tert-butyl-2-phenoxy)titanium dichloride, isopropylidene(fluorenyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, isopropylidene(fluorenyl)(3-phenyl-2-phenoxy)titanium dichloride, isopropylidene(fluorenyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, isopropylidene(fluorenyl)(3-trimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, isopropylidene(fluorenyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, isopropylidene(fluorenyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, diphenylmethylene(cyclopentadienyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, diphenylmethylene(cyclopentadienyl)(3-tert-butyl-2-phenoxy)titanium dichloride, diphenylmethylene(cyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, diphenylmethylene(cyclopentadienyl)(3-phenyl-2-phenoxy)titanium dichloride, diphenylmethylene(cyclopentadienyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, diphenylmethylene(cyclopentadienyl)(3-trimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, diphenylmethylene(cyclopentadienyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, diphenylmethylene(cyclopentadienyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, diphenylmethylene(methylcyclopentadienyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, diphenylmethylene(methylcyclopentadienyl)(3-tert-butyl-2-phenoxy)titanium dichloride, diphenylmethylene(methylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, diphenylmethylene(methylcyclopentadienyl)(3-phenyl-2-phenoxy)titanium dichloride, diphenylmethylene(methylcyclopentadienyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, diphenylmethylene(methylcyclopentadienyl)(3-trimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, diphenylmethylene(methylcyclopentadienyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, diphenylmethylene(methylcyclopentadienyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, diphenylmethylene(tert-butylcyclopentadienyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, diphenylmethylene(tert-butylcyclopentadienyl)(3-tert-butyl-2-phenoxy)titanium dichloride, diphenylmethylene(tert-butylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, diphenylmethylene(tert-butylcyclopentadienyl)(3-phenyl-2-phenoxy)titanium dichloride, diphenylmethylene(tert-butylcyclopentadienyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, diphenylmethylene(tert-butylcyclopentadienyl)(3-trimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, diphenylmethylene(tert-butylcyclopentadienyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, diphenylmethylene(tert-butylcyclopentadienyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, diphenylmethylene(tetramethylcyclopentadienyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, diphenylmethylene(tetramethylcyclopentadienyl)(3-tert-butyl-2-phenoxy)titanium dichloride, diphenylmethylene(tetramethylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, diphenylmethylene(tetramethylcyclopentadienyl)(3-phenyl-2-phenoxy)titanium dichloride, diphenylmethylene(tetramethylcyclopentadienyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, diphenylmethylene(tetramethylcyclopentadienyl)(3-trimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, diphenylmethylene(tetramethylcyclopentadienyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, diphenylmethylene(tetramethylcyclopentadienyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, diphenylmethylene(trimethylsilylcyclopentadienyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, diphenylmethylene(trimethylsilylcyclopentadienyl)(3-tert-butyl-2-phenoxy)titanium dichloride, diphenylmethylene(trimethylsilylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, diphenylmethylene(trimethylsilylcyclopentadienyl)(3-phenyl-2-phenoxy)titanium dichloride, diphenylmethylene(trimethylsilylcyclopentadienyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, diphenylmethylene(trimethylsilylcyclopentadienyl)(3-trimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, diphenylmethylene(trimethylsilylcyclopentadienyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, diphenylmethylene(trimethylsilylcyclopentadienyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, diphenylmethylene(fluorenyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, diphenylmethylene(fluorenyl)(3-tert-butyl-2-phenoxy)titanium dichloride, diphenylmethylene(fluorenyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, diphenylmethylene(fluorenyl)(3-phenyl-2-phenoxy)titanium dichloride, diphenylmethylene(fluorenyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, diphenylmethylene(fluorenyl)(3-trimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, diphenylmethylene(fluorenyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, diphenylmethylene(fluorenyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, dimethylsilylene(cyclopentadienyl)(2-phenoxy)titanium dichloride, dimethylsilylene(cyclopentadienyl)(3-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(cyclopentadienyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, dimethylsilylene(cyclopentadienyl)(3-tert-butyl-2-phenoxy)titanium dichloride, dimethylsilylene(cyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(cyclopentadienyl)(3,5-di-tert-butyl-2-phenoxy)titanium dichloride, dimethylsilylene(cyclopentadienyl)(5-methyl-3-phenyl-2-phenoxy)titanium dichloride, dimethylsilylene(cyclopentadienyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(cyclopentadienyl)(5-methyl-3-trimethylsilyl-2-phenoxy)titanium dichloride, dimethylsilylene(cyclopentadienyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, dimethylsilylene(cyclopentadienyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, dimethylsilylene(cyclopentadienyl)(3,5-diamyl-2-phenoxy)titanium dichloride, dimethylsilylene(methylcyclopentadienyl)(2-phenoxy)titanium dichloride, dimethylsilylene(methylcyclopentadienyl)(3-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(methylcyclopentadienyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, dimethylsilylene(methylcyclopentadienyl)(3-tert-butyl-2-phenoxy)titanium dichloride, dimethylsilylene(methylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(methylcyclopentadienyl)(3,5-di-tert-butyl-2-phenoxy)titanium dichloride, dimethylsilylene(methylcyclopentadienyl)(5-methyl-3-phenyl-2-phenoxy)titanium dichloride, dimethylsilylene(methylcyclopentadienyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(methylcyclopentadienyl)(5-methyl-3-trimethylsilyl-2-phenoxy)titanium dichloride, dimethylsilylene(methylcyclopentadienyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, dimethylsilylene(methylcyclopentadienyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, dimethylsilylene(methylcyclopentadienyl)(3,5-diamyl-2-phenoxy)titanium dichloride, dimethylsilylene(n-butylcyclopentadienyl)(2-phenoxy)titanium dichloride, dimethylsilylene(n-butylcyclopentadienyl)(3-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(n-butylcyclopentadienyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, dimethylsilylene(n-butylcyclopentadienyl)(3-tert-butyl-2-phenoxy)titanium dichloride, dimethylsilylene(n-butylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(n-butylcyclopentadienyl)(3,5-di-tert-butyl-2-phenoxy)titanium dichloride, dimethylsilylene(n-butylcyclopentadienyl)(5-methyl-3-phenyl-2-phenoxy)titanium dichloride, dimethylsilylene(n-butylcyclopentadienyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(n-butylcyclopentadienyl)(5-methyl-3-trimethylsilyl-2-phenoxy)titanium dichloride, dimethylsilylene(n-butylcyclopentadienyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, dimethylsilylene(n-butylcyclopentadienyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, dimethylsilylene(n-butylcyclopentadienyl)(3,5-diamyl-2-phenoxy)titanium dichloride, dimethylsilylene(tert-butylcyclopentadienyl)(2-phenoxy)titanium dichloride, dimethylsilylene(tert-butylcyclopentadienyl)(3-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(tert-butylcyclopentadienyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, dimethylsilylene(tert-butylcyclopentadienyl)(3-tert-butyl-2-phenoxy)titanium dichloride, dimethylsilylene(tert-butylcyclopentadienyl)(3-tert-butyl-5-m ethyl-2-phenoxy)titanium dichloride, dimethylsilylene(tert-butylcyclopentadienyl)(3,5-di-tert-butyl-2-phenoxy)titanium dichloride, dimethylsilylene(tert-butylcyclopentadienyl)(5-methyl-3-phenyl-2-phenoxy)titanium dichloride, dimethylsilylene(tert-butylcyclopentadienyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(tert-butylcyclopentadienyl)(5-methyl-3-trimethylsilyl-2-phenoxy)titanium dichloride, dimethylsilylene(tert-butylcyclopentadienyl)(3-tert-butyl-5-m ethoxy-2-phenoxy)titanium dichloride, dimethylsilylene(tert-butylcyclopentadienyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, dimethylsilylene(tert-butylcyclopentadienyl)(3,5-diamyl-2-phenoxy)titanium dichloride, dimethylsilylene(tetramethylcyclopentadienyl)(2-phenoxy)titanium dichloride, dimethylsilylene(tetramethylcyclopentadienyl)(3-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(tetramethylcyclopentadienyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, dimethylsilylene(tetramethylcyclopentadienyl)(3-tert-butyl-2-phenoxy)titanium dichloride, dimethylsilylene(tetramethylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(tetramethylcyclopentadienyl)(3,5-di-tert-butyl-2-phenoxy)titanium dichloride, dimethylsilylene(tetramethylcyclopentadienyl)(5-methyl-3-phenyl-2-phenoxy)titanium dichloride, dimethylsilylene(tetramethylcyclopentadienyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(tetramethylcyclopentadienyl)(5-methyl-3-trimethylsilyl-2-phenoxy)titanium dichloride, dimethylsilylene(tetramethylcyclopentadienyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, dimethylsilylene(tetramethylcyclopentadienyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, dimethylsilylene(tetramethylcyclopentadienyl)(3,5-diamyl-2-phenoxy)titanium dichloride, dimethylsilylene(trimethylsilylcyclopentadienyl)(2-phenoxy)titanium dichloride, dimethylsilylene(trimethylsilylcyclopentadienyl)(3-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(trimethylsilylcyclopentadienyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, dimethylsilylene(trimethylsilylcyclopentadienyl)(3-tert-butyl-2-phenoxy)titanium dichloride, dimethylsilylene(trimethylsilylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(trimethylsilylcyclopentadienyl)(3,5-di-tert-butyl-2-phenoxy)titanium dichloride, dimethylsilylene(trimethylsilylcyclopentadienyl)(5-methyl-3-phenyl-2-phenoxy)titanium dichloride, dimethylsilylene(trimethylsilylcyclopentadienyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(trimethylsilylcyclopentadienyl)(5-methyl-3-trimethylsilyl-2-phenoxy)titanium dichloride, dimethylsilylene(trimethylsilylcyclopentadienyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, dimethylsilylene(trimethylsilylcyclopentadienyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, dimethylsilylene(trimethylsilylcyclopentadienyl)(3,5-diamyl-2-phenoxy)titanium dichloride, dimethylsilylene(indenyl)(2-phenoxy)titanium dichloride, dimethylsilylene(indenyl)(3-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(indenyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, dimethylsilylene(indenyl)(3-tert-butyl-2-phenoxy)titanium dichloride, dimethylsilylene(indenyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(indenyl)(3,5-di-tert-butyl-2-phenoxy)titanium dichloride, dimethylsilylene(indenyl)(5-methyl-3-phenyl-2-phenoxy)titanium dichloride, dimethylsilylene(indenyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(indenyl)(5-methyl-3-trimethylsilyl-2-phenoxy)titanium dichloride, dimethylsilylene(indenyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, dimethylsilylene(indenyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, dimethylsilylene(indenyl)(3,5-diamyl-2-phenoxy)titanium dichloride, dimethylsilylene(fluorenyl)(2-phenoxy)titanium dichloride, dimethylsilylene(fluorenyl)(3-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(fluorenyl)(3,5-dimethyl-2-phenoxy)titanium dichloride, dimethylsilylene(fluorenyl)(3-tert-butyl-2-phenoxy)titanium dichloride, dimethylsilylene(fluorenyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(fluorenyl)(3,5-di-tert-butyl-2-phenoxy)titanium dichloride, dimethylsilylene(fluorenyl)(5-methyl-3-phenyl-2-phenoxy)titanium dichloride, dimethylsilylene(fluorenyl)(3-tert-butyldimethylsilyl-5-methyl-2-phenoxy)titanium dichloride, dimethylsilylene(fluorenyl)(5-methyl-3-trimethylsilyl-2-phenoxy)titanium dichloride, dimethylsilylene(fluorenyl)(3-tert-butyl-5-methoxy-2-phenoxy)titanium dichloride, dimethylsilylene(fluorenyl)(3-tert-butyl-5-chloro-2-phenoxy)titanium dichloride, dimethylsilylene(fluorenyl)(3,5-diamyl-2-phenoxy)titanium dichloride, and dimethylsilylene(tetramethylcyclopentadienyl)(1-naphthoxy-2-yl)titanium dichloride; compounds obtained by replacing the term “(2-phenoxy)” of those compounds with the term “(3-phenyl-2-phenoxy)”, “(3-trimethylsilyl-2-phenoxy)” or “(3-tert-butyldimethylsilyl-2-phenoxy)”; compounds obtained by replacing the term “dimethylsilylene” of those compounds with the term “diethylsilylene”, “diphenylsilylene” or “dimethoxysilylene”; and compounds obtained by replacing the term “dichloride” of those compounds with the term “difluoride”, “dibromide”, “diiodide”, “dimethyl”, “diethyl”, “diisopropyl”, “bis(dimethylamido)”, “bis(diethylamido)”, “dimethoxide”, “diethoxide”, “di-n-butoxide” or “diisopropoxide”.
[0084] Further examples of the transition metal compound represented by formula (4), wherein M 1 is a titanium atom, are (tert-butylamido)tetramethylcyclopentadienyl-1,2-ethanediyltitanium dichloride, (tert-butylamido)tetramethylcyclopentadienyl-1,2-ethanediyltitanium dimethyl, (tert-butylamido)tetramethylcyclopentadienyl-1,2-ethanediyltitanium dibenzyl, (methylamido)tetramethylcyclopentadienyl-1,2-ethanediyltitanium dichloride, (ethylamido)tetramethylcyclopentadienyl-1,2-ethanediyltitanium dichloride, (tert-butylamido)tetramethylcyclopentadienyl dimethylsilanetitanium dichloride, (tert-butylamido)tetramethylcyclopentadienyl dimethylsilanetitanium dimethyl, (tert-butylamido)tetramethylcyclopentadienyl dimethylsilanetitanium dibenzyl, (benzylamido)tetramethylcyclopentadienyl dimethylsilanetitanium dichloride, (phenylphosphido)tetramethylcyclopentadienyl dimethylsilanetitanium dibenzyl, (tert-butylamido)indenyl-1,2-ethanediyltitanium dichloride, (tert-butylamido)indenyl-1,2-ethanediyltitanium dimethyl, (tert-butylamido)tetrahydroindenyl-1,2-ethanediyl titanium dichloride, (tert-butylamido)tetrahydroindenyl-1,2-ethanediyl titanium dimethyl, (tert-butylamido)fluorenyl-1,2-ethanediyltitanium dichloride, (tert-butylamido)fluorenyl-1,2-ethanediyltitanium dimethyl, (tert-butylamido)indenyldimethylsilanetitanium dichloride, (tert-butylamido)indenyldimethylsilanetitanium dimethyl, (tert-butylamido)tetrahydroindenyldimethylsilane titanium dichloride, (tert-butylamido)tetrahydroindenyldimethylsilane titanium dimethyl, (tert-butylamido)fluorenyldimethylsilanetitanium dichloride, (tert-butylamido)fluorenyldimethylsilanetitanium dimethyl, (dimethylaminomethyl)tetramethylcyclopentadienyl titanium(III) dichloride, (dimethylaminoethyl)tetramethylcyclopentadienyl titanium(III) dichloride, (dimethylaminopropyl)tetramethylcyclopentadienyl titanium(III) dichloride, (N-pyrrolidinylethyl)tetramethylcyclopentadienyl titanium dichloride, (B-dimethylaminoborabenzene)cyclopentadienylzirconium dichloride, cyclopentadienyl(9-mesitylboraanthracenyl)zirconium dichloride, 2,2′-thiobis(4-methyl-6-tert-butylphenoxy)titanium dichloride, 2,2′-thiobis[4-methyl-6-(1-methylethyl)phenoxy]titanium dichloride, 2,2′-thiobis[4,6-dimethylphenoxy]titanium dichloride, 2,2′-methylenebis(4-methyl-6-tert-butylphenoxy)titanium dichloride, 2,2′-ethylenebis(4-methyl-6-tert-butylphenoxy)titanium dichloride, 2,2′-sulfinylbis(4-methyl-6-tert-butylphenoxy)titanium dichloride, 2,2′-(4,4′,6,6′-tetra-tert-butyl-1,1′-biphenoxy)titanium dichloride, 2,2′-thiobis[4-methyl-6-tert-butylphenoxy]titanium diisopropoxide, 2,2′-methylenebis(4-methyl-6-tert-butylphenoxy)titanium diisopropoxide, 2,2′-ethylenebis(4-methyl-6-tert-butylphenoxy)titanium diisopropoxide, 2,2′-sulfinylbis(4-methyl-6-tert-butylphenoxy)titanium diisopropoxide, (di-tert-butyl-1,3-propanediamido)titanium dichloride, (dicyclohexyl-1,3-propanediamido)titanium dichloride, [bis(trimethylsilyl)-1,3-propanediamido]titanium dichloride, [bis(tert-butyldimethylsilyl)-1,3-propanediamido]titanium dichloride, [bis(2,6-dimethylphenyl)-1,3-propanediamido]titanium dichloride, [bis(2,6-diisopropylphenyl)-1,3-propanediamido]titanium dichloride, [bis(2,6-di-tert-butylphenyl)-1,3-propanediamido]titanium dichloride, [bis(triisopropylsilyl)naphthalenediamido]titanium dichloride, [bis(trimethylsilyl)naphthalenediamido]titanium dichloride, [bis(tert-butyldimethylsilyl)naphthalenediamido]titanium dichloride, [bis(tert-butyldimethylsilyl)naphthalenediamido]titanium dibromide, [hydrotris(3,5-dimethylpyrazolyl)borate]titanium trichloride, [hydrotris(3,5-dimethylpyrazolyl)borate]titanium tribromide, [hydrotris(3,5-dimethylpyrazolyl)borate]titanium triiodide, [hydrotris(3,5-diethylpyrazolyl)borate]titanium trichloride, [hydrotris(3,5-diethylpyrazolyl)borate]titanium tribromide, [hydrotris(3,5-diethylpyrazolyl)borate]titanium triiodide, [hydrotris(3,5-di-tert-butylpyrazolyl)borate]titanium trichloride, [hydrotris(3,5-di-tert-butylpyrazolyl)borate]titanium tribromide, [hydrotris(3,5-di-tert-butylpyrazolyl)borate]titanium triiodide, [tris(3,5-dimethylpyrazolyl)methyl]titanium trichloride, [tris(3,5-dimethylpyrazolyl)methyl]titanium tribromide, [tris(3,5-dimethylpyrazolyl)methyl]titanium triiodide, [tris(3,5-diethylpyrazolyl)methyl]titanium trichloride, [tris(3,5-diethylpyrazolyl)methyl]titanium tribromide, [tris(3,5-diethylpyrazolyl)methyl]titanium triiodide, [tris(3,5-di-tert-butylpyrazolyl)methyl]titanium trichloride, [tris(3,5-di-tert-butylpyrazolyl)methyl]titanium tribromide, [tris(3,5-di-tert-butylpyrazolyl)methyl]titanium triiodide, μ-oxobis[isopropylidene(cyclopentadienyl)(2-phenoxy)titanium chloride], μ-oxobis[isopropylidene (cyclopentadienyl)(2-phenoxy)titanium methoxide], μ-oxobis[isopropylidene(cyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium chloride], μ-oxobis[isopropylidene(cyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium methoxide], μ-oxobis[isopropylidene (methylcyclopentadienyl)(2-phenoxy)titanium chloride], μ-oxobis[isopropylidene(methylcyclopentadienyl)(2-phenoxy)titanium methoxide], μ-oxobis[isopropylidene (methylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium chloride], μ-oxobis[isopropylidene (methylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium methoxide], μ-oxobis[isopropylidene (tetramethylcyclopentadienyl)(2-phenoxy)titanium chloride], μ-oxobis[isopropylidene(tetramethylcyclopentadienyl) (2-phenoxy)titanium methoxide], 1-oxobis[isopropylidene (tetramethylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium chloride], 1-oxobis[isopropylidene (tetramethylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium methoxide], 1-oxobis[dimethylsilylene (cyclopentadienyl)(2-phenoxy)titanium chloride], μ-oxobis[dimethylsilylene(cyclopentadienyl)(2-phenoxy)titanium methoxide], μ-oxobis[dimethylsilylene (cyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium chloride], μ-oxobis[dimethylsilylene(cyclopentadienyl) (3-tert-butyl-5-methyl-2-phenoxy)titanium methoxide], μ-oxobis[dimethylsilylene(methylcyclopentadienyl)(2-phenoxy)titanium chloride], μ-oxobis[dimethylsilylene (methylcyclopentadienyl)(2-phenoxy)titanium methoxide], μ-oxobis[dimethylsilylene(methylcyclopentadienyl) (3-tert-butyl-5-methyl-2-phenoxy)titanium chloride], μ-oxobis[dimethylsilylene(methylcyclopentadienyl) (3-tert-butyl-5-methyl-2-phenoxy)titanium methoxide], μ-oxobis[dimethylsilylene(tetramethylcyclopentadienyl) (2-phenoxy)titanium chloride], 1-oxobis[dimethylsilylene (tetramethylcyclopentadienyl)(2-phenoxy)titanium methoxide], μ-oxobis[dimethylsilylene(tetramethylcyclopentadienyl) (3-tert-butyl-5-methyl-2-phenoxy)titanium chloride], μ-oxobis[dimethylsilylene(tetramethylcyclopentadienyl) (3-tert-butyl-5-methyl-2-phenoxy)titanium methoxide], di-μ-oxobis[isopropylidene(cyclopentadienyl)(2-phenoxy)titanium], di-μ-oxobis[isopropylidene(cyclopentadienyl) (3-tert-butyl-5-methyl-2-phenoxy)titanium], di-μ-oxobis[isopropylidene(methylcyclopentadienyl)(2-phenoxy)titanium], di-μ-oxobis[isopropylidene(methylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium], di-μ-oxobis[isopropylidene(tetramethylcyclopentadienyl)(2-phenoxy)titanium], di-μ-oxobis[isopropylidene (tetramethylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium], di-μ-oxobis[dimethylsilylene (cyclopentadienyl)(2-phenoxy)titanium], di-μ-oxobis[dimethylsilylene(cyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium], di-μ-oxobis[dimethylsilylene (methylcyclopentadienyl)(2-phenoxy)titanium], di-1-oxobis[dimethylsilylene(methylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium], di-μ-oxobis[dimethylsilylene (tetramethylcyclopentadienyl)(2-phenoxy)titanium], and di-μ-oxobis[dimethylsilylene(tetramethylcyclopentadienyl) (3-tert-butyl-5-methyl-2-phenoxy)titanium].
[0085] Examples of the transition metal compound represented by formula (4), wherein M 1 is a zirconium atom or a hafnium atom, are compounds obtained by replacing the term “titanium” of the above-exemplified titanium compounds with the term “zirconium” or “hafnium”.
[0086] Examples of the transition metal compound represented by formula (4), wherein M 1 is a vanadium atom, are vanadium acetylacetonate, vanadium tetrachloride and vanadium oxy trichloride.
[0087] An example of the transition metal compound represented by formula (4), wherein M 1 is a samarium atom, is bis(pentamethylcyclopentadienyl)samarium methyltetrahydrofuran.
[0088] An example of the transition metal compound represented by formula (4), wherein M 1 is an ytterbium atom, is bis(pentamethylcyclopentadienyl)ytterbium methyltetrahydrofuran.
[0089] Examples of the transition metal compound represented by formula (4), wherein M 1 is a palladium atom, are 2,2′-methylenebis[(4R)-4-phenyl-5,5′-dimethyloxazoline]palladium dichloride, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-dimethyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-diethyloxazoline]palladium dichloride, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-diethyloxazoline]palladium dibromide,2,2′-methylenebis[(4R)-4-phenyl-5,5′-di-n-propyloxazoline]palladium dichloride, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-di-n-propyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-diisopropyloxazoline]palladium dichloride, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-diisopropyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-dicyclohexyloxazoline]palladium dichloride, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-dicyclohexyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-dimethoxyoxazoline]palladium dichloride, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-dimethoxyoxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-diethoxyoxazoline]palladium dichloride, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-diethoxyoxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-diphenyloxazoline]palladium dichloride, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-diphenyloxazoline]palladium dibromide, methylenebis[(4R)-4-methyl-5,5′-di-(2-methylphenyl)oxazoline]palladium dibromide, methylenebis[(4R)-4-methyl-5,5′-di-(3-methylphenyl)oxazoline]palladium dibromide, methylenebis[(4R)-4-methyl 5-5,5′-di-(4-methylphenyl)oxazoline]palladium dibromide, methylenebis[(4R)-4-methyl-5,5′-di-(2-methoxyphenyl)oxazoline]palladium dibromide, methylenebis[(4R)-4-methyl-5,5′-di-(3-methoxyphenyl)oxazoline]palladium dibromide, methylenebis[(4R)-4-methyl-5,5′-di-(4-methoxyphenyl)oxazoline]palladium dibromide, methylenebis[spiro{(4R)-4-methyloxazoline-5,1′-cyclobutane}]palladium dibromide, methylenebis[spiro{(4R)-4-methyloxazoline-5,1′-cyclopentane}]palladium dibromide, methylenebis[spiro{(4R)-4-methyloxazoline-5,1′-cyclohexane}]palladium dibromide, methylenebis[spiro{(4R)-4-methyloxazoline-5,1′-cycloheptane}]palladium dibromide, 2,2′-methylenebis[(4R)-4-isopropyl-5,5′-dimethyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-isopropyl-5,5′-diethyloxazoline]palladium dibromide, 2,2′-methylenebis [(4R)-4-isopropyl-5,5′-di-n-propyloxazoline]palladium dibromide, methylenebis[(4R)-4-isopropyl-5,5′-diisopropyloxazoline]palladium dibromide, 2,2′-methylenebis [(4R)-4-isopropyl-5,5′-dicyclohexyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-isopropyl-5,5′-diphenyloxazoline]palladium dibromide, 2,2′-methylenebis [(4R)-4-isopropyl-5,5′-di-(2-methylphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-isopropyl-5,5′-di-(3-methylphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-isopropyl-5,5′-di-(4-methylphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-isopropyl-5,5′-di-(2-methoxyphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-isopropyl-5,5′-di-(3-methoxyphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-isopropyl-5,5′-di-(4-methoxyphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[spiro{(4R)-4-isopropyloxazoline-5,1′-cyclobutane}]palladium dibromide, 2,2′-methylenebis[spiro{(4R)-4-isopropyloxazoline-5,1′-cyclopentane}]palladium dibromide, 2,2′-methylenebis[spiro{(4R)-4-isopropyloxazoline-5,1′-cyclohexane}]palladium dibromide, 2,2′-methylenebis[spiro{(4R)-4-isopropyloxazoline-5,1′-cycloheptane}]palladium dibromide, 2,2′-methylenebis[(4R)-4-isobutyl-5,5′-dimethyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-isobutyl-5,5′-diethyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-isobutyl-5,5′-di-n-propyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-isobutyl-5,5′-diisopropyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-isobutyl-5,5′-dicyclohexyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-isobutyl-5,5′-diphenyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-isobutyl-5,5′-di-(2-methylphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-isobutyl-5,5′-di-(3-methylphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-isobutyl-5,5′-di-(4-methylphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-isobutyl-5,5′-di-(2-methoxyphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-isobutyl-5,5′-di-(3-methoxyphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-isobutyl-5,5′-di-(4-methoxyphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[spiro{(4R)-4-isobutyloxazoline-5,1′-cyclobutane}]palladium dibromide, 2,2′-methylenebis[spiro{(4R)-4-isobutyloxazoline-5,1′-cyclopentane}]palladium dibromide, 2,2′-methylenebis[spiro{(4R)-4-isobutyloxazoline-5,1′-cyclohexane}]palladium dibromide, 2,2′-methylenebis[spiro{(4R)-4-isobutyloxazoline-5,1′-cycloheptane}]palladium dibromide, 2,2′-methylenebis[(4R)-4-tert-butyl-5,5′-dimethyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-tert-butyl-5,5′-diethyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-tert-butyl-5,5′-di-n-propyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-tert-butyl-5,5′-diisopropyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-tert-butyl-5,5′-diphenyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-tert-butyl-5,5′-dicyclohexyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-tert-butyl-5,5′-di-(2-methylphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-tert-butyl-5,5′-di-(3-methylphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-tert-butyl-5,5′-di-(4-methylphenyl)oxazoline]palladium dibromide, 2′-methylenebis[(4R)-4-tert-butyl-5,5′-di-(2-methoxyphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-tert-butyl-5,5′-di-(3-methoxyphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-tert-butyl-5,5′-di-(4-methoxyphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[spiro{(4R)-4-tert-butyloxazoline-5,1′-cyclobutane}]palladium dibromide, 2,2′-methylenebis[spiro{(4R)-4-tert-butyloxazoline-5,1′-cyclopentane}]palladium dibromide, 2,2′-methylenebis[spiro{(4R)-4-tert-butyloxazoline-5,1′-cyclohexane}]palladium dibromide, 2,2′-methylenebis[spiro{(4R)-4-tert-butyloxazoline-5,1′-cycloheptane}]palladium dibromide, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-dimethyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-diethyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-di-n-propyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-diisopropyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-dicyclohexyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-diphenyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-di-(2-methylphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-di-(3-methylphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-di-(4-methylphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-di-(2-methoxyphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-di-(3-methoxyphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-phenyl-5,5′-di-(4-methoxyphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[spiro{(4R)-4-phenyloxazoline-5,1′-cyclobutane}]palladium dibromide, 2,2′-methylenebis[spiro{(4R)-4-phenyloxazoline-5,1′-cyclopentane}]palladium dibromide, 2,2′-methylenebis[spiro{(4R)-4-phenyloxazoline-5,1′-cyclohexane}]palladium dibromide, 2,2′-methylenebis[spiro{(4R)-4-phenyloxazoline-5,1′-cycloheptane}]palladium dibromide, 2,2′-methylenebis[(4R)-4-benzyl-5,5′-dimethyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-benzyl-5,5′-diethyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-benzyl-5,5′-di-n-propyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-benzyl-5,5′-diisopropyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-benzyl-5,5′-dicyclohexyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-benzyl-5,5′-diphenyloxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-benzyl-5,5′-di-(2-methylphenyl)oxazoline]palladium dibromide, 2′-methylenebis[(4R)-4-benzyl-5,5′-di-(3-methylphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-benzyl-5,5′-di-(4-methylphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-benzyl-5,5′-di-(2-methoxyphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-benzyl-5,5′-di-(3-methoxyphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[(4R)-4-benzyl-5,5′-di-(4-methoxyphenyl)oxazoline]palladium dibromide, 2,2′-methylenebis[spiro{(4R)-4-benzyloxazoline-5,1′-cyclobutane}]palladium dibromide, 2,2′-methylenebis[spiro{(4R)-4-benzyloxazoline-5,1′-cyclopentane}]palladium dibromide, 2,2′-methylenebis[spiro{(4R)-4-benzyloxazoline-5,1′-cyclohexane}]palladium dibromide, and 2,2′-methylenebis[spiro{(4R)-4-benzyloxazoline-5,1′-cycloheptane}]palladium dibromide; compounds obtained by replacing the term “(4R)” of the above-exemplified compounds with the term “(4S)”; and antipodes and diasteromers of the above-exemplified compounds.
[0090] Further examples of the transition metal compound represented by formula (4), wherein M 1 is a palladium atom, are [hydrotris(3,5-dimethylpyrazolyl)borate]palladium chloride, [hydrotris(3,5-dimethylpyrazolyl)borate]palladium bromide, [hydrotris(3,5-dimethylpyrazolyl)borate]palladium iodide, [hydrotris(3,5-dimethylpyrazolyl)borate]palladium methyl, [hydrotris(3,5-dimethylpyrazolyl)borate]palladium ethyl, [hydrotris(3,5-dimethylpyrazolyl)borate]palladium allyl, [hydrotris(3,5-dimethylpyrazolyl)borate]palladium methallyl, [hydrotris(3,5-diethylpyrazolyl)borate]palladium chloride, [hydrotris(3,5-diethylpyrazolyl)borate]palladium bromide, [hydrotris(3,5-diethylpyrazolyl)borate]palladium iodide, [hydrotris(3,5-diethylpyrazolyl)borate]palladium methyl, [hydrotris(3,5-diethylpyrazolyl)borate]palladium ethyl, [hydrotris(3,5-diethylpyrazolyl)borate]palladium allyl, [hydrotris(3,5-diethylpyrazolyl)borate]palladium methallyl, [hydrotris(3,5-di-tert-butylpyrazolyl)borate]palladium chloride, [hydrotris(3,5-di-tert-butylpyrazolyl)borate]palladium bromide, [hydrotris(3,5-di-tert-butylpyrazolyl)borate]palladium iodide, [hydrotris(3,5-di-tert-butylpyrazolyl)borate]palladium methyl, [hydrotris(3,5-di-tert-butylpyrazolyl)borate]palladium ethyl, [hydrotris(3,5-di-tert-butylpyrazolyl)borate]palladium allyl, [hydrotris(3,5-di-tert-butylpyrazolyl)borate]palladium methallyl, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(aniline-κN)]palladium, chloro(methyl)[N,N′-(ethane-1,2-diylidene)bis(2-methylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2-ethylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2-n-propylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2-isopropylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2-n-butylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2-isobutylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2-n-hexylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(4-methylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2,6-dimethylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2,6-diethylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2,6-di-n-propylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2,6-diisopropylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2,6-di-n-butylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2,6-diisobutylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2,6-di-n-hexylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2-methyl-6-ethylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2-methyl-6-n-propylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2-methyl-6-isopropylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2-methyl-6-butylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2-ethyl-6-n-propylaniline-κN)]palladium, chloro(methyl)[N,N′-(ethane-1,2-diylidene)bis(2-ethyl-6-isopropylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2-ethyl-6-n-butylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2-n-propyl-6-isopropylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2-n-propyl-6-n-butylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2-isopropyl-6-n-butylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis(2,4,6-trimethylaniline-κN)]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis{2,4-dimethyl-6-(2-methylphenyl)aniline-N}]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis{2,4-dimethyl-6-(2-ethylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis{2,4-dimethyl-6-(2-n-propylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis{2,4-dimethyl-6-(2-isopropylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis{2,4-dimethyl-6-(2,6-dimethylphenyl)aniline-N}]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis{2,4-dimethyl-6-(2,6-diethylphenyl)aniline-N}]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis{2,4-dimethyl-6-(2,6-di-n-propylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis{2,4-dimethyl-6-(2,6-diisopropylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis{2,4-dimethyl-6-(2-methyl-6-ethylphenyl)aniline-N}]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis{2,4-dimethyl-6-(2-methyl-6-n-propylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis{2,4-dimethyl-6-(2-methyl-6-isopropylphenyl)aniline-N}]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis{2,4-dimethyl-6-(2-ethyl-6-n-propylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis{2,4-dimethyl-6-(2-ethyl-6-isopropylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(ethane-1,2-diylidene)bis{2,4-dimethyl-6-(1-naphthyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis(aniline-κN)]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis(2-methylaniline-κN)]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis(2-ethylaniline-κN)]palladium, chloro(methyl)[N,N′-(butane-2,3-diylidene)bis (2-n-propylaniline-κN)]palladium, chloro(methyl)[N,N′-(butane-2,3-diylidene)bis (2-isopropylaniline-κN)]palladium, chloro(methyl)[N,N′-(butane-2,3-diylidene)bis (2-n-butylaniline-κN)]palladium, chloro(methyl)[N,N′-(butane-2,3-diylidene)bis (2-isobutylaniline-κN)]palladium, chloro(methyl)[N,N′-(butane-2,3-diylidene)bis (2-n-hexylaniline-κN)]palladium, chloro(methyl)[N,N′-(butane-2,3-diylidene)bis (4-methylaniline-κN)]palladium, chloro(methyl)[N,N′-(butane-2,3-diylidene)bis (2,6-dimethylaniline-κN)]palladium, chloro(methyl)[N,N′-(butane-2,3-diylidene)bis (2,6-diethylaniline-κN)]palladium, chloro(methyl)[N,N′-(butane-2,3-diylidene)bis (2,6-di-n-propylaniline-κN)]palladium, chloro(methyl)[N,N′-(butane-2,3-diylidene)bis (2,6-diisopropylaniline-κN)]palladium, chloro(methyl)[N,N′-(butane-2,3-diylidene)bis (2,6-di-n-butylaniline-κN)]palladium, chloro(methyl)[N,N′-(butane-2,3-diylidene)bis (2,6-diisobutylaniline-κN)]palladium, chloro(methyl)[N,N′-(butane-2,3-diylidene)bis (2,6-di-n-hexylaniline-κN)]palladium, chloro(methyl)[N,N′-(butane-2,3-diylidene)bis (2-methyl-6-ethylaniline-κN)]palladium, chloro(methyl)[N,N′-(butane-2,3-diylidene)bis (2-methyl-6-n-propylaniline-κN)]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis(2-methyl-6-isopropylaniline-κN)]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis(2-methyl-6-butylaniline-κN)]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis(2-ethyl-6-n-propylaniline-κN)]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis(2-ethyl-6-isopropylaniline-κN)]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis(2-ethyl-6-n-butylaniline-κN)]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis(2-n-propyl-6-isopropylaniline-κN)]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis(2-n-propyl-6-n-butylaniline-κN)]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis(2-isopropyl-6-n-butylaniline-κN)]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis(2,4,6-trimethylaniline-κN)]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis{2,4-dimethyl-6-(2-methylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis{2,4-dimethyl-6-(2-ethylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis{2,4-dimethyl-6-(2-n-propylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis{2,4-dimethyl-6-(2-isopropylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis{2,4-dimethyl-6-(2,6-dimethylphenyl)aniline-N}]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis{2,4-dimethyl-6-(2,6-diethylphenyl)aniline-N}]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis{2,4-dimethyl-6-(2,6-di-n-propylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis{2,4-dimethyl-6-(2,6-diisopropylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis{2,4-dimethyl-6-(2-methyl-6-ethylphenyl)aniline-N}]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis{2,4-dimethyl-6-(2-methyl-6-n-propylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis{2,4-dimethyl-6-(2-methyl-6-isopropylphenyl)aniline-N}]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis{2,4-dimethyl-6-(2-ethyl-6-n-propylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis{2,4-dimethyl-6-(2-ethyl-6-isopropylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(butane-2,3-diylidene)bis{2,4-dimethyl-6-(1-naphthyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(aniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2-methylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2-ethylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2-n-propylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2-isopropylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2-n-butylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2-isobutylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2-n-hexylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(4-methylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2,6-dimethylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2,6-diethylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2,6-di-n-propylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2,6-diisopropylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2,6-di-n-butylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2,6-diisobutylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2,6-di-n-hexylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2,6-dichloroaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2-methyl-6-ethylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2-methyl-6-n-propylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2-methyl-6-isopropylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2-methyl-6-butylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2-ethyl-6-n-propylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2-ethyl-6-isopropylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2-ethyl-6-n-butylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2-n-propyl-6-isopropylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2-n-propyl-6-n-butylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2-isopropyl-6-n-butylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis(2,4,6-trimethylaniline-κN)]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis{2,4-dimethyl-6-(2-methylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis{2,4-dimethyl-6-(2-ethylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis{2,4-dimethyl-6-(2-n-propylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis{2,4-dimethyl-6-(2-isopropylphenyl)aniline-κN}]palladium, chloro(methyl) [N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis{2,4-dimethyl-6-(2,6-dimethylphenyl)aniline-N}]palladium, chloro(methyl)[N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis{2,4-dimethyl-6-(2,6-diethylphenyl)aniline-κN}]palladium, chloro(methyl)[N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis{2,4-dimethyl-6-(2,6-di-n-propylphenyl)aniline-κN}]palladium, chloro(methyl)[N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis{2,4-dimethyl-6-(2,6-diisopropylphenyl)aniline-κN}]palladium, chloro(methyl)[N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis{2,4-dimethyl-6-(2-methyl-6-ethylphenyl)aniline-κN}]palladium, chloro(methyl)[N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis{2,4-dimethyl-6-(2-methyl-6-n-propylphenyl)aniline-κN}]palladium, chloro(methyl)[N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis{2,4-dimethyl-6-(2-methyl-6-isopropylphenyl)aniline-κN}]palladium, chloro(methyl)[N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis{2,4-dimethyl-6-(2-ethyl-6-n-propylphenyl)aniline-κN}]palladium, chloro(methyl)[N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis{2,4-dimethyl-6-(2-ethyl-6-isopropylphenyl)aniline-κN}]palladium, and chloro(methyl)[N,N′-(1,2-dihydroacenaphthylene-1,2-diylidene)bis{2,4-dimethyl-6-(1-naphthyl)aniline-N}]palladium.
[0091] Examples of the transition metal compound represented by formula (4), wherein M 1 is a nickel atom, a cobalt atom, a rhodium atom or a ruthenium atom, are compounds obtained by replacing the term “palladium” of the above-exemplified palladium compounds with the term “nickel”, “cobalt”, “rhodium” or “ruthenium”.
[0092] Examples of the transition metal compound represented by formula (4), wherein M is an iron atom, are 2,6-bis-[1-(2,6-dimethylphenylimino)ethyl]pyridineiron dichloride, 2,6-bis-[1-(2,6-diisopropylphenylimino)ethyl]pyridineiron dichloride, 2,6-bis-[1-(2,6-dichlorophenylimino)ethyl]pyridineiron dichloride, 2,6-bis-[1-(2-methyl-6-isopropylphenylimino)ethyl]pyridineiron dichloride, 2,6-bis-[1-(2-tert-butylphenylimino)ethyl]pyridineiron dichloride, [hydrotris(3,5-dimethylpyrazolyl)borate]iron chloride, [hydrotris(3,5-dimethylpyrazolyl)borate]iron bromide, [hydrotris(3,5-dimethylpyrazolyl)borate]iron iodide, [hydrotris(3,5-dimethylpyrazolyl)borate]iron methyl, [hydrotris(3,5-dimethylpyrazolyl)borate]iron ethyl, [hydrotris(3,5-dimethylpyrazolyl)borate]iron allyl, [hydrotris(3,5-dimethylpyrazolyl)borate]iron methallyl, [hydrotris(3,5-diethylpyrazolyl)borate]iron chloride, [hydrotris(3,5-diethylpyrazolyl)borate]iron bromide, [hydrotris(3,5-diethylpyrazolyl)borate]iron iodide, [hydrotris(3,5-diethylpyrazolyl)borate]iron methyl, [hydrotris(3,5-diethylpyrazolyl)borate]iron ethyl, [hydrotris(3,5-diethylpyrazolyl)borate]iron allyl, [hydrotris(3,5-diethylpyrazolyl)borate]iron methallyl, [hydrotris(3,5-di-tert-butylpyrazolyl)borate]iron chloride, [hydrotris(3,5-di-tert-butylpyrazolyl)borate]iron bromide, [hydrotris(3,5-di-tert-butylpyrazolyl)borate]iron iodide, [hydrotris(3,5-di-tert-butylpyrazolyl)borate]iron methyl, [hydrotris(3,5-di-tert-butylpyrazolyl)borate]iron ethyl, [hydrotris(3,5-di-tert-butylpyrazolyl)borate]iron allyl, and [hydrotris(3,5-di-tert-butylpyrazolyl)borate]iron methallyl.
[0093] Examples of the transition metal compound represented by the formula (4), wherein M 1 is a cobalt atom or a nickel atom, are compounds obtained by replacing the term “iron” of the above-exemplified iron compounds with the term “cobalt” or “nickel”.
[0094] The above-mentioned transition metal compounds may be used in combination of two or more thereof.
[0095] The transition metal compound is preferably a compound represented by the following formula [I]:
[0000]
[0000] wherein M 1 is a transition metal atom of Group 10 of the Periodic Table of the elements; R 3 and R 4 are independently of each other a hydrogen atom, a halogen atom, an alkyl group, an aralkyl group, an aryl group, a silyl group, a siloxy group, an alkoxy group, an aralkyloxy group or an aryloxy group; R 5 and R 6 are independently of each other a hydrocarbyl group having 1 to 30 carbon atoms; and R 7 and R 8 are independently of each other a hydrogen atom or a hydrocarbyl group having 1 to 20 carbon atoms, and R 7 and R 8 may be linked with each other to form a ring.
[0096] M 2 is preferably a nickel atom or a palladium atom, and further preferably a palladium atom.
[0097] Examples of the halogen atom of R 3 and R 4 are a fluorine atom, a chlorine atom, a bromine atom, and an iodine atom. Among them, preferred is a chlorine atom or a bromine atom.
[0098] Examples of the alkyl group of R 3 and R 4 are linear alkyl groups such as a methyl group, an ethyl group, and a n-butyl group; branched alkyl groups such as an isopropyl group, an isobutyl group, a tert-butyl group, and a neopentyl group; and cyclic alkyl groups such as a cyclohexyl group and a cyclooctyl group. Among them, preferred is a linear alkyl group, more preferred is a linear alkyl group having 1 to 12 carbon atoms, and further preferred is a methyl group.
[0099] Examples of the aralky group of R 3 and R 4 are a benzyl group and a phenethyl group. Among them, preferred is a benzyl group.
[0100] Examples of the aryl group of R 3 and R 4 are a phenyl group, a naphthyl group, a 4-tolyl group, a mesityl group, and a biphenyl group. Among them, preferred is a phenyl group, a 4-tolyl group or a mesityl group.
[0101] Examples of the silyl group of R 3 and R 4 are monosubstituted silyl group such as a methylsilyl group, an ethylsilyl group, and a phenylsilyl group; disubstituted silyl groups such as a dimethylsilyl group, a diethylsilyl group, and a diphenylsilyl group; and trisubstituted silyl groups such as a trimethylsilyl group, a trimethoxysilyl group, a dimethylmethoxysilyl group, a methyldimethoxysilyl group, a triethylsilyl group, a triethoxysilyl group, a tri-n-propylsilyl group, a triisopropylsilyl group, a tri-n-butylsilyl group, a tri-sec-butylsilyl group, a tert-butyldimethylsilyl group, a triisobutylsilyl group, a tert-butyldiphenylsilyl group, a cyclohexyldimethylsilyl group, a tricyclohexylsilyl group, and a triphenylsilyl group. Among them, preferred are trisubstituted silyl groups, and more preferred is a trimethylsilyl group, a triethylsilyl group, a triphenylsilyl group, a tert-butyldimethylsilyl group, a tert-butyldiphenylsilyl group, a cyclohexyldimethylsilyl group, or a triisopropylsilyl group.
[0102] Examples of the siloxy group of R 3 and R 4 are a trimethylsiloxy group, a trimethoxysiloxy group, a dimethylmethoxysiloxy group, a methyldimethoxysiloxy group, a triethylsiloxy group, a triethoxysiloxy group, a tri-n-propylsiloxy group, a triisopropylsiloxy group, a tri-n-butylsiloxy group, a tri-sec-butylsiloxy group, a tert-butyldimethylsiloxy group, a triisobutylsiloxy group, a tert-butyldiphenylsiloxy group, a cyclohexyldimethylsiloxy group, a tricyclohexylsiloxy group, and a triphenylsiloxy group. Among them, preferred is a trimethylsiloxy group, a triethylsiloxy group, a triphenylsiloxy group, a tert-butyldimethylsiloxy group, a tert-butyldiphenylsiloxy group, a cyclohexyldimethylsiloxy group,
[0103] Examples of the alkoxy group of R 3 and R 4 are a methoxy group, an ethoxy group, a n-propoxy group, an isopropoxy group, a n-butoxy group, a sec-butoxy group, a tert-butoxy group, a n-pentyloxy group, a neopentyloxy group, a n-hexyloxy group, a n-octyloxy group, a n-dodecyloxy group, a n-pentadecyloxy group, and a n-eicosyloxy group. Among them, preferred is an alkoxy group having 1 to 20 carbon atoms, and more preferred is a methoxy group, an ethoxy group, an isopropoxy group, or a tert-butoxy group.
[0104] Examples of the aralkyloxy group of R 3 and R 4 are a benzyloxy group, a (2-methylphenyl)methoxy group, a (3-methylphenyl)methoxy group, a (4-methylphenyl)methoxy group, a (2,3-dimethylphenyl)methoxy group, a (2,4-dimethylphenyl)methoxy group, a (2,5-dimethylphenyl)methoxy group, a (2,6-dimethylphenyl)methoxy group, a (3,4-dimethylphenyl)methoxy group, a (3,5-dimethylphenyl)methoxy group, a (2,3,4-trimethylphenyl)methoxy group, a (2,3,5-trimethylphenyl)methoxy group, a (2,3,6-trimethylphenyl)methoxy group, a (2,4,5-trimethylphenyl)methoxy group, a (2,4,6-trimethylphenyl)methoxy group, a (3,4,5-trimethylphenyl)methoxy group, a (2,3,4,5-tetramethylphenyl)methoxy group, a (2,3,4,6-tetramethylphenyl)methoxy group, a (2,3,5,6-tetramethylphenyl)methoxy group, a (pentamethylphenyl)methoxy group, an (ethylphenyl)methoxy group, a (n-propylphenyl)methoxy group, an (isopropylphenyl)methoxy group, a (n-butylphenyl)methoxy group, a (sec-butylphenyl)methoxy group, a (tert-butylphenyl)methoxy group, a (n-hexylphenyl)methoxy group, a (n-octylphenyl)methoxy group, a (n-decylphenyl)methoxy group, a naphthylmethoxy group, and an anthrathenylmethoxy group. Among them, preferred is a benzyloxy group.
[0105] Examples of the aryloxy group of R 3 and R 4 are a phenoxy group, a 2-methylphenoxy group, a 3-methylphenoxy group, a 4-methylphenoxy group, a 2,3-dimethylphenoxy group, a 2,4-dimethylphenoxy group, a 2,5-dimethylphenoxy group, a 2,6-dimethylphenoxy group, a 3,4-dimethylphenoxy group, a 3,5-dimethylphenoxy group, a 2-tert-butyl-3-methylphenoxy group, a 2-tert-butyl-4-methylphenoxy group, a 2-tert-butyl-5-methylphenoxy group, a 2-tert-butyl-6-methylphenoxy group, a 2,3,4-trimethylphenoxy group, a 2,3,5-trimethylphenoxy group, a 2,3,6-trimethylphenoxy group, a 2,4,5-trimethylphenoxy group, a 2,4,6-trimethylphenoxy group, a 2-tert-butyl-3,4-dimethylphenoxy group, a 2-tert-butyl-3,5-dimethylphenoxy group, a 2-tert-butyl-3,6-dimethylphenoxy group, a 2,6-di-tert-butyl-3-methylphenoxy group, a 2-tert-butyl-4,5-dimethylphenoxy group, a 2,6-di-tert-butyl-4-methylphenoxy group, a 3,4,5-trimethylphenoxy group, a 2,3,4,5-tetramethylphenoxy group, a 2-tert-butyl-3,4,5-trimethylphenoxy group, a 2,3,4,6-tetramethylphenoxy group, a 2-tert-butyl-3,4,6-trimethylphenoxy group, a 2,6-di-tert-butyl-3,4-dimethylphenoxy group, a 2,3,5,6-tetramethylphenoxy group, a 2-tert-butyl-3,5,6-trimethylphenoxy group, a 2,6-di-tert-butyl-3,5-dimethylphenoxy group, a pentamethylphenoxy group, an ethylphenoxy group, a n-propylphenoxy group, an isopropylphenoxy group, a n-butylphenoxy group, a sec-butylphenoxy group, a tert-butylphenoxy group, a n-hexylphenoxy group, a n-octylphenoxy group, a n-decylphenoxy group, a naphthoxy group, and an anthrathenoxy group. Among them, preferred is an aryloxy group having 6 to 20 carbon atoms.
[0106] R 3 and R 4 are preferably a hydrogen atom, a halogen atom, an alkyl group or an aryl group; more preferably a hydrogen atom, a halogen atom or a non-substituted linear alkyl group having 1 to 12 carbon atoms; and particularly preferred is a chlorine atom or a methyl group.
[0107] Examples of the hydrocarbyl group having 1 to 30 carbon atoms of R 5 and R 6 are an alkyl group, an aralkyl group and an aryl group. Those groups may have a substituent such as a halogen atom, a hydrocarbyloxy group, a nitro group, a sulfonyl group, and a silyl group.
[0108] Examples of the alkyl group of R 5 and R 6 are linear alkyl groups such as a methyl group, an ethyl group, and a n-butyl group; branched alkyl groups such as an isopropyl group, an isobutyl group, a tert-butyl group, and a neopentyl group; and cyclic alkyl groups such as a cyclohexyl group and a cyclooctyl group. Among them, preferred is a branched alkyl group, more preferred is a branched alkyl group having 1 to 12 carbon atoms, and further preferred is an isopropyl group or a tert-butyl group.
[0109] Examples of the aralkyl group of R 5 and R 6 are a benzyl group and a phenethyl group. Among them, preferred is a benzyl group.
[0110] Examples of the aryl group of R 5 and R 6 are a phenyl group, a 2-methylphenyl group, a 2-ethylphenyl group, a 2-n-propylphenyl group, a 2-isopropylphenyl group, a 2-n-butylphenyl group, a 2-isobutylphenyl group, a 2-n-hexylphenyl group, a 4-methylphenyl group, a 2,6-dimethylphenyl group, a 2,6-diethylphenyl group, a 2,6-di-n-propylphenyl group, a 2,6-diisopropylphenyl group, a 2,6-di-n-butylphenyl group, a 2,6-diisobutylphenyl group, a 2,6-di-n-hexylphenyl group, a 2-methyl-6-ethylphenyl group, a 2-methyl-6-n-propylphenyl group, a 2-methyl-6-isopropylphenyl group, a 2-methyl-6-butylphenyl group, a 2-ethyl-6-n-propylphenyl group, a 2-ethyl-6-isopropylphenyl group, a 2-ethyl-6-n-butylphenyl group, a 2-n-propyl-6-isopropylphenyl group, a 2-n-propyl-6-n-butylphenyl group, a 2-isopropyl-6-n-butylphenyl group, a 2,4,6-trimethylphenyl group, a 2,4-dimethyl-6-(2-methylphenyl)phenyl group, a 2,4-dimethyl-6-(2-ethylphenyl)phenyl group, a 2,4-dimethyl-6-(2-n-propylphenyl)phenyl group, a 2,4-dimethyl-6-(2-isopropylphenyl)phenyl group, a 2,4-dimethyl-6-(2,6-dimethylphenyl)phenyl group, a 2,4-dimethyl-6-(2,6-diethylphenyl)phenyl group, a 2,4-dimethyl-6-(2,6-di-n-propylphenyl)phenyl group, a 2,4-dimethyl-6-(2,6-diisopropylphenyl)phenyl group, a 2,4-dimethyl-6-(2-methyl-6-ethylphenyl)phenyl group, a 2,4-dimethyl-6-(2-methyl-6-n-propylphenyl)phenyl group, a 2,4-dimethyl-6-(2-methyl-6-isopropylphenyl)phenyl group, a 2,4-dimethyl-6-(2-ethyl-6-n-propylphenyl)phenyl group, a 2,4-dimethyl-6-(2-ethyl-6-isopropylphenyl)phenyl group, and a 2,4-dimethyl-6-(1-naphthyl)phenyl group. Among them, preferred is an aryl group having 6 to 30 carbon atoms, and more preferred is an aryl group having 7 to 30 carbon atoms.
[0111] Examples of the hydrocarbyl group having 1 to 20 carbon atoms of R 7 and R 8 are an alkyl group and an aryl group. Those groups may have a substituent such as a halogen atom, a hydrocarbyloxy group, a nitro group, a sulfonyl group, and a silyl group.
[0112] Examples of the alkyl group of R 7 and R 8 are linear alkyl groups such as a methyl group, an ethyl group, and a n-butyl group; branched alkyl groups such as an isopropyl group, an isobutyl group, a tert-butyl group, and a neopentyl group; and cyclic alkyl groups such as a cyclohexyl group and a cyclooctyl group. Among them, preferred is a linear alkyl group, more preferred is a linear alkyl group having 1 to 12 carbon atoms, and further preferred is a methyl group or an ethyl group.
[0113] Examples of the aryl group of R 7 and R 8 are a phenyl group, a naphthyl group, a 4-tolyl group, and a mesityl group. Among them, preferred is an aryl group having 6 to 20 carbon atoms, more preferred is an aryl group having 6 to 12 carbon atoms, and further preferred is a phenyl group or a mesityl group.
[0114] When R 7 and R 8 are linked with each other to form a ring, examples of the ring are an aliphatic ring and an aromatic ring. Those rings may have a substituent. Examples of a divalent group forming the aliphatic ring are a 1,2-ethylene group, a 1,2-cyclohexylene group, a 1,2-norbornene group, a 2,3-butene group, a 2,3-dimethyl-2,3-butene group, and a 2,4-pentene group. Examples of a divalent group forming the aromatic ring are a 1,2-phenylene group and a naphthalen-1,8-diyl group. Among them, preferred is a naphthalen-1,8-diyl group. One bond contained in each of these divalent groups is linked with the R 7 -carrying carbon atom in formula [I], and the other bond contained therein is linked with the R 8 -carrying carbon atom therein.
[0115] A transition metal compound used in the present invention is preferably a compound represented by the following formula [II] encompassed by the formula [I], from a viewpoint of production of a polymer containing more than 25% by mol of diisotactic triad, and preferably threodiisotactic triad:
[0000]
[0000] wherein M 2 , R 3 , R 4 , R 7 and R 8 are the same as those defined in the above formula [I]; R 9 and R 10 are independently of each other a hydrogen atom, a halogen atom, an alkyl group, an aralkyl group, a silyl group, a siloxy group, an alkoxy group, an aralkyloxy group, an amino group, an amide group, an imide group, or a hydrocarbylthio group; R 11 and R 12 are independently of each other an aryl group having 7 to 20; and R 13 and R 14 are independently of each other a hydrogen atom, a halogen atom, an alkyl group, an aralkyl group, an aryl group, a silyl group, a siloxy group, an alkoxy group, an aralkyloxy group, an aryloxy group, an amino group, an amide group, an imide group, or a hydrocarbylthio group.
[0116] R 9 and R 10 are preferably an alkyl group, further preferably an alkyl group having 1 to 12 carbon atoms, and particularly preferably a methyl group, an ethyl group, a n-propyl group, an isopropyl group, a n-butyl group, an isobutyl group, or a tert-butyl group.
[0117] Examples of R 11 and R 12 are a 2-methylphenyl group, a 3-methylphenyl group, a 4-methylphenyl group, a 2,3-dimethylphenyl group, a 2,4-dimethylphenyl group, a 2,5-dimethylphenyl group, a 2,6-dimethylphenyl group, a 3,4-dimethylphenyl group, a 3,5-dimethylphenyl group, a 3,6-dimethylphenyl group, a naphthyl group, a 2-methyl-1-naphthyl group, a 3-methyl-1-naphthyl group, a 4-methyl-1-naphthyl group, a 2,3-dimethyl-1-naphthyl group, a 2,4-dimethyl-1-naphthyl group, a 2,5-dimethyl-1-naphthyl group, a 2,6-dimethyl-1-naphthyl group, a 3,4-dimethyl-1-naphthyl group, a 3,5-dimethyl-1-naphthyl group, a 3,6-dimethyl-1-naphthyl group, an anthracenyl group, a 2-methyl-1-anthracenyl group, a 3-methyl-10-anthracenyl group, a 4-methyl-10-anthracenyl group, a 2,3-dimethyl-10-anthracenyl group, a 2,4-dimethyl-10-anthracenyl group, a 2,5-dimethyl-10-anthracenyl group, a 2,6-dimethyl-10-anthracenyl group, a 3,4-dimethyl-10-anthracenyl group, a 3,5-dimethyl-10-anthracenyl group, a 3,6-dimethyl-10-anthracenyl group, and 2-methyl-10-anthracenyl group. Among them, preferred is a substituent-having phenyl group, a naphthyl group or an anthracenyl group, and further preferred is a 2-methylphenyl group or a naphthyl group.
[0118] R 13 and R 14 are preferably a hydrogen atom or an alkyl group, more preferably a hydrogen atom or an alkyl group having 1 to 12 carbon atoms, and further preferably a methyl group, an ethyl group, a n-propyl group, an isopropyl group, a n-butyl group, or an isobutyl group.
[0119] Also, a transition metal compound used in the present invention is preferably a compound represented by the following formula [III] encompassed by the formula [I], from a viewpoint of production of a polymer containing more than 25% by mol of disyndiotactic triad, and preferably threodisyndiotactic triad:
[0000]
[0000] wherein M 2 , R 3 , R 4 , R 7 and R 8 are the same as those defined in the above formula [I]; R 15 , R 16 , R 17 and R 18 are independently of one another a hydrogen atom, a halogen atom, an alkyl group, an aralkyl group, an aryl group, a silyl group, a siloxy group, an alkoxy group, an aralkyloxy group, an aryloxy group, an amino group, an amide group, an imide group, or a hydrocarbylthio group; and R 19 and R 20 are independently of each other a hydrogen atom, a halogen atom, an alkyl group, an aralkyl group, an aryl group, a silyl group, a siloxy group, an alkoxy group, an aralkyloxy group, an aryloxy group, an amino group, an amide group, an imide group, or a hydrocarbylthio group.
[0120] R 15 , R 16 , R 17 and R 18 are preferably a hydrogen atom, an alkyl group or an aryl group, more preferably a hydrogen atom, an alkyl group having 1 to 12 carbon atoms, or an aryl group having 6 to 20 carbon atoms, and further preferably a hydrogen atom, a methyl group, an ethyl group, a n-propyl group, an isopropyl group, a n-butyl group, an isobutyl group, a tert-butyl group, or a phenyl group.
[0121] R 19 and R 20 are preferably a hydrogen atom, an alkyl group or an aryl group, more preferably a hydrogen atom, an alkyl group having 1 to 12 carbon atoms, or an aryl group having 6 to 20 carbon atoms, and further preferably a hydrogen atom, a methyl group, an ethyl group, a n-propyl group, an isopropyl group, a n-butyl group, an isobutyl group, a tert-butyl group, or a phenyl group.
[0122] Compounds represented by the following formula [IV] are also preferable as a transition metal compound used in the present invention:
[0000]
[0000] wherein M 3 is a transition metal atom of Group 8 to 11 of the Periodic Table of the elements; R 3 and R 4 are the same as those defined in the above formula [I]; and R 21 to R 27 are independently of one another a hydrogen atom, a halogen atom, an alkyl group, an aralkyl group, an aryl group, a silyl group, a siloxy group, an alkoxy group, an aralkyloxy group, an aryloxy group, an amino group, an amide group, an imide group, or a hydrocarbylthio group, and any two or more of R 21 to R 27 may be linked with one another to form a ring.
[0123] M 3 is preferably an iron atom, a ruthenium atom, a cobalt atom, a rhodium atom, a nickel atom, a palladium atom, or a copper atom, and further preferably an iron atom or a cobalt atom.
[0124] Examples of the halogen atom of R 21 to R 27 are a fluorine atom, a chlorine atom, a bromine atom, and an iodine atom. Among them, preferred is a chlorine atom or a bromine atom.
[0125] Examples of the alkyl group of R 21 to R 27 are linear alkyl groups such as a methyl group, an ethyl group, a n-propyl group, a n-butyl group, and a n-pentyl group; branched alkyl groups such as an isopropyl group, an isobutyl group, a tert-butyl group, and a neopentyl group; and cyclic alkyl groups such as a cyclopropyl group, a cyclobutyl group, a cyclopentyl group, a cyclohexyl group and a cyclooctyl group. Among them, preferred is a branched alkyl group, more preferred is a branched alkyl group having 1 to 12 carbon atoms, and further preferred is an isopropyl group or a tert-butyl group.
[0126] Examples of the aralkyl group of R 21 to R 27 are a benzyl group and a phenethyl group. Among them, preferred is a benzyl group.
[0127] Examples of the aryl group of R 21 to R 27 are a phenyl group, a 2-methylphenyl group, a 2-ethylphenyl group, a 2-n-propylphenyl group, a 2-isopropylphenyl group, a 2-n-butylphenyl group, a 2-isobutylphenyl group, a 2-tert-butylphenyl group, a 2-n-hexylphenyl group, a 2-cyclohexylphenyl group, a 3-methylphenyl group, a 3-ethylphenyl group, a 3-n-propylphenyl group, a 3-isopropylphenyl group, a 3-n-butylphenyl group, a 3-isobutylphenyl group, a 3-tert-butylphenyl group, a 3-n-hexylphenyl group, a 3-cyclohexylphenyl group, a 4-methylphenyl group, a 4-ethylphenyl group, a 4-n-propylphenyl group, a 4-isopropylphenyl group, a 4-n-butylphenyl group, a 4-isobutylphenyl group, a 4-tert-butylphenyl group, a 4-n-hexylphenyl group, a 4-cyclohexylphenyl group, a 2,6-dimethylphenyl group, a 2,6-diethylphenyl group, a 2,6-di-n-propylphenyl group, a 2,6-diisopropylphenyl group, a 2,6-di-n-butylphenyl group, a 2,6-diisobutylphenyl group, a 2,6-di-tert-butylphenyl group, a 2,6-di-n-hexylphenyl group, a 2,6-dicyclohexylphenyl group, a 2-methyl-6-ethylphenyl group, a 2-methyl-6-n-propylphenyl group, a 2-methyl-6-isopropylphenyl group, a 2-methyl-6-n-butylphenyl group, a 2-methyl-6-isobutylphenyl group, a 2-methyl-6-tert-butylphenyl group, a 2-methyl-6-n-hexylphenyl group, a 2-methyl-6-cyclohexylphenyl group, a 2-ethyl-6-n-propylphenyl group, a 2-ethyl-6-isopropylphenyl group, a 2-ethyl-6-n-butylphenyl group, a 2-ethyl-6-isobutylphenyl group, a 2-ethyl-6-tert-butylphenyl group, a 2-ethyl-6-n-hexylphenyl group, a 2-ethyl-6-cyclohexylphenyl group, a 2-n-propyl-6-isopropylphenyl group, a 2-n-propyl-6-n-butylphenyl group, a 2-n-propyl-6-isobutylphenyl group, a 2-n-propyl-6-tert-butylphenyl group, a 2-n-propyl-6-n-hexylphenyl group, a 2-n-propyl-6-cyclohexylphenyl group, a 2-isopropyl-6-n-butylphenyl group, a 2-isopropyl-6-isobutylphenyl group, a 2-isopropyl-6-tert-butylphenyl group, a 2-isopropyl-6-n-hexylphenyl group, a 2-isopropyl-6-cyclohexylphenyl group, a 2-n-butyl-6-isobutylphenyl group, a 2-n-butyl-6-tert-butylphenyl group, a 2-n-butyl-6-n-hexylphenyl group, a 2-n-butyl-6-cyclohexylphenyl group, a 2-isobutyl-6-tert-butylphenyl group, a 2-isobutyl-6-n-hexylphenyl group, a 2-isobutyl-6-cyclohexylphenyl group, a 2-tert-butyl-6-n-hexylphenyl group, a 2-tert-butyl-6-cyclohexylphenyl group, a 2-n-hexyl-6-cyclohexylphenyl group, a 2,4-diisopropylphenyl group, a 2,4-di-n-butylphenyl group, a 2,4-diisobutylphenyl group, a 2,4-di-tert-butylphenyl group, a 2,4-di-n-hexylphenyl group, a 2,4-dicyclohexylphenyl group, a 2-ethyl-4-methylphenyl group, a 2-n-propyl-4-methylphenyl group, a 2-isopropyl-4-methylphenyl group, a 2-n-butyl-4-methylphenyl group, a 2-isobutyl-4-methylphenyl group, a 2-tert-butyl-4-methylphenyl group, a 2-n-hexyl-4-methylphenyl group, a 2-cyclohexyl-4-methylphenyl group, a 2-n-propyl-4-ethylphenyl group, a 2-isopropyl-4-ethylphenyl group, a 2-n-butyl-4-ethylphenyl group, a 2-isobutyl-4-ethylphenyl group, a 2-tert-butyl-4-ethylphenyl group, a 2-n-hexyl-4-ethylphenyl group, a 2-cyclohexyl-4-ethylphenyl group, a 2-isopropyl-4-n-propylphenyl group, a 2-n-butyl-4-n-propylphenyl group, a 2-isobutyl-4-n-propylphenyl group, a 2-tert-butyl-4-n-propylphenyl group, a 2-n-hexyl-4-n-propylphenyl group, a 2-cyclohexyl-4-n-propylphenyl group, a 2-n-butyl-4-isopropylphenyl group, a 2-isobutyl-4-isopropylphenyl group, a 2-tert-butyl-4-isopropylphenyl group, a 2-n-hexyl-4-isopropylphenyl group, a 2-cyclohexyl-4-isopropylphenyl group, a 2-isobutyl-4-n-butylphenyl group, a 2-tert-butyl-4-n-butylphenyl group, a 2-n-hexyl-4-n-butylphenyl group, a 2-cyclohexyl-4-n-butylphenyl group, a 2-tert-butyl-4-isobutylphenyl group, a 2-n-hexyl-4-isobutylphenyl group, a 2-cyclohexyl-4-isobutylphenyl group, a 2-n-hexyl-4-tert-butylphenyl group, a 2-cyclohexyl-4-tert-butylphenyl group, a 2-cyclohexyl-4-n-hexylphenyl group, a 2,5-dimethylphenyl group, a 2,5-diethylphenyl group, a 2,5-di-n-propylphenyl group, a 2,5-diisopropylphenyl group, a 2,5-di-n-butylphenyl group, a 2,5-diisobutylphenyl group, a 2,5-di-tert-butylphenyl group, a 2,5-di-n-hexylphenyl group, a 2,5-dicyclohexylphenyl group, a 2,4,6-trimethylphenyl group, a 2,4,6-triethylphenyl group, a 2,4,6-tri-n-propylphenyl group, a 2,4,6-triisopropylphenyl group, a 2,4,6-tri-n-butylphenyl group, a 2,4,6-triisobutylphenyl group, a 2,4,6-tri-tert-butylphenyl group, a 2,4,6-tri-n-hexylphenyl group, a 2,4,6-tricyclohexylphenyl group, a 2,6-diethyl-4-methylphenyl group, a 2,6-di-n-propyl-4-methylphenyl group, a 2,6-diisopropyl-4-methylphenyl group, a 2,6-di-n-butyl-4-methylphenyl group, a 2,6-diisobutyl-4-methylphenyl group, a 2,6-di-tert-butyl-4-methylphenyl group, a 2,6-di-n-hexyl-4-methylphenyl group, a 2,6-dicyclohexyl-4-methylphenyl group, a 2,4-dimethyl-6-(2-methylphenyl)phenyl group, a 2,4-dimethyl-6-(2-ethylphenyl)phenyl group, a 2,4-dimethyl-6-(2-n-propylphenyl)phenyl group, a 2,4-dimethyl-6-(2-isopropylphenyl)phenyl group, a 2,4-dimethyl-6-(2,6-dimethylphenyl)phenyl group, a 2,4-dimethyl-6-(2,6-diethylphenyl)phenyl group, a 2,4-dimethyl-6-(2,6-di-n-propylphenyl)phenyl group, a 2,4-dimethyl-6-(2,6-diisopropylphenyl)phenyl group, a 2,4-dimethyl-6-(2-methyl-6-ethylphenyl)phenyl group, a 2,4-dimethyl-6-(2-methyl-6-n-propylphenyl)phenyl group, a 2,4-dimethyl-6-(2-methyl-6-isopropylphenyl)phenyl group, a 2,4-dimethyl-6-(2-ethyl-6-n-propylphenyl)phenyl group, a 2,4-dimethyl-6-(2-ethyl-6-isopropylphenyl)phenyl group, and a 2,4-dimethyl-6-(1-naphthyl)phenyl group.
[0128] Examples of the silyl group of R21 to R 27 are mono-substituted silyl groups such as a methylsilyl group, an ethylsilyl group, and a phenylsilyl group; di-substituted silyl groups such as a dimethylsilyl group, a diethylsilyl group, and a diphenylsilyl group; and tri-substituted silyl groups such as a trimethylsilyl group, a trimethoxysilyl group, a dimethylmethoxysilyl group, a methyldimethoxysilyl group, a triethylsilyl group, a triethoxysilyl group, a tri-n-propylsilyl group, a triisopropylsilyl group, a tri-n-butylsilyl group, a tri-sec-butylsilyl group, a tert-butyldimethylsilyl group, a triisobutylsilyl group, a tert-butyldiphenylsilyl group, a cyclohexyldimethylsilyl group, a tricyclohexylsilyl group, and a triphenylsilyl group. Among them, preferred are tri-substituted silyl groups, and further preferred is a trimethylsilyl group, a triethylsilyl group, a triphenylsilyl group, a tert-butyldimethylsilyl group, a tert-butyldiphenylsilyl group, a cyclohexyldimethylsilyl group, or a triisopropylsilyl group.
[0129] Examples of the siloxy group of R 21 to R 27 are a trimethylsiloxy group, a trimethoxysiloxy group, a dimethylmethoxysiloxy group, a methyldimethoxysiloxy group, a triethylsiloxy group, a triethoxysiloxy group, a tri-n-propylsiloxy group, a triisopropylsiloxy group, a tri-n-butylsiloxy group, a tri-sec-butylsiloxy group, a tert-butyldimethylsiloxy group, a triisobutylsiloxy group, a tert-butyldiphenylsiloxy group, a cyclohexydimethylsiloxy group, a tricyclohexylsiloxy group, and a triphenylsiloxy group. Among them, preferred is a trialkylsiloxy group, and further preferred is a trimethylsiloxy group, a triethylsiloxy group, and a triphenylsiloxy group, a tert-butyldimethylsiloxy group, a tert-butyldiphenylsiloxy group, a cyclohexyldimethylsiloxy group, or a triisopropylsiloxy group.
[0130] Examples of the alkoxy group of R 21 to R 27 are a methoxy group, an ethoxy group, a n-propoxy group, an isopropoxy group, a n-butoxy group, a sec-butoxy group, a tert-butoxy group, a n-pentyloxy group, a neopentyloxy group, a n-hexyloxy group, a n-octyloxy group, a n-dodecyloxy group, a n-pentadecyloxy group, and a n-eicosyloxy group. Among them, preferred is a methoxy group, an ethoxy group, an isopropoxy group, or a tert-butoxy group.
[0131] Examples of the aralkyloxy group of R 21 to R 27 are a benzyloxy group, a (2-methylphenyl)methoxy group, a (3-methylphenyl)methoxy group, a (4-methylphenyl)methoxy group, a (2,3-dimethylphenyl)methoxy group, a (2,4-dimethylphenyl)methoxy group, a (2,5-dimethylphenyl)methoxy group, a (2,6-dimethylphenyl)methoxy group, a (3,4-dimethylphenyl)methoxy group, a (3,5-dimethylphenyl)methoxy group, a (2,3,4-trimethylphenyl)methoxy group, a (2,3,5-trimethylphenyl)methoxy group, a (2,3,6-trimethylphenyl)methoxy group, a (2,4,5-trimethylphenyl)methoxy group, a (2,4,6-trimethylphenyl)methoxy group, a (3,4,5-trimethylphenyl)methoxy group, a (2,3,4,5-tetramethylphenyl)methoxy group, a (2,3,4,6-tetramethylphenyl)methoxy group, a (2,3,5,6-tetramethylphenyl)methoxy group, a (pentamethylphenyl)methoxy group, an (ethylphenyl)methoxy group, a (n-propylphenyl)methoxy group, an (isopropylphenyl)methoxy group, a (n-butylphenyl)methoxy group, a (sec-butylphenyl)methoxy group, a (tert-butylphenyl)methoxy group, a (n-hexylphenyl)methoxy group, a (n-octylphenyl)methoxy group, a (n-decylphenyl)methoxy group, a naphthylmethoxy group, and an anthrathenylmethoxy group. Among them, preferred is a benzyloxy group.
[0132] Examples of the aryloxy group of R 21 to R 27 are a phenoxy group, a 2-methylphenoxy group, a 3-methylphenoxy group, a 4-methylphenoxy group, a 2,3-dimethylphenoxy group, a 2,4-dimethylphenoxy group, a 2,5-dimethylphenoxy group, a 2,6-dimethylphenoxy group, a 3,4-dimethylphenoxy group, a 3,5-dimethylphenoxy group, a 2-tert-butyl-3-methylphenoxy group, a 2-tert-butyl-4-methylphenoxy group, a 2-tert-butyl-5-methylphenoxy group, a 2-tert-butyl-6-methylphenoxy group, a 2,3,4-trimethylphenoxy group, a 2,3,5-trimethylphenoxy group, a 2,3,6-trimethylphenoxy group, a 2,4,5-trimethylphenoxy group, a 2,4,6-trimethylphenoxy group, a 2-tert-butyl-3,4-dimethylphenoxy group, a 2-tert-butyl-3,5-dimethylphenoxy group, a 2-tert-butyl-3,6-dimethylphenoxy group, a 2,6-di-tert-butyl-3-methylphenoxy group, a 2-tert-butyl-4,5-dimethylphenoxy group, a 2,6-di-tert-butyl-4-methylphenoxy group, a 3,4,5-trimethylphenoxy group, a 2,3,4,5-tetramethylphenoxy group, a 2-tert-butyl-3,4,5-trimethylphenoxy group, a 2,3,4,6-tetramethylphenoxy group, a 2-tert-butyl-3,4,6-trimethylphenoxy group, a 2,6-di-tert-butyl-3,4-dimethylphenoxy group, a 2,3,5,6-tetramethylphenoxy group, a 2-tert-butyl-3,5,6-trimethylphenoxy group, a 2,6-di-tert-butyl-3,5-dimethylphenoxy group, a pentamethylphenoxy group, an ethylphenoxy group, a n-propylphenoxy group, an isopropylphenoxy group, a n-butylphenoxy group, a sec-butylphenoxy group, a tert-butylphenoxy group, a n-hexylphenoxy group, a n-octylphenoxy group, a n-decylphenoxy group, a naphthoxy group, and an anthrathenoxy group.
[0133] Examples of the amino group of R 21 to R 27 are linear alkylamino groups such as an N-methylamino group, an N-ethylamino group, an N-n-butylamino group, an N,N-dimethylamino group, an N,N-diethylamino group, and an N,N-di-n-butylamino group; branched alkylamino groups such as an N,N-diisopropylamino group, an N,N-diisobutylamino group, an N,N-di-tert-butylamino group, and an N,N-dineopentylamino group; and cyclic alkylamino groups such as an N,N-dicyclohexylamino group and an N,N-dicyclooctylamino group.
[0134] Examples of the amide group of R 21 to R 27 are an ethanamide group, an N-n-butylethanamide group, an N-methylethanamide group, an N-ethylethanamide group, an N-n-butylhexanamide group, an isopropanamide group, an isobutanamide group, a tert-butanamide group, a neopentanamide group, a cyclohexanamide group, and a cyclooctanamide group.
[0135] Examples of the imide group of R 21 to R 27 are a succinimide group, a maleimide group, and a phthalimide group.
[0136] Examples of the hydrocarbylthio group of R 21 to R 27 are alkylthio groups such as a methylthio group, an ethylthio group, an isopropylthio group, and a tert-butylthio group; arylthio groups such as a phenylthio group and a naphthylthio group; and aralkylthio groups such as a benzylthio group and a 9-fluorenylmethylthio group.
[0137] R 21 to R 27 may have one or more substituents such as a halogen atom, an alkoxy group, an aryloxy group, an aralkyloxy group, a nitro group, an amino group, an amide group, an imide group, a silyl group, a siloxy group, a sulfonyl group, and a hydrocarbylthio group.
[0138] When any two or more of R 21 to R 27 are linked with one another to form a ring, examples of the ring are an aliphatic ring and an aromatic ring. Those rings may have one or more substituents such as a halogen atom, an alkoxy group, an aryloxy group, an aralkyloxy group, a nitro group, an amino group, an amide group, an imide group, a silyl group, a siloxy group, a sulfonyl group, and a hydrocarbylthio group.
[0139] When any two of R 21 to R 27 are linked with each other to form an aliphatic ring, examples of a divalent group forming the aliphatic ring are a methylene group, an ethane-1,2-diyl group, a propane-1,3-diyl group, a propane-1,2-diyl group, a butane-1,2-diyl group, a butane-1,3-diyl group, a butane-1,4-diyl group, a pentane-1,2-diyl group, a pentane-1,3-diyl group, a pentane-1,4-diyl group, a pentane-1,5-diyl group, an ethylene-1,2-diyl group, a cyclohexane-1,2-diyl group, a cyclohexane-1,3-diyl group, a norbornane-1,2-diyl group, a norbornane-1-ene-1,2-diyl group, a butane-1-ene-1,2-diyl group, a butane-1-ene-1,3-diyl group, a butane-1-ene-2,3-diyl group, a butane-2-ene-1,2-diyl group, a butane-2-ene-1,3-diyl group, a butane-2-ene-2,3-diyl group, a butane-1,3-diene-1,2-diyl group, a butane-1,3-diene-1,3-diyl group, a butane-1,3-diene-1,4-diyl group, a dimethyl-2,3-butene-2,3-diyl group, and a pentene-2,4-diyl group.
[0140] When any two of R 21 to R 27 are linked with each other to form an aromatic ring, examples of a divalent group forming the aromatic ring are a benzen-1,2-diyl group, a 3-methylbenzen-1,2-diyl group, a 4-methylbenzen-1,2-diyl group, a 3-ethylbenzen-1,2-diyl group, a 4-ethylbenzen-1,2-diyl group, a 3-n-propylbenzen-1,2-diyl group, a 4-n-propylbenzen-1,2-diyl group, a 3-n-butylbenzen-1,2-diyl group, a 4-n-butylbenzen-1,2-diyl group, a 3-isopropylbenzen-1,2-diyl group, a 4-isopropylbenzen-1,2-diyl group, a 3-isobutylbenzen-1,2-diyl group, a 4-isobutylbenzen-1,2-diyl group, a 3-tert-butylbenzen-1,2-diyl group, a 4-tert-butylbenzen-1,2-diyl group, a benzen-1,3-diyl group, a 2-methylbenzen-1,3-diyl group, a 4-methylbenzen-1,3-diyl group, a biphenyl-2,2′-diyl group, a benzene-1,2-dimethylene group, abenzene-1,3-dimethylene group, and a naphthalen-1,8-diyl group.
[0141] One bond contained in each of the above-mentioned divalent groups is linked with a carbon atom carrying one of R 21 to R 27 , and the other bond contained therein is linked with a carbon atom carrying another of R 21 to R 27 ,
[0142] An organoaluminum compound in the present invention may be a compound known in the art. Examples of the organoaluminum compound are the following compounds (1) to (3), and a combination of two or more thereof:
[0143] (1) an organoaluminum compound represented by the formula, E 1 d AlX 2 3-d ;
[0144] (2) a cyclic alumoxane represented by the formula, {—Al(E 2 )-O—} e ; and
[0145] (3) a linear alumoxane represented by the formula, E 3 {—Al(E 3 )-O—} f AlE 3 2 ,
[0000] wherein E 1 , E 2 and E 3 are independently of one another a hydrocarbyl group, and when plural E 1 s, E 2 s or E 3 s exist, they are the same as, or different from one another; X 2 is a hydrogen atom or a halogen atom, and when plural Xs exist, they are the same as, or different from one another; d is a number satisfying 0<d≦3; e is an integer of 2 or more, and preferably an integer of 2 to 40; and f is an integer of 1 or more, and preferably an integer of 1 to 40.
[0146] The hydrocarbyl group of E 1 , E 2 and E 3 is preferably a hydrocarbyl group having 1 to 8 carbon atoms, and more preferably an alkyl group having 1 to 8 carbon atoms. Examples of the alkyl group of E 1 , E 2 and E 3 are a methyl group, an ethyl group, a n-propyl group, an isopropyl group, a n-butyl group, an isobutyl group, a n-pentyl group, and a neopentyl group. Among them, preferred is a methyl group or an isobutyl group.
[0147] Examples of the above-mentioned organoaluminum compound (1) are trialkylaluminums such as trimethylaluminum, triethylaluminum, tripropylaluminum, triisobutylaluminum, and trihexylaluminum; dialkylaluminum chlorides such as dimethylaluminum chloride, diethylaluminum chloride, dipropylaluminum chloride, diisobutylaluminum chloride and dihexylaluminum chloride; alkylaluminum dichlorides such as methylaluminum dichloride, ethylaluminum dichloride, propylaluminum dichloride, isobutylaluminum dichloride and hexylaluminum dichloride; and dialkylaluminum hydrides such as dimethylaluminum hydride, diethylaluminum hydride, dipropylaluminum hydride, diisobutylaluminum hydride and dihexylaluminum hydride. Among them, preferred is a trialkylaluminum, and more preferred is triethylaluminum or triisobutylaluminum.
[0148] The above-mentioned cyclic alumoxane (2) and linear alumoxane (3) can be produced according to various processes. Those processes are not particularly limited, and may be those known in the art. Examples of the process are (i) a process comprising the step of contacting a solution of a trialkylaluminum such as trimethylaluminum in a suitable organic solvent such as benzene and an aliphatic hydrocarbon with water, and (ii) a process comprising the step of contacting a trialkylaluminum such as trimethylaluminum with a crystal water-containing metal salt such as copper sulfate hydrate.
[0149] A boron compound in the present invention may be a compound known in the art. Examples of the boron compound are the following compounds (1) to (3), and a combination of two or more thereof:
[0150] (1) a boron compound represented by the formula, BQ 1 Q 2 Q 3 ;
[0151] (2) a boron compound represented by the formula, G + (BQ 1 Q 2 Q 3 Q 4 ) − ; and
[0152] (3) a boron compound represented by the formula, (J−H) + (BQ 1 Q 2 Q 3 Q 4 ) − ;
[0000] wherein B is a trivalent boron atom; Q 1 , Q 2 , Q 3 and Q 4 are independently of one another a halogen atom, a hydrocarbyl group, a halogenated hydrocarbyl group, a silyl group, a siloxy group, an alkoxy group, an amino group, an amido group, or an imido group; G + is an inorganic or organic cation; J is a neutral Lewis base; and (J−H) + is a Broensted acid.
[0153] Q 1 , Q 2 , Q 3 and Q 4 in the above-mentioned formulas are preferably a halogen atom, a hydrocarbyl group having 1 to 20 carbon atoms, a halogenated hydrocarbyl group having 1 to 20 carbon atoms, a silyl group having 1 to 20 carbon atoms, a siloxy group having 1 to 20 carbon atoms, a C 2-20 hydrocarbyl group-carrying amino group, a C 2-20 hydrocarbyl group-carrying amido group, or a C 2-20 hydrocarbyl group-carrying imido group; more preferably a halogen atom, a hydrocarbyl group having 1 to 20 carbon atoms, or a halogenated hydrocarbyl group having 1 to 20 carbon atoms; further preferably a C 1-20 fluorinated hydrocarbyl group containing one or more fluorine atoms; and particularly preferably a C 6-20 fluorinated aryl group containing one or more fluorine atoms.
[0154] Examples of the above-mentioned boron compound (1) are tris(pentafluorophenyl)borane, tris(2,3,5,6-tetrafluorophenyl)borane, tris(2,3,4,5-tetrafluorophenyl)borane, tris(3,4,5-trifluorophenyl)borane, tris(2,3,4-trifluorophenyl)borane, and phenyl bis(pentafluorophenyl)borane. Among them, most preferred is tris(pentafluorophenyl)borane.
[0155] Examples of an inorganic cation, G + , in the above-mentioned boron compound (2) are a ferrocenium cation, an alkyl group-having ferrocenium cation, and a silver cation. An example of an organic cation, G + , therein is a barbenium cation such as a triphenylmethyl cation. Among them, G + is preferably a carbenium cation, and particularly preferably a triphenylmethyl cation.
[0156] Examples of (BQ 1 Q 2 Q 3 Q 4 ) − in the above-mentioned boron compound (2) are tetrakis(pentafluorophenyl)borate, tetrakis(2,3,5,6-tetrafluorophenyl)borate, tetrakis(2,3,4,5-tetrafluorophenyl)borate, tetrakis(3,4,5-trifluorophenyl)borate, tetrakis(2,3,4-trifluorophenyl)borate, phenyltris(pentafluorophenyl)borate, and tetrakis(3,5-bistrifluoromethylphenyl)borate.
[0157] Examples of the above-mentioned boron compound (2) are lithium tetrakis(3,5-bistrifluoromethylphenyl)borate, sodium tetrakis(3,5-bistrifluoromethylphenyl)borate, potassium tetrakis(3,5-bistrifluoromethylphenyl)borate, silver tetrakis(pentafluorophenyl)borate, ferrocenium tetrakis(pentafluorophenyl)borate, 1,1′-dimethylferrocenium tetrakis(pentafluorophenyl)borate, tetrabutylphosphponium tetrakis(pentafluorophenyl)borate, tetraphenylphosphponium tetrakis(pentafluorophenyl)borate, tetramethylammonium tetrakis(pentafluorophenyl)borate, trimethylsulphonuim tetrakis(pentafluorophenyl)borate, diphenyliodonium tetrakis(pentafluorophenyl)borate, triphenylcarbenium tetrakis(pentafluorophenyl)borate, and triphenylcarbenium tetrakis(3,5-bistrifluoromethylphenyl)borate. Among them, most preferred is triphenylcarbenium tetrakis(pentafluorophenyl)borate.
[0158] Examples of (J−H) + in the above-mentioned boron compound (3) are a trialkylammonium, an N,N-dialkylanilinium, a dialkylammonium, and a triarylphosphonium. Examples of the (BQ 1 Q 1 Q 3 Q 4 ) therein are the same as those mentioned above.
[0159] Examples of the above-mentioned boron compound (3) are triethylammonium tetrakis(pentafluorophenyl)borate, tripropylammonium tetrakis(pentafluorophenyl)borate, tri(n-butyl)ammonium tetrakis(pentafluorophenyl)borate, tri(n-butyl)ammonium tetrakis(3,5-bistrifluoromethylphenyl)borate, N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate, N,N-diethylanilinium tetrakis(pentafluorophenyl)borate, N,N-dimethyl-2,4,6-trimethylanilinium tetrakis (pentafluorophenyl)borate, N,N-dimethylanilinium tetrakis (3,5-bistrifluoromethylphenyl)borate, diisopropylammonium tetrakis(pentafluorophenyl)borate, dicyclohexylammonium tetrakis(pentafluorophenyl)borate, triphenylphosphonium tetrakis(pentafluorophenyl)borate, tri(methylphenyl) phosphonium tetrakis(pentafluorophenyl)borate, and tri(dimethylphenyl)phosphonium tetrakis(pentafluorophenyl)borate. Among them, most preferred is tri(n-butyl)ammonium tetrakis(pentafluorophenyl)borate, or N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate.
[0160] The boron compound is preferably the above-mentioned boron compound (2) or (3), and particularly preferably triphenylcarbenium tetrakis(pentafluorophenyl)borate, tri(n-butyl)ammonium tetrakis(pentafluorophenyl)borate, or N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate.
[0161] A molecular weight of the polymer of the present invention is not particularly limited. Its weight-average molecular weight (Mw) is preferably 1,000 to 10,000,000, more preferably 2,000 to 5,000,000, and most preferably 4,000 to 3,000,000.
[0162] A molecular weight distribution of the polymer of the present invention is not particularly limited. It is preferably 1.0 to 100, more preferably 1.0 to 50, and most preferably 1.0 to 20.
[0163] A glass-transition temperature or a melting point of the polymer of the present invention is preferably −20° C. or higher, more preferably 20° C. or higher, and most preferably 50° C. or higher.
[0164] In the present invention, a method for contacting (i) the above-mentioned transition metal compound, (ii) the above-mentioned organoaluminum compound and/or boron compound, (iii) the compound represented by the formula (3), and (iv) the above-mentioned olefin, with one another, is not particularly limited.
[0165] When forming a polymerization catalyst by contacting the transition metal compound with the organoaluminum compound, the organoaluminum compound is preferably the above-mentioned cyclic alumoxane, linear alumoxane, or a combination thereof, in order to form a high activity-having polymerization catalyst. When forming a polymerization catalyst by contacting the transition metal compound, the organoaluminum compound and the boron compound with one another, the organoaluminum compound is preferably the organoaluminum compound represented by the above-mentioned first formula, E 1 d AlZ 3-d , in order to form a high activity-having polymerization catalyst.
[0166] The organoaluminum compound is used in amount of generally 0.1 to 10,000 parts by mol, and preferably 5 to 2,000 parts by mol, per one mol of the transition metal compound. The amount of smaller than 0.1 part by mol may result in an insufficient activity of a polymerization catalyst. The amount of larger than 10,000 parts by mol may result in production of a too low molecular weight-having polymer, because of, for example, chain transfer to the organoaluminum compound, or may result in a too low activity-having polymerization catalyst. The boron compound is used in amount of generally 0.01 to 100 parts by mol, and preferably 0.5 to 10 parts by mol, per one mol of the transition metal compound. The amount of smaller than 0.01 part by mol may result in an insufficient activity of a polymerization catalyst. The amount of larger than 100 parts by mol is not preferable from an economical point of view.
[0167] Each of the transition metal compound, the organoaluminum compound, and the boron compound may be used as a solution thereof. Examples of a solvent for the solution are methylene chloride, chloroform, toluene, pentane, hexane, and heptane. Among them, preferred is methylene chloride, chloroform, or toluene.
[0168] A solution of the transition metal compound has a concentration of generally 0.01 to 500 μmol/L, preferably 0.05 to 100 μmol/L, and more preferably 0.05 to 50 μmol/L. A solution of the organoaluminum compound has a concentration of generally 0.01 to 10,000 μmol/L, preferably 0.1 to 5,000 μmol/L, and more preferably 0.1 to 2,000 μmol/L, in terms of an amount of an aluminum atom contained in the solution. A solution of the boron compound has a concentration of generally 0.01 to 500 μmol/L, preferably 0.05 to 200 μmol/L, and more preferably 0.05 to 100 mmol/L. When the solution of the transition metal compound has a concentration of lower than 0.01 μmol/L, when the solution of the organoaluminum compound has a concentration of lower than 0.01 μmol/L in terms of an amount of an aluminum atom contained in the solution, or when the solution of the boron compound has a concentration of lower than 0.01 μmol/L, a large amount of a solvent is necessary to prepare the solution, which is not preferable from an economical point of view. When the solution of the transition metal compound has a concentration of higher than 500 μmol/L, when the solution of the organoaluminum compound has a concentration of higher than 10,000 μmol/L in terms of an amount of an aluminum atom contained in the solution, or when the solution of the boron compound has a concentration of higher than 500 μmol/L, the transition metal compound, the organoaluminum compound, or the boron compound may not be sufficiently dissolved in a solvent, and therefore, the compound may be deposited in the solution.
[0169] A polymerization catalyst in the present invention may be combined with a carrier or a support comprising particles of inorganic or organic compounds. Examples of the inorganic compounds are silica gel and alumina, and an example of the organic compounds is a styrene unit-containing polymer.
[0170] A polymerization method is not particularly limited in the present invention. Examples thereof are a gas-phase polymerization method, a bulk polymerization method, a solution polymerization method using a suitable polymerization solvent, and a suspension polymerization method using the same, which are a batch-wise polymerization method or a continuous polymerization method. The polymerization solvent is a solvent non-deactivating a polymerization catalyst. Examples of the solvent are a hydrocarbon solvent such as benzene, toluene, pentane, hexane, heptane, and cyclohexane; and a halogenated solvent such as dichloromethane and chloroform.
[0171] A polymerization temperature is not particularly limited in the present invention, and generally −100 to 250° C., and preferably −50 to 200° C. The polymerization temperature of lower than −100° C. may result in an insufficient activity of a polymerization catalyst. The polymerization temperature of higher than 250° C. may result in production of a too low molecular weight-having polymer, or may result in no production of a polymer containing the unit represented by the formula (1), due to occurrence of a side reaction such as an isomerization reaction.
[0172] In order to regulate a molecular weight of a polymer produced, a chain transfer agent such as hydrogen may be used.
[0173] A polymerization time is not particularly limited in the present invention, and generally one minute to 72 hours. The polymerization time of shorter than one minute may result in an insufficient yield of a polymer produced. The polymerization time of longer than 72 hours is disadvantageous from an economical point of view.
[0174] The polymer of the present invention may be used in combination with various additives such as weatherability stabilizers, lubricants, pigments, dyes, antistatic agents, antioxidants, antifogging agents, rust-inhibiting agents, surfactants, and electroconductive agents. The polymer of the present invention may also be used in combination with a polymer known in the art such as a low-density polyethylene, a high-density polyethylene, a linear low-density polyethylene, an ethylene-acrylic acid ester copolymer, an ethylene-methacrylic acid ester copolymer, an ethylene-vinyl acetate copolymer, an ethylene-α-olefin copolymer elastomer, and polypropylene.
[0175] The polymer of the present invention can be molded according to an extrusion molding method or an injection molding method. Those methods may be known in the art. Examples of the extrusion molding method are (1) an inflation molding method comprising the steps of (1-1) extruding a molten resin through a circular die, thereby forming an extruded product, (1-2) blowing the extruded product into a cylindrical film or sheet, and (1-3) rewinding the film or sheet, (2) a T-die molding method comprising the steps of (2-1) extruding a molten resin through a linear die, thereby forming a film or sheet, and (2-2) rewinding the film or sheet, and (3) a calender molding method.
[0176] Also, the polymer of the present invention can be used as a fiber. A fiber-forming method may be known in the art. Examples thereof are a melt-spinning method, a solution-spinning method and a gel-spinning method.
EXAMPLE
[0177] The present invention is explained with reference to the following Examples, which do not limit the scope of the present invention.
Example 1
[0178] There were put 5.89 mg of chloro(methyl)[N,N′-(1,2-dihydroacenaphthylen-1,2-diylidene)bis(2,4,6-trimethylaniline-κN)]palladium (transition metal compound) prepared according to a method disclosed in Recueil des Travaux Chimiques de Pays-Bas, Vol. 113, page 88 (1994), and 10.6 mg of sodium tetrakis(3,5-bistrifluoromethylphenyl)borate (boron compound) prepared according to a method disclosed in Organometallics, Vol. 11, page 3920 (1992), in a 25 mL-Schlenk tube. There was added thereto 0.5 mL of dry methylene chloride, and the resultant mixture was stirred for 5 minutes. There was added thereto 0.124 g of 2,2-diallylcyclopentan-1,3-dione represented by the formula (3), and the mixture was stirred at room temperature for 24 hours, thereby obtaining 0.031 g of a homopolymer of 2,2-diallylcyclopentan-1,3-dione having units represented by the formula (1).
[0179] The homopolymer was soluble in chloroform. The homopolymer had a number-average molecular weight (Mn) of 1,800; a molecular weight distribution (Mw/Mn) of 1.5; 100% by mol of a trans-form in view of its relative configuration between A 7 and A 8 ; and no stereoregularity. Results are shown in Table 1.
[0180] The above-mentioned number-average molecular weight (Mn) and molecular weight distribution (Mw/Mn) were measured under the following conditions according to a gel permeation chromatography (GPC) using an equipment manufactured by JASCO Corporation having a degasser (DG-980-50), a pump (PU-980), an auto-sampler (AS-950), a column oven (CO-966), an R1 detector (RI-930) and a UV detector (UV-975), with a calibration curve prepared using standard polystyrenes:
two columns, SHODEX-806L, manufactured by Showa Denko K.K.; measurement temperature of 40° C.; solvent of chloroform; and sample concentration of 1 mg-sample/mL-solution.
[0185] The above-mentioned proportion of the trans-form was measured under the following conditions according to a 13 C-NMR method using an equipment, LA-500, manufactured by JEOL LTD; and the above-mentioned existence of the unit represented by the formula (1) was confirmed by assigning signals in the range of 23 to 50 ppm of a 13 C-NMR spectrum obtained by the 13 C-NMR method to a linear hydrocarbyl structure and a 5-membered hydrocarbyl structure contained in the unit represented by the formula (1)
measurement solvent of chloroform-d 1 ; measurement temperature of room temperature; sample concentration of 50 mg-sample/0.5 mL-solution; and reference material of chloroform-d 1 (77 ppm).
[0190] The above-mentioned stereoregularity was measured using an equipment, LA-500, manufactured by JEOL LTD according to a 13 C-NMR method comprising the steps of:
[0191] (1) preparing a solution of a polymer in chloroform-d 1 having a concentration of preferably 286 mg/mL;
[0192] (2) measuring a 13 C-NMR spectrum of the solution;
[0193] (3) obtaining a peak area (A 1 ) existing in a range of 46.2 to 46.6 ppm in the spectrum, and a peak area (A 2 ) existing in a range of 46.9 to 47.3 ppm therein, respectively, provided that a peak assigned to chloroform-d 1 appears at 77 ppm; and
[0194] (4) calculating the stereoregularity based on the following formulas,
[0000] threodiisotactic triad (%)=100 A 1 /( A 1 +A 2 )
[0000] threodisyndiotactic triad (%)=100 A 2 /( A 1 +A 2 )
Example 2
[0195] Example 1 was repeated except that 0.124 g of 2,2-diallylcyclopentan-1,3-dione was changed to 0.134 g of 2,2-diallylcyclohexan-1,3-dione represented by the formula (3), thereby obtaining 0.067 g of a homopolymer of 2,2-diallylcyclohexan-1,3-dione having units represented by the formula (1).
[0196] The homopolymer was soluble in chloroform. The homopolymer had a number-average molecular weight (Mn) of 1,400; a molecular weight distribution (Mw/Mn) of 1.4; 100% by mol of a trans-form in view of its relative configuration between A 7 and A 8 ; no stereoregularity; and a glass-transition temperature of 162° C. in a range between −20° C. and 200° C. Results are shown in Table 1.
[0197] The above-mentioned glass-transition temperature was measured according to a differential scanning calorimetry (DSC) using an equipment, SSC-5200, manufactured by Seiko Instruments & Electronics Ltd. under the following conditions:
heating from 25° C. to 135° C. at a rate of 10° C./minute, and keeping at 135° C. for 5 minutes; then, cooling from 135° C. to −60° C. at a rate of 20° C./minute, and keeping at −60° C. for 5 minutes; and then, measuring under heating from −60° C. to 150° C. at a rate of 10° C./minute.
Example 3
[0202] Example 1 was repeated except that (i) the transition metal compound was changed to 6.60 mg of chloro(methyl)[N,N′-(1,2-dihydroacenaphthylen-1,2-diylidene)bis(2,6-diisopropylaniline-κN)]palladium prepared according to a method disclosed in Recueil des Travaux Chimiques de Pays-Bas, Vol. 113, page 88 (1994), (ii) the 5 minute-stirring after addition of methylene chloride was changed to 30 minutes, and (iii) that 0.124 g of 2,2-diallylcyclopentan-1,3-dione was changed to 0.158 g of 2,2-diallylindan-1,3-dione represented by the formula (3), thereby obtaining 0.134 g of a homopolymer of 2,2-diallylindan-1,3-dione having units represented by the formula (1).
[0203] The homopolymer was soluble in chloroform. The homopolymer had a number-average molecular weight (Mn) of 12,000; a molecular weight distribution (Mw/Mn) of 1.6; 100% by mol of a trans-form in view of its relative configuration between A 7 and A 8 ; and no stereoregularity. Results are shown in Table 1.
[0000]
TABLE 1
Example
1
2
3
Polymerization condition
Transition metal compound (Note 1)
Me 3 AN
Me 3 AN
iPr 2 AN
Stirring time (minute) after addition of
5
5
30
CH 2 Cl 2
Kind of monomer (Note 2)
CPDO
CHDO
IDDO
Result
Solubility
Chloroform
soluble
soluble
soluble
Mn
1,800
1,400
12,000
Mw/Mn
1.5
1.4
1.6
Trans-form (% by mol)
100
100
100
Stereoregularity
no
no
no
Tg (° C.)
—
162
—
(Note 1):
Me 3 AN: chloro(methyl)[N,N′-(1,2-dihydroacenaphthylen-1,2-diylidene)bis(2,4,6-trimethylaniline-κN)]palladium
iPr 2 AN: chloro(methyl)[N,N′-(1,2-dihydroacenaphthylen-1,2-diylidene)bis(2,6-diisopropylaniline-κN)]palladium
(Note 2):
CPDO: 2,2-diallylcyclopentan-1,3-dione
CHDO: 2,2-diallylcyclohexan-1,3-dione
IDDO: 2,2-diallylindan-1,3-dione | A polymer containing units represented by the defined formula (1); and a process for producing the polymer, which comprises the step of polymerizing a compound represented by the defined formula (3), the units represented by the formula (1) being polymerized units of the compound represented by the formula (3) such as 2,2-dially-1,3-cyclopentanedione. | 2 |
BACKGROUND OF THE INVENTION
The present invention is related generally to the isolation and cloning of genes and obtaining products encoded by the gene. More particularly, the present invention is related to the isolation, cloning, sequencing and expression of the human CRIPTO gene and producing an isolated, substantially pure gene products including mRNA and recombinant CRIPTO protein.
"CRIPTO" is a new human gene which has never been previously described. The gene has been isolated, cloned and completely sequenced. FIG. 1 shows the nucleotide sequence of the CRIPTO cDNA and the amino acid sequence deduced therefrom. FIG. 1 also shows the amino acid sequence of the natural CRIPTO protein and FIG. 2 the amino acid sequence of the recombinant E. coli derived CRIPTO protein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 (which consists of FIGS. 1A through 1C) shows the nucleotide sequence of the human CRIPTO gene cDNA and the corresponding amino acid sequence.
FIG. 2 shows the amino acid sequence of the human CRIPTO protein as it is recombinantly reproduced in E. coli.
FIG. 3 is a comparison of the amino acid sequence of the human CRIPTO gene to several prior art proteins.
FIG. 4 demonstrates the focus forming activity of the human CRIPTO gene when transfected into NIH 3T3 cells.
FIG. 5 is a Northern blot showing expression of the CRIPTO gene by various human colon tumor cell lines.
FIG. 6 is a Northern blot demonstrating that the CRIPTO gene is not expressed in normal human colon tissue.
DETAILED DESCRIPTION
Isolation and Characterization of Human CRIPTO cDNA
In screening 3×10 7 independent clones of a human teratocarcinoma NT2D1 cell line cDNA library that was expressed in λgt10 and that was originally derived from NT2D1 poly(A)+RNA to isolate a full-length glucose-6-phosphate dehydrogenase (G6Pd) cDNA, 16 different clones were identified (Persico et al., Nucleic Acid Research, 14:2511-2522, 1986). One of these clones exceeded the expected size for the G6PD mRNA. Restriction mapping and sequencing showed that the aberrant cDNA which was approximately 5 kb in length to be a composite of two separate coding entities. A nucleotide segment of 2.8 kb corresponded to G6PD while the remaining 2.2 kb fragment (16B6 cDNA) had no relationship to the G6PD gene. The 16B6 cDNA fragment was used to probe the same NT2D1 cDNA library to isolate a full-length cDNA.
From several positive clones, 10 clones were isolated and subcloned into pUC18 after EcoR1 digestion. Analysis by restriction enzyme mapping and agarose gel electrophoresis demonstrated that the size of the various cDNA inserts varied from about 0.9 Kb to 2.0 Kb. The two largest cDNA clones, p3B2 and p1C1, and the shortest p2B3, were sequenced by the Sanger method. The complete nucleotide sequence has been deposited in the EMBL Gene Data Bank. The open reading frame of 564 base pairs codes for a protein of 188 amino acids in length (FIG. 1). Proteolytic cleavage sites are present in this protein designated CRIPTO at V-A (amino acid residues 28-29 and 159-160), R-K (residues 111-112), K-K (residues 126-127) and R-T-T-T (residues 171-174). One potential asparagine glycosylation sequence (Asn-Arg-Thr) is present at residues 79-81.
Production and Purification of Recombinant CRIPTO Protein in E. Coli
The buffers are prepared as follows:
Buffer A: 25% sucrose, 10 mM Tris-HCl (pH 8.0), ImM EDTA, 150 mM NaCl and 10 μg lysozyme.
Buffer B: 10 mM Tris-HCl (pH 7.6), ImM EDTA and 0.5% Triton X-100.
Buffer C: 0.1% SDS. 0.05M Tris-HCl (pH 8.0), 0.ImM EDTA, 5 mM DTT and 0.20M NaCl.
1. Grow an inoculum of suitably transformed strain of bacteria in LB broth containing 100 μg/ml of ampicillin overnight at about 32° C.
2. Dilute the bacterial culture 100-fold in LB broth and grow at 32° C. until OD 600 reaches 0.2.
3. Shift the bacterial culture to 44° C. for 20 minutes and then to 42° C. for 4 hours until OD 600 reaches 1.7.
4. Spin 50 ml of the bacterial culture at 5,000 g for 10 minutes at 4° C. and resuspend the bacterial pellet in 10 ml LB broth at room temperature (RT).
5. To 10 ml of frozen buffer A add 10 ml of bacterial suspension and defrost at RT prior to incubation for 15 minutes at 37° C.
6. Spin at 27,000 g for 10 minutes at 4° C.
7. Resuspend the pellet in 3 ml of buffer B and spin at 15000 rpm for 15 minutes at 4° C.
8. Repeat step #7 three times, saving the supernatant each time.
9. Sonicate the final spheroplast suspension 6 times for 30 seconds at 40 watts.
10. Divide into 4 Eppendorff tubes and spin at RT in a microfuge at 12,000 g for 10 minutes.
11. Discard the supernatant and resuspend the pellet of inclusion bodies in 1 ml of IM urea. Incubate for 30 minutes at 37° C. Spin 10 minutes in microfuge at 12,000 g.
12. Repeat step #11 twice.
13. Each pellet of the inclusion bodies is then dissolved in 200 μl of Laemmli sample buffer and analyzed by SDS-PAGE. Alternatively, resuspend inclusion body pellets in 600 μl of buffer C to solubilize the recombinant CRIPTO protein.
Recombinant CRIPTO Protein Characterization
1. The CRIPTO cDNA is used to produce a recombinant CRIPTO protein in E. coli as described above. The amino acid sequence of the CRIPTO protein is shown in FIG. 2. The inclusion body pellets are resuspended in 600 μl of buffer C and incubated at 37° C. for 18 hours to achieve almost 100% solubilization of the CRIPTO protein.
2. A partial solubilization is achieved in either 0.1M Tris-HCl buffer (pH 8.0) containing 6M guanidine HCl, 10M reduced glutathione and IM oxidized glutathione or in 0.05M Tris-HCl buffer (pH 8.0) containing ImM EDTA, 0.1M NaCl, 8M urea diluted with nine volumes of 0.05M KH 2 PO 4 (pH 10.7), 1 mM EDTA (pH 8.0) and 0.05M NaCl.
3. Following solubilization and SDS-PAGE analysis, the CRIPTO protein has a Mr of about 20,000 to 22,000.
A deposit of the cloned cDNA of the CRIPTO gene has been made at the ATCC on Feb. 28, 1990 under accession number 61412. The deposit shall be viably maintained, replacing if it becomes non-viable during the life of the patent, for a period of 30 years from the date of the deposit, or for 5 years from the last date of request for a sample of the deposit, whichever is longer, and upon issuance of the patent made available to the public without restriction in accordance with the provisions of the law. The Commissioner of Patents and Trademarks, upon request, shall have access to the deposit.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are now described. All publications mentioned hereunder are incorporated herein by reference. Unless mentioned otherwise, the techniques employed or contemplated herein are standard methodologies well known to one of ordinary skill in the art. The materials, methods and examples are illustrative only and not limiting.
The term "substantially pure" as used herein means as pure as can be obtained by standard isolation and purification techniques conventionally known to one of ordinary skill in the art.
The term "a reactive amount" as used herein means a quantity of the protein that would function in a manner desired in a particular application or utility of the protein.
As mentioned above, CRIPTO is transcribed into 2200 nucleotide long mRNA which is translated into a protein of 188 amino acid residues. Table 1 shows the expression of CRIPTO gene in humans and mice. The gene is active in teratocarcinoma cells, but inactive both in normal and other transformed cells and shut off when the teratocarcinoma cells are induced to differentiate by retinoic acid.
The amino acid sequence of CRIPTO protein was screened against a representative protein sequence database (Microgenie, Beckman). This search revealed that the CRIPTO protein is similar to several proteins, some of which are shown in FIG. 3. The similarity is restricted to a .sup.˜ 40 amino acid long, cysteine-rich, sequence known as the EGF-like segment. Besides the six cysteine residues in the characteristic spatial array, other amino acids are conserved among these proteins, e.g. the glycine, phenylalanine and tyrosine residues boxed in FIG. 1.
Transforming potential of the CRIPTO gene
It has been shown that certain oncogenes, such as K-FGF, c-sis, proto-dbl and c-erbB-2 can transform murine fibroblasts when their expression is driven by a strong promoter. Similarly, TGFα and EGF genes under the control of a strong promoter can induce transformation and tumorigenicity in fibroblasts.
To investigate whether the human CRIPTO gene has these properties, its cDNA was introduced into an expression vector in which transcription is controlled by the RSV long terminal repeats (LTR) (Gorman et al, 1982). The construct was transfected into NIH3T3 cells and its focus-forming activity was monitored (FIG. 4). In this experiment, the CRIPTO cDNA induced foci of transformed cells at an efficiency of 600 focus-forming units per pmol of DNA.
When CRIPTO cDNA was placed into a retroviral expression vector plasmid and transfected into mouse NIH-3T3 fibroblasts and into mouse NOG-8 mammary epithelial cells, in both of these cell types overexpression of this gene resulted in the in vitro transformation of these cells. (Tables 2 and 3).
In addition, substantially pure, isolated, recombinant CRIPTO protein (rCRIPTO) was obtained from a baculo virus expression vector in which the CRIPTO cDNA had been integrated. The availability of the CRIPTO cDNA and rCRIPTO protein now make it possible to detect cells or tissues expressing the CRIPTO gene. Various utilities of the CRIPTO cDNA and CRIPTO protein are now described.
Application and utilities of the CRIPTO cDNA and CRIPTO protein
Since the mRNA for the CRIPTO gene is expressed in approximately 60% to 70% of human colon tumor cell lines and at an equal frequency in primary human colon tumors, but not in normal human colon tissue (see Northern blot FIGS. 5 and 6), therefore, expression of CRIPTO mRNA and CRIPTO protein in a tissue would be a major tumor specific marker for the diagnosis and eventual prognosis of different types of cancer such as colorectal cancer. In addition, the CRIPTO gene maps to human chromosome 3 potentially at a region where deletions frequently occur and where such deletions have been found to be associated with a subset of primary human breast tumors and with a majority of small cell lung carcinomas. Hence, a loss of heterozygosity for this gene and/or a loss of or a reduction in CRIPTO mRNA expression due to deletions of one or both alleles of the CRIPTO gene may serve as adjunct tumor specific markers for other types of human cancer. Additionally, it has been experimentally demonstrated that introduction and subsequent overexpression of the human CRIPTO gene in a retroviral expression vector can lead to the in vitro transformation as detected by focus-forming activity or by anchorage-independent growth in soft agar of mouse NIH-3T3 fibroblast cells and of mouse NOG-8 mammary epithelial cells (Tables 2 and 3) indicating a role of this gene in the neoplastic process. Based on these facts, the availability of the CRIPTO cDNA and recombinant CRIPTO protein now allows the following applications:
1. The molecularly cloned, full-length human CRIPTO cDNA can be nick-translated, isotopically labeled, for example, with 32 P nucleotides and subsequently used as a probe for the analysis of Southern blots containing endonuclease digested DNA preparations to ascertain if there are amplifications, rearrangements, deletions or restriction fragment length polymorphisms of the CRIPTO gene in normal versus tumor tissue.
2. The labeled nick-translated CRIPTO cDNA can also be utilized for the analysis of Northern blots that contain poly(A)+RNA to determine the relative levels of CRIPTO mRNA expression in various normal and pathologic tissue samples.
3. The CRIPTO cDNA can be cloned into an SP6/T7 pGEM expression vector and the like and can then be used to generate a corresponding cRNA antisense riboprobe. This antisense riboprobe could then be labeled with 35 S nucleotides and utilized as a suitable probe for in situ RNA:RNA hybridization for histologic localization in normal or pathologic cells expressing CRIPTO mRNA.
4. CRIPTO sense oligonucleotides can be chemically synthesized and can be used as appropriate probes in a polymerase chain reaction (PCR) for potential detection of low levels of CRIPTO mRNA and for amplification of CRIPTO genomic sequences for subsequent isolation and cloning.
5. The CRIPTO cDNA can be utilized to generate either expression vector plasmids for transfection or to generate replication defective recombinant ecotropic or amphotropic retroviral expression vectors for infection into cells for determining whether overexpression of this gene in vitro might lead to malignant transformation or might alter the growth or differentiation properties of different mammalian cell types.
6. The CRIPTO cDNA when placed in an appropriate expression vector plasmid or in a comparable retroviral expression vector in the opposite orientation can be used to generate antisense mRNA. Such antisense expression vectors can then be used to transfect or to infect normal and malignant cells in vitro in order to determine whether endogenous CRIPTO expression is important in maintaining the proliferation, differentiation or transformation of these cells.
7. Nonderivatized or thio-derivatized CRIPTO antisense oligonucleotides can be chemically synthesized and used to treat cells in vitro similarly as described in #6 above. Additionally, antisense CRIPTO oligonucleotides can be incorporated into liposomes for site-directed delivery in vivo to tumors when appropriate tumor-specific monoclonal antibodies are also incorporated into these same vesicles.
8. The CRIPTO cDNA can be placed into various bacterial, yeast, insect baculo virus or mammalian expression vectors in order to obtain sufficient quantities of a potentially biologically active, recombinant CRIPTO protein.
9. A recombinant CRIPTO protein can be used to generate a panel of polyclonal (in rabbits, sheep, goat or pigs) and mouse monoclonal antibodies such that these immunological reagents can be used to screen for CRIPTO protein expression in normal and pathologic human and animal tissue samples by immunocytochemistry, by Western blot analysis, by enzyme-linked immune substrate assay (ELISA), by radioimmunoassay (RIA) and the like.
10. Since the CRIPTO protein is a member of the epidermal growth factor (EGF) supergene family that contains a variety of peptide mitogens and growth inhibitors, a biologically active recombinant CRIPTO protein can be used to determine if this peptide has any growth regulatory activity on a variety of normal and tumor cells in vitro.
11. Additionally, a recombinant CRIPTO protein can be iodinated and can be utilized to identify and characterize specific cell surface receptors for this potential growth modulatory peptide using conventional chemical cross-linking techniques.
It is noted that the methodologies for the above noted utilities are well known to one of ordinary skill in the art and no novel techniques are seen involved in making such usages. A composition of matter, in accordance with the present invention, comprises a reactive amount of the rCRIPTO protein in a sterile, non-toxic carrier or vehicle.
It is understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and scope of the appended claims.
TABLE 1______________________________________EXPRESSION OF CRIPTO GENE IN HUMANS AND MICE Total Poly (A).sup.+ RNA RNA______________________________________Organs and tissuesPlacenta (human) -- --Testis (mouse) -- --Cell linesHL60 (undifferentiated human myeloid -- NDcells)JEG (human choriocarcinoma cells) -- --PA-1 (human neuroblastoma cells) -- NDCa-Ma (human mammary carcinoma cells) -- NDHuman T lymphocyte -- NDHeLa -- --NA43 (human fibroblasts) ND --NT2D1 (undifferentiated human teratocar- + +cinoma cells)ΔNT2D1 (differentiated human teratocar- -- --cinoma cells)Term placenta fibroblasts ND --Term placenta primary culture ND --F9 (undifferentiated mouse teratocarcinoma + NDcells)ΔF9 (differentiated mouse teratocarcinoma -- --cells)NIH3T3 (mouse fibroblasts) -- ND______________________________________ ND, Not determined
TABLE 2______________________________________Anchorage-Independent Growth of Mouse NOG-8 MammaryEpithelial Cells Transfected with a Human cripto cDNA in aRSV Expression Vector PlasmidClone Total number of colonies/dish______________________________________NOG-8 (parental nontransfected) 10 ± 5.sup.a (-)2E 1690 ± 80 (+++)2L 925 ± 70 (++)2F 175 ± 25 (+)2H 166 ± 10 (+)______________________________________ .sup.a 2 × 10.sup.4 cells were seeded in 0.3% soft agar over a 0.8% agar overlay in 35 mm tissue culture dishes. Cultures were maintained for 14 days prior to staining of the cells with nitroblue tetrazolium. Colonies greater than 50 μm were scored and counted on an Artek colony counter. Results are the average from four separate dishes ± S.D. Numbers in parenthesis represent relative amounts of cripto mRNA as detected in cells following Northern blot hybridization with a labeled human cripto cDNA insert.
TABLE 3______________________________________Focus-Forming Activity of Human cripto cDNA in a RSVExpression Vector Plasmid after Transfection into MouseNIH-3T3 CellsClone Total number of foci/dish______________________________________NIH-3T3 (parental nontransfected) .sup. 5 ± 2.sup.aClone γ9 82 ± 5______________________________________ .sup.a 2 × 10.sup.3 cells were seeded in 35 mm dishes and maintaine for 2 weeks prior to staining with crystal violet. | A new human gene designated as "CRIPTO" gene has been identified and cloned. CRIPTO gene products and derivatives thereof have been obtained and various utilities of the same have been described. Association of CRIPTO gene with cancers, such as colorectal cancer and breast carcinoma, has been indicated. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to thickened cyanoacrylate compositions.
[0003] 2. Brief Description of Related Technology
[0004] Cyanoacrylate compositions are well known as one component reactive adhesives, which are quick bonding and suitable for applications on variety of substrates.
[0005] Because cyanoacrylate compositions are inherently of a low viscosity, some applications, such as those where a substrate having large pores is used, are cumbersome. For that reason, thickened cyanoacrylate compositions were developed. Reported thickeners include acrylate resins, such as poly(methyl(meth)acrylate), polymeric alkylcyanoacrylates, cellulose esters, such as cellulose acetate and cellulose butyrate, and polyvinyl ethers, such as polyvinylmethyl ether. See U.S. Pat. No. 3,742,018.
[0006] However, traditional cyanoacrylate compositions have been thickened successfully commercially with only a poly(methylmethacrylate) or poly(vinylacetate), which been used in higher viscosity versions of cyanoacrylate compositions, such as those available commercially under the LOCTITE tradename, bearing for instance the product numbers 406, 416, 424 or 431. In addition, in terms of cyanoacrylate compositions in gel form thixopropic agents such as fumed silica have been used successfully on a commercial scale, such as with those products commercially under the LOCTITE tradename, bearing for instance the product number 454. See U.S. Pat. Nos. 4,533,422 and Re. 32,889, and 4,837,260. The thixotropic, fumed-silica-containing cyanoacrylate compositions are described as being in the form of a nonflowable gel which will not substantially move when placed on a substrate. These cyanoacrylate compositions may also contain thickeners, such as for the purpose of preventing the fumed silica from settling in the composition. Disclosed thickeners include poly(meth)acrylates, polycyanoacrylates, and poly(vinyl)acetates.
[0007] It is well known to formulate adhesives in the form “stick” compositions. The patent literature on adhesives in “stick” form is extensive and covers a broad range of adhesive types, describing for instance emulsion adhesives, solvent based adhesives, and contact adhesives. In addition, gelling and solidifying additives for the preparation of such stick adhesives report the use of natural polymers and inert fillers. An example of one such adhesive stick is sold under the tradename PRITT STICK by Henkel KGaA. This is an emulsion-based adhesive.
[0008] A number of patent documents identify adhesive compositions that have been formulated as soft-solids, and in some cases sticks. For instance, U.S. Pat. No. 5,433,775 discloses an adhesive stick consisting of a water-based preparation of starch derivatives and a soap gel as the shaping gel-forming component. See also U.S. Pat. No. 5,371,131.
[0009] U.S. Pat. No. 3,846,363 relates to an adhesive crayon composition containing a sorbitol-benzaldehyde reaction product as an additive. U.S. Pat. No. 4,639,475 discloses an adhesive stick composed of the reaction product of sorbitol and/or xylitol and benzaldehyde as the gel-forming composition together with an adhesive resin which is the reaction product of methyl vinyl ether/maleic acid anhydride copolymers with partially neutralized acid phosphate esters of non-ionic wetting agents of the lower alkylene oxide adduct type. Room temperature dimensionally stable cyanoacrylate compositions have also been prepared with condensation products of aldehydes and ketones with polyols, such as dibenzylidene sorbital. See International Patent Publication Nos. WO 00/32709 and WO 01/91915, and Canadian Patent Application No. CA 2,353,605.
[0010] Japanese Patent Document No. 51-103,939 describes a stick-like epoxy adhesive and a stick-like epoxy hardening agent which is used therewith. The sticks in JP '939 patent document seem to be obtained by compounding a gelling agent and/or water and/or organic solvent with a liquid or solution type epoxy adhesive and an epoxy hardening agent.
[0011] German Patent Document No. DE 199 57 677 A1 describes a cyanoacrylate adhesive, coating or sealing material, which also contains at least one condensation product of an aldehyde or ketone with a polyol. The adhesive may be in stick form.
[0012] U.S. Pat. No. 4,497,916 discloses a continuous liquid phase non-cyanoacrylate adhesive composition to which is added solid wax-like particles dispersed therein. These particles may be chosen from polyethylene glycol materials having 4,000 to 20,000 molecular weight, stearic acid, acid waxes or stearic esters. The compositions disclosed in the '916 patent are formed by heating this combination of materials in slurry form and applying it, while heated, to threads. The composition then cools to obtain a non-mobile coating. This composition requires substantial preparation in order to obtain the composition and apply it on parts. U.S. Pat. No. 3,547,851 discloses anaerobic compositions, which have been rendered non-flowable through the inclusion of various waxes.
[0013] U.S. Pat. No. 6,451,927 describes a non-flowable poly(meth)acrylate adhesive composition having a polymeric matrix in sufficient quantity where it is non-flowable at temperatures up to 180° F. (82° C.) while being dispensable at room temperature without the application of heat.
[0014] Recently, Henkel Corporation introduced a line of adhesive products in the form of a stick. For instance, LOCTITE QUICK STIK 248, 268, 668, 548, 536 and PST 561 are members of that product line. However, conspicuously absent from this product line is one based on cyanoacrylates. One reason for this is that cyanoacrylates are notoriously sensitive to premature polymerization or destabilization, which is because of the cure profile or physical characteristics of the cyanoacrylate.
[0015] Accordingly, it would be desirable to provide a thickening agent for use as a constituent in cyanoacrylates that can be used in a variety of concentrations without adversely affecting the shelf life of the cyanoacrylate while having a dramatic impact on the viscosity, permitting the formulation of cyanoacrylates in a variety of viscosities up to and including a non-flowable form at room temperature.
SUMMARY OF THE INVENTION
[0016] The present invention is directed to a thickened cyanoacrylate composition which includes, beyond the cyanoacrylate component, a polymer component, such as one constructed from poly(ethylene glycol) and poly(butylene terephthlate) segments. A particularly desirable polymer component for use herein is poly[butyleneterephthalate-co-poly(ethyleneglycol)terephthalate]. The addition of this polymer component allows for the formulation of cyanoacrylate compositions in the form of low viscosity emulsions, gels and non-flowable forms, depending on the nature and level of the polymer material used in the composition.
[0017] In another aspect, the present invention is directed to a method of bonding two or more substrates including the steps of providing at least two substrates; applying, onto at least a portion of a surface of one or both of the at least two substrates, a cyanoacrylate composition as noted above; contacting the surfaces of the at least two substrates having the cyanoacrylate composition there between; and curing the cyanoacrylate composition.
[0018] In still another aspect, the present invention is directed to a bonded assembly including: a first substrate having a first surface; another substrate having a second surface; and a cured cyanoacrylate composition disposed between the first and second surfaces, the composition having included prior to cure: a cyanoacrylate component and the polymer component as noted above.
[0019] In yet another aspect, the present invention is directed to a method of preparing the cyanoacrylate composition as noted above.
[0020] In a further aspect, the present invention is directed to an article of manufacture. In this aspect, there is included a dispensing container for housing and dispensing a non-flowable adhesive composition. The container includes a generally elongate hollow body having first and second ends, with one of the ends having a dispense opening. The container houses the room-temperature-flowable polymerizable cyanoacrylate composition as noted above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a perspective view of a lipstick-type dispenser container with a dispenser cap.
[0022] FIG. 2 is a perspective view of a lipstick-type dispenser container showing a non-flowable cyanoacrylate composition contained therein.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The present invention is directed to a thickened cyanoacrylate composition, which includes, beyond the cyanoacrylate component, a polymer material.
[0024] The cyanoacrylate component includes at least one α-cyanoacrylate monomer of the formula:
where R 1 represents a straight chain or branched chain alkyl group having 1 to 12 carbon atoms (which may be substituted with a substituent such as a halogen atom or an alkoxy group), a straight chain or branched chain alkenyl group having 2 to 12 carbon atoms, a straight chain or branched chain alkynyl group having 2 to 12 carbon atoms, a cycloalkyl group, an aralkyl group or any aryl group. Specific examples of R 1 are a methyl group, an ethyl group, an n-propyl group, an isopropyl group, an n-butyl group, an isobutyl group, a pentyl group, a hexyl group, an allyl group, a methallyl group, a crotyl group, a propargyl group, a cyclohexyl group, a benzyl group, a phenyl group, a cresyl group, a 2-choroethyl group, a 3-choropropyl group, a 2-chorobutyl group, a trifluoroethyl group, a 2-methoxyethyl group, a 3-methoxybutyl group and a 2-ethoxyethyl group. Ethyl cyanoacrylate is a particularly desirable choice for use in the inventive compositions.
[0025] A single α-cyanoacrylate monomer or a mixture of two or more of these α-cyanoacrylate monomers can be used. Generally, the above α-cyanoacrylate monomer used alone as an adhesive, and one or more components such as those set forth below, are used to formulate a commercial composition. The additional components includes, but are not limited to, accelerators; anionic polymerization inhibitors; radical polymerization inhibitors; additives, such as plasticizers, heat stabilizers and toughening agents; and/or perfumes, dyes, and pigments.
[0026] A suitable amount of α-cyanoacrylate monomer present in the inventive compositions is from about 50 to 99.5% by weight, such as 60 to 90% by weight, desirable 75% by weight, based on the total weight of the composition.
[0027] The polymer material may be one constructed from poly(ethylene glycol) and poly(butylene terephthlate) sections. For instance, one commercially available example of such a material is sold by Octoplus, Netherlands under the tradename PolyActive. PolyActive-brand products are described as biodegradable polymer-based drug delivery systems. PolyActive-brand products represent a series of poly(ether ester) and multiblock copolymers based on poly(ethylene glycol), PEG, and poly(butylene terephthalate), PBT. The amount and length of each of the two building blocks is reported to create a diverse family of polymers with physical properties such as rate of controlled release, degradation, swelling and strength that can be precisely controlled by the approprite combination of the two copolymer segments. The disclosure of PolyActive-brand products may be shown as
[0028] OctoPlus has reported that due to the presence of hydrophilic poly(ethylene glycol) segments, PolyActive-brand products exhibit a hydrogel character.
[0029] The polymer material should be used in the present invention in amounts of about 0.5% to about 30%, for instance about 2.5% to about 20%, such as about 5% to about 15%, by weight based on the total weight of the composition. When present in these amounts, the increased viscosity, gel and non-flowability characteristics of a composition can be obtained. Additionally, these materials can be added directly in solid form, such as in powder or particulate form, without pre-melting or even heating of the polymeric matetial.
[0030] An anionic polymerization inhibitor is generally added to α-cyanoacrylate compositions in an amount from about 0.0001 to 10% by weight based on the total weight of the composition, to increase the stability of the composition during storage. Examples of useful inhibitors include sulfur dioxide, sulfur trioxide, nitric oxide, hydrogen fluoride, organic sultone inhibitors, boron trifluoride and methane sulfonic acid, aromatic sulfonic acids, aliphatic sulfonic acids, and sulfones. The amount of inhibitor will suitably be any convenient amount in order to slow down cure of the composition. Desirably, inhibitors of anionic polymerization are present at about 0.0001% to about 0.1% by weight based on the total weight of the composition.
[0031] A radical polymerization inhibitor is generally added to α-cyanoacrylate compositions as well, in an amount from about 0.001 to 2.0%, particularly 0.03 to 0.5%, based on the total weight of the composition, for the purpose of capturing radicals which are formed by light during storage. Such inhibitors are ordinarily of the phenolic type include, for example, hydroquinone and hydroquinone monomethyl ether. Other inhibitors suitable for use herein include butylated hydroxytoluene and butylated hydroxyanisole.
[0032] A thickener may be added to increase the viscosity of the α-cyanoacrylate composition; however, with the recited polymeric material, it may not be as desirable. Nevertheless, various polymers can be used as thickeners, and examples include poly(methyl methacrylate), methacrylate-type copolymers, acrylic rubbers, cellulose derivatives, polyvinyl acetate and poly(α-cyanoacrylate). A suitable amount of thickener is generally about 0.01 to 30% by weight, preferably 5.0 to 25% by weight based on the total weight of the cyanoacrylate adhesive composition.
[0033] Phthalic anhydride and other plasticizers may also be added to the cyanoacrylate component to further aid in durability and impact, heat, and moisture resistance. The plasticizer is preferably present in an amount of about 0.005% to about 5.0%, more preferably about 0.01% to about 2.0% by weight based on the total weight of the composition.
[0034] Perfumes, dyes, pigments, and the like may be added to the inventive composition depending on use purposes in amounts which do not adversely affect the stability of the α-cyanoacrylate monomer. The use of such additives is within the skill of those practicing in the cyanoacrylate adhesive art and need not be detailed herein.
[0035] Accelerators that may be useful in the cyanoacrylate compositions include for example calixarenes, oxacalixarenes, and combinations thereof. Of the calixarenes and oxacalixarenes, many are known, and are reported in the patent literature. See e.g. U.S. Pat. Nos. 4,556,700, 4,622,414, 4,636,539, 4,695,615, 4,718,966, and 4,855,461, the disclosures of each of which are hereby expressly incorporated herein by reference.
[0036] Another potentially useful accelerator component is a crown ether. A host of crown ethers are known. For instance, examples which may be used herein either individually or in combination, or in combination with the calixarenes and oxacalixarenes described above include 15-crown-5,18-crown-6, dibenzo-18-crown-6, benzo-15-crown-5, dibenzo-24-crown-8, dibenzo-30-crown-10, tribenzo-18-crown-6, asym-dibenzo-22-crown-6, dibenzo-14-crown-4, dicyclohexyl-18-crown-6, dicyclohexyl-24-crown-8, cyclohexyl-12-crown-4,1,2-decalyl-15-crown-5,1,2-naphtho-15-crown-5,3,4,5-naphthyl-16-crown-5,1,2-methyl-benzo-18-crown-6,1,2-methylbenzo-5,6-methylbenzo-18-crown-6,1,2-t-butyl-18-crown-6,1,2-vinylbenzo-15-crown-5,1,2-vinylbenzo-18-crown-6,1,2-t-butyl-cyclohexyl-18-crown-6, asym-dibenzo-22-crown-6 and 1,2-benzo-1,4-benzo-5-oxygen-20-crown-7. See U.S. Pat. No. 4,837,260 (Sato), the disclosure of which is hereby expressly incorporated here by reference.
[0037] Other suitable accelerators include those described in U.S. Pat. No. 5,312,864 (Wenz), which are hydroxyl group derivatives of an α-, β- or γ-cyclodextrin which is at least partly soluble in the cyanoacrylate; in U.S. Pat. No. 4,906,317 (Liu), which are silacrown compounds to accelerate fixturing and cure on de-activating substrates such as wood, examples of which are within the following structure:
where R 3 and R 4 are organo groups which do not themselves cause polymerization of the cyanoacrylate monomer, R 5 is H or CH 3 and n is an integer of between 1 and 4. Examples of suitable R 3 and R 4 groups are R groups, alkoxy groups such as methoxy, and aryloxy groups such as phenoxy. The R 3 and R 4 groups may contain halogen or other substituents, an example being trifluoropropyl. However, groups not suitable as R 4 and R 5 groups are basic groups such as amino, substituted amino and alkylamino.
[0038] Specific examples of silacrown compounds useful in the inventive compositions include:
dimethylsila-11-crown-4;
dimethylsila-14-crown-5; and
dimethylsila-17-crown-6.
[0039] The accelerator component should be included in the compositions in an amount within the range of from about 0.1% to about 10%, with the range of about 0.5% to about 5% being desirable, and about 0.1% to about 1% by weight based on the total weight of the composition being particularly desirable. See e.g. U.S. Pat. Nos. 4,170,585; 4,450,265; 6,294,629; and 6,475,331, the contents of which are all incorporated herein by reference.
[0040] Preparation of the compositions and products of the present invention can be achieved by mixing the polymer material into the cyanoacrylate composition at elevated temperature. Desirably, these constituents are mixed at about 1000 rpm under elevated temperature conditions, for example, 80° C. to 140° C. The polymer material may then be added, while maintaining the temperature at about 80° C. to 140° C. Or, the polymer material may be preheated to the above-described temperatures before its addition. The actual temperature used may vary depending upon the melting point or the solubility in a cyanoacrylate of the polymer material. The so-formed composition may then be dispensed into a dispensing container, such as a lipstick-type dispenser, while hot. The dispensers are then allowed to cool to create the composition of the present invention.
[0041] Mixing is performed for a time sufficient to disperse or dissolve the polymer material into the cyanoacrylate composition, which can vary depending on the batch size. Generally, only seconds or minutes are required to achieve the desired blending in of the polymer material. The composition will thus become thickened upon returning to room temperature.
[0042] Reference to FIGS. 1-2 shows the dispenser to be typically in a generally elongate shape and designed to mechanically advance the composition through a dispense opening. The dispense opening can be defined as the entire perimeter of the container wall or it can be smaller apertures such as slots or holes located on the end surface of the container. Alternatively, the dispense opening can extend away from the container wall, narrowing or telescoping as it so extends to form a dispense opening with an internal diameter less then that of the container wall itself. It may be desirable to have the narrowed dispense end include at the distal end thereof a flow through applicator or brush for more precise application. A portion of the dispense end of the container can be concave to accommodate a threaded member or tubular body which requires application of the composition. And since the cyanoacrylate adhesive composition is in a non-flowable form, the mechanic or maintenance worker can readily carry it without fear of spillage.
[0043] The container is generally fitted with a cap, which fits over and around the container walls.
[0044] At the container end opposite the dispense opening, i.e., the bottom end of the container is proximally located a mechanism for mechanically advancing the adhesive. These mechanisms are generally well known in the art and include a pusher means which can include a knob located at the bottom of the container which when turned in one direction advances the composition contained therein to the dispense opening and when turned in the other direction moves the composition in the opposite direction. This mechanism for mechanically advancing the cyanoacrylate adhesive composition creates a friction on the non-flowable cyanoacrylate compositions, which friction renders the composition free flowable while it is applied.
[0045] More specifically, reference to FIGS. 1-2 depicts an article of manufacture in more particular detail. FIG. 1 shows container 10 having a generally elongate tubular shape defined by wall 20 and having a dispense end defined by perimeter 21 . Cap 50 as shown is designed for closingly engaging tubular wall 20 by fitting thereover. Desirably, cap 50 engages the tubular wall 20 to provide a barrier against ambient humidity to prevent premature curing of the cyanoacrylate adhesive composition disposed within container 10 . Composition 30 is shown in FIG. 1 within container 10 . FIG. 2 shows composition 30 being advanced above perimeter 21 using knurled knob 40 which was turned to mechanically advance the composition within container 10 . In one embodiment, knob 40 may be turned in the opposition direction to cause composition 30 to descend back within container 10 .
[0046] The container 10 (or for that matter alternative designs thereof) may be constructed from a material to which cyanoacrylate materials do not stick, like poyolefins, e.g., polyethylene, polypropylene, or polymethylpentene. Desirably, materials that have a low penetrability to gases and moisture should be used, in order to ensure good shelf life of the cyanoacrylate. Thus, high density polyethylene (HDPE), or co-extruded multi layer materials (e.g., inner layer polyethylene, outer layer a gas barrier plastic) may be used, examples of such gas barrier plastics include polyvinylidenechloride, co-polymers of vinylidenechloride, polycarbonate, co-polymers of vinylacohol and ethyleneglycol). In addition, metal containers with laquered inner surfaces may be used.
[0047] The cyanoacrylate compositions of the present invention are useful in bonding two or more substrates. A sufficient portion of the composition may be placed on a surface of one of the two or more substrates. The other substrate is then positioned adjacent to the cyanoacrylate composition and the two substrates are placed in contact to form an assembly, upon curing of the cyanoacrylate.
[0048] The following non-limiting examples are intended to further illustrate the present invention.
EXAMPLES
[0049] Cyanoacrylate compositions labeled Sample Nos. 1-6 were prepared by incorporating the amount indicated in Table 1 of poly[butyleneterephthalate-co-poly(alkyleneglycol)terephthalate], available commercially from Aldrich Chemical Co., and mixing for about 10 minutes at about 120° C., until the polymer material dissolved in the cyanoacrylate composition.
TABLE 1 Sample No./Amt. (wt %) Component 1 2 3 4 5 6 Ethyl cyanoacrylate monomer Bal. Bal. Bal. Bal. Bal. — n-Butyl cyanoacrylate — — — — — Bal. monomer Polymer Material 1 2.5 5 10 15 10
[0050] Table 2 shows the visual observation of gel formation and aspect of Sample Nos. 1-6.
TABLE 2 Sample No. Gel Formation Aspect 1 No semitransparent emulsion 2 Yes semitransparent 3 Yes opaque 4 Yes opaque 5 Yes opaque 6 Yes colorless
[0051] An inventive composition in stick form was prepared from 6.25% by weight polymer material in ethyl cyanoacrylate. Once mixed, the composition was cast into an empty container, and after returning to room temperature, the composition solidified into what appeared to be a non-flowable mass.
[0052] The so-formed composition in non-flowable form was used by application first onto paper in the same way as a conventional PRITT STICK-brand adhesive stick would. Within 10 seconds, a resulting fixture formed. The so-formed composition was also used on black acrylonitrile-butadiene-styrene-terpolymer plastic, and resulted in a fixture time of 8 seconds. | The present invention relates to thickened cyanoacrylate compositions, such as those in gel or non-flowable forms. More particularly, the present invention relates to non-flowable cyanoacrylate compositions which can be packaged in a convenient pocket-sized applicator dispenser for use in spreading the cyanoacrylate compositions onto substrates. | 2 |
BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to a suspension system that incorporates a torque beam that can be connected to a variety of axle seat assemblies and to the form of a bushing for mounting the torque beam to a hanger. The invention further relates to means to break the torque beam free of the axle seat assembly even though rusted in place.
There are several embodiments to the invention. These embodiments differ primarily in the different structure of the axle seat assembly. Some axle seat assemblies are overslung and some are underslung. All are designed to accommodate various installation parameters dictated by the kind of vehicle with which the suspension system is to be installed and the kind of air spring that is to be used. Also important is the location of the axle relative to the chassis and relative to the hanger.
Each of the suspension systems of this invention includes a hanger, a torque beam, a bushing assembly for mounting an end of the torque beam to the hanger, an axle seat assembly connected to the vehicle axle, an air spring mounted between the axle seat assembly and the chassis, and means for connecting the torque beam to the axle seat assembly. Each axle seat assembly may be distinct in structure, but it has means defining a sleeve. The torque beam has means defining a tubular member that is complementary to the sleeve. The tubular member is fitted telescopically within the sleeve and connected rigidly in place. The connecting means includes bolts and spacer plates between the sides of the tubular member and the inner sides of the sleeve.
In an embodiment of the invention, one of these spacer plates can be knocked free in the event of rust so that the parts can be more readily separated. Also, the means defining the sleeve of the axle seat assembly may include straps across the lower side of the torque beam that are removable to further facilitate separation of the components.
The bushing assembly includes an inner sleeve, an outer sleeve, and an annular elastomeric member between the inner and outer sleeves. The outer sleeve is formed at an end of the torque rod. The elastomeric member has special recesses in it to facilitate flow of the elastomeric member under compression.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view of a suspension system according to one embodiment of this invention;
FIG. 2 is a top plan view of the suspension system of FIG. 1 as viewed along the plane of the line 2--2 of FIG. 1;
FIG. 3 is a front elevation view of the suspension system of FIG. 1 as viewed along the plane of the line 3--3 of FIG. 1;
FIG. 4 is a rear elevation view of the suspension system of FIG. 1 as viewed along the plane of the line 4--4 of FIG. 1;
FIG. 5 is a view in section taken along the plane of the line 5--5 of FIG. 1;
FIG. 6 is a side elevation view of a second embodiment of the suspension system of this invention;
FIG. 7 is a top plan view of the suspension system of FIG. 6;,
FIG. 8 is a front elevation view of the suspension system of FIG. 6 as viewed from the left side of FIG. 6;
FIG. 9 is a rear elevation view of the suspension system of FIG. 6 as viewed from the right side of FIG. 6;
FIG. 10 is a view in section taken along the plane of the line 10--10 of FIG. 6;
FIG. 11 is a side elevation view of a third embodiment of the suspension system of this invention;
FIG. 12 is a top plan view taken along the plane of the line 12--12 of FIG. 11;
FIG. 13 is a rear elevation view of the suspension system of FIG. 11 as viewed along the plane of the line 13--13 of FIG. 11;
FIG. 14 is an enlarged view in vertical medial section through a preferred bushing assembly used in any of the embodiments of this invention to mount a torque rod to a hanger;
FIG. 15 is a view in section taken along the plane of the line 15--15 of FIG. 14;
FIG. 16 is a side elevation view of a fourth embodiment of the suspension system of this invention;
FIG. 17 is a top plan view of the suspension system of FIG. 16;
FIG. 18 is a front elevation view of the suspension system of FIG. 16 as viewed along the plane of the line 18--18 of FIG. 16;
FIG. 19 is a rear elevation view of the suspension system of FIG. 16 as viewed along the plane of the line 19--19 of FIG. 16;
FIG. 20 is a view in section taken along the plane of the line 20--20 of FIG. 16;
FIG. 21 is a partial side elevation view of the suspension system of FIG. 16 but showing a modification for installation on a square axle;
FIG. 22 is a side elevation view of a fifth embodiment of the suspension system of this invention;
FIG. 23 is a top plan view taken along the plane of the line 23--23 of FIG. 22;
FIG. 24 is a front elevation view of the suspension system of FIG. 22 as viewed along the plane of the line 24--24 of FIG. 22;
FIG. 25 is a rear elevation view of the suspension system of FIG. 22 as viewed along the plane of the line 25--25 of FIG. 22;
FIG. 26 is a side elevation view of a sixth embodiment of the suspension system of this invention;
FIG. 27 is a top plan view of the suspension system of FIG. 26; and
FIG. 28 is a rear elevation view of the suspension system of FIG. 26 as viewed along the plane of the line 28--28 of FIG. 26.
DESCRIPTION OF PREFERRED EMBODIMENT
The suspension system 40 shown in FIG. 1 is installed on a vehicle having a chassis 42 and an axle 44 spaced a relatively large distance below the chassis 42. The suspension system 40 includes a torque beam 45 connected by a bushing assembly 46 to a hanger assembly 47. The torque beam 45 is connected to an axle seat assembly 48 that is welded to the axle 44. An air spring 49 is mounted between the chassis 42 and the axle seat assembly 48.
In greater detail, the torque beam 45 comprises a hollow tubular member 50 of square cross section formed by a top 52, a bottom 54 and sides 56 and 57, and preferably, the cross section of the tubular member 50 is five inches wide and five inches high. One end 58 of the tubular member 50 is squared off. The other end is welded to a transverse cylindrical sleeve 60 that functions as the outer housing for the bushing assembly 46.
The torque beam 45 is universal in that it can be used with a number of different axle seat assemblies. The axle seat assembly 48 of FIG. 1 is an example. This axle seat assembly 48 is designed to accommodate the various influencing parameters of the vehicle, such as axle height, ground clearance, location of vehicle components, size of the air spring 54, desired location of the air spring 54, and whether the axle seat assembly is to be overslung or underslung, among others.
The universality of the torque beam 45 is also such that its connection to the axle seat assembly is by fixed connections, as will be described, making the torque beam a rigid part of the axle seat assembly.
The torque beam is large (five inches square). This allows the use of lighter-gauge material, and the wall thickness of the torque beam is only 1/4 inch. Yet the overall area of the torque beam is greater so that its section modulus is greater.
The bushing assembly 46 is illustrated in FIGS. 14 and 15. It should be understood that the bushing assembly 46 may incorporate an eccentric bolt 62, such as the kind disclosed in U.S. Pat. No. 3,510,149 issued to John E. Raidel, for the purpose of axle alignment. Such a bolt 62 is tightened against blocks 64 and 66 on the opposite sides of a pair of spaced plates 68 and 70 that are part of the hanger assembly 47. A hole 72 through the plate 68 is large enough to allow removal of the eccentric bolt 62.
A sleeve 74 is mounted on the eccentric bolt 62 and is locked in place upon tightening of the bolt 62 to press the blocks 64 and 66 against the plates 68 and 70. Between the inner sleeve 74 and the outer sleeve 60, there is an elastomeric bushing member 76 having an annular resilient wall 78 with an inner cylindrical face 80 in contact with the inner sleeve 74 and an outer cylindrical face 82 in contact with the outer sleeve 60. The ends 84 and 86 of the annular wall 78 are beveled, reducing the width of the annular wall 78 from the inner face 80 to about 51/4 inches to the outer face 82 to allow for flow of the annular wall 78 under compression. The uncompressed outside diameter of the bushing member 76 is about 51/4 inches before it is compressed into a sleeve 60 having an inside diameter of about five inches.
In its non-deformed condition, the annular wall 78 has an annular groove 88 midway between its ends 84 and 86 that is about 1/4 inch deep and tapers inwardly from a width of about 3/4 inch. The annular groove 88 allows for the flow of rubber when the bushing member 76 is compressed, at which time the annular groove 88 will be reduced in size or may disappear due to such rubber flow.
In addition, the resilient bushing member 78 has a group of three upper recesses 90 and a group of three lower recesses 92 extending from the end 84 and another group of three upper recesses 94 together with the group of three lower recesses 96 extending from the opposite end 86.
As shown in FIG. 15, the three upper recesses 90 are generally equally spaced and on a common radius, occupying generally the upper quadrant of the bushing member 76. The lower three recesses 92 are similarly oriented but lie generally within the lower quadrant of the bushing member 76. On the opposite end 86, the upper recesses 94 are aligned with the recesses 90 and the lower recesses 96 are aligned with the recesses 92. Each recess 90, 92, 94 and 96 is tapered from a radius of about 7/16 inch at its mouth to a radius of about 5/16 inch at the closed end of the recess.
There is an arcuate groove 98 extending between the three upper recesses 90. Another arcuate groove 100 extends between the lower recesses 92. A similar arcuate groove 102 extends between the recesses 94, and an arcuate groove 104 extends between the recesses 96. These arcuate grooves 98, 100, 102 and 104 allow the edges of the recesses 90, 92, 94 and 96 to move without cracking. The depth of the grooves 98, 100, 102 and 104 is about 1/2 inch.
Although FIG. 14 shows the bushing assembly 46 installed in the sleeve 60, the figure shows the resilient annular wall 78 in its uncompessed condition for illustrative purposes. It will be understood that in actual use, the outer sleeve 60 will have compressed the resilient annular wall 78 and distorted it from the condition that is illustrated in FIGS. 14 and 15. In the compressed condition, the resilient material comprising the annular wall 78 will flow with the annular groove 88 being reduced in size or disappearing and the recesses 90, 92, 94 and 96 being distorted.
Because the recesses 90, 92, 94 and 96 are in the upper and lower quadrants of the resilient member 98, the bushing assembly 46 is more flexible in a vertical direction. Longitudinal movement is more firmly resisted.
Because the axle 44 is relatively low relative to the chassis 42 in the particular vehicle shown in FIG. 1, the hanger 47 is relatively long to locate the bushing assembly 46 at approximately the same elevation as the axle 44. The hanger 47 includes the spaced plates 68 and 70 which are part of a vertical U-channel 110. The U-channel 110 is welded to a horizontal plate 112 that is welded to or otherwise connected to the chassis 42. A reinforcing pipe 114 extends between the side plates 68 and 70 and also extends across the vehicle to a similar hanger like the hanger 47 on the opposite side of the vehicle.
The axle seat assembly 48 includes a U-channel 114 having a bottom 116 and sides 118 and 120 (see FIG. 4) and having side flanges 122 and 124 to which a plate 126 is welded. The plate 126 functions as a lower spring seat for the air spring 54, and the upper side of the air spring is connected to the chassis 42 such as by bolts 128. Gusset plates 130 welded to the channel member 114 and the horizontal plate 126 provide reinforcement.
The plate 126 is inclined downwardly and rearwardly as is shown in FIG. 1. It covers the section of the flanges 122 and 124 lying rearward of the axle 44. A rectangular sleeve 130 having a top wall 132, a bottom wall 134 and side walls 136 and 138 fits between the side walls 118 and 120 of the channel member 120. The width of the sleeve 130 between the sides 136 and 138 is about the same as the span between the sides 118 and 120, enabling the sleeve 130 to be fit within and welded in place to the channel member 120.
The sides 136 and 138 have cutouts 140 that receive the axle 44 and allow the axle seat assembly 52 to be welded to the axle 44. There are reinforcing cross members 142 and 144 between the side plates 136 and 138, and these cross member 142 and 144 are also welded to the axle 44. In addition, gusset plates 146 and 148 are welded to the side walls 120 and 122 and to the axle 44. Additional gussets 150 and 152 are welded to the sides 136 and 138 of the sleeve 130 and to the axle 44.
When it is installed, the torque beam 45 fits within the sleeve 130. As shown in FIG. 5, the top and bottom walls 52 and 54 of the torque beam 45 bear against the top and bottom walls 132 and 134 of the sleeve 130 whereas the side walls 56 and 57 of the torque beam 45 are spaced from the side walls 136 and 138 of the sleeve. Within the resulting space, there are spacer plates 156 and 158, and in this embodiment, they are welded to the side walls 136 and 138, respectively. These spacer plates 156 and 158 act as bearing surfaces for the sides of the torque beam 45.
The torque beam 45 is locked within the sleeve 130 by a pair of bolts 160 and 162. The bolts 160 and 162 pass through spacer sleeves 164 before the bolts are tightened by nuts 166. Because the parts are close fitting, tightening of the nuts 166 causes the spacer plates 156 and 158 to be pressed against the sides 56 and 57 of the torque beam 45, in turn pressing those torque beam sides against the spacer sleeve 164.
The welded spacer plates 156 and 158 are satisfactory for most installations. However, if rust forms between the spacers and the torque beam 45, together with rust formed on the torque beam 45 beyond the spacers 156 and 158, separation of the torque beam 45 from the axle seat assembly 48 can be difficult. As will be described, other embodiments of this invention confront this problem.
FIGS. 6 through 10 illustrate a second embodiment of the invention wherein a suspension system 170 is installed on a different vehicle that has a chassis 172 and an axle 174 that may be further below the chassis 172 than is the axle 44 relative to the chassis 42. For the suspension system 170, the same hanger assembly 47 may be used.
The same torque beam 45 is incorporated and the same bushing assembly 46 is used to install the torque beam 45 on the hanger assembly 47. However, the axle seat assembly 176 is different, being adapted to the particular vehicle as well as to the fact that the air spring 178 is different, being a triple convolute air spring mounted between the chassis 172 and the axle seat assembly 176 at a location that is partially over the axle 174.
The axle seat assembly 176 comprises an inverted channel member 180 having a top wall 182 and side walls 184 and 186 terminating in outwardly extending flanges 188 and 190. The sides 184 and 186 of the channel member 180 have cutout sections 192 that fit around the upper side of the axle where the sides 184 and 186, together with reinforcing strips 194, are welded to the axle 174. Rearwardly of the axle 174, the channel member 180 is cut to form downwardly and rearwardly inclined upper edges 196 to which a spring seat connecting plate 198 is welded. The air spring 178 is connected between the plate 198 and the chassis 172 by suitable bolts 200 and 202, respectively. There are suitable reinforcing gussets, for example the gussets 204, welded between the sides 184 and 186 and the plate 198 to reinforce the structure.
The connection between the torque beam 45 and the axle seat assembly 176 includes a spacer plate 206 that is welded to the side 184 of the channel member 180, but not to the side wall 56 of the tubular member 50. On the opposite side, there is a spacer plate 208 that is not welded to either the side wall 186 or the side 58. The spacer plate 208 has a front end 210 formed as an outwardly projecting lug by which it can be struck by a hammer to drive the spacer plate 208 clear of the space between the side wall 186 and the side 58 even though the spacer plate 208 may have become rusted in place. Knocking the spacer plate 208 clear makes it easier to separate other areas that may have rusted together.
There are two spacer sleeves 212 and 214 that are welded between the sides 56 and 58 of the tubular member 50. Two bolts 216 and 218 extend through the side wall 184, the spacer plate 206, the tubular sleeves 212 and 214, respectively, the side 58, the spacer plate 208, and the side wall 186, and they are tightened in place by nuts 220 and 222, respectively. After tightening, the bolts 216 and 218 and/or the nuts 220 and 222 may be spot welded in place.
A pair of retainer straps 224 and 226 span the lower side of the axle seat assembly 176 and are fastened to the flanges 188 and 190 by bolts 228. Straps 224 and 226 strengthen the connection between the torque beam 45 and the axle seat assembly 176 and yet, upon removal of the bolts 216 and 218 and removal of the straps 224 and 226, facilitate knocking the torque beam 45 free of the axle seat assembly 176 even when rusted.
This is in contrast to the suspension system 40 of FIG. 1 where the separation of the torque beam 45 from the axle seat assembly 48 must be by sliding those parts free of one another against the resistance of rusted joints.
FIGS. 11 through 13 illustrate another embodiment of the invention wherein a suspension system 240 is installed on a vehicle having a chassis 242 and an axle 244. The suspension system 240 includes the torque beam 45, the bushing assembly 46, and the hanger 47. It also includes an axle seat assembly 246 that is similar to the axle seat assembly 176 of the suspension system 170 except that it accommodates a smaller span between the axle 244 and the chassis 242 and accommodates an air spring 248 that is further forward and more directly above the axle 244.
The axle seat assembly 246 is formed with a rectangular sleeve 250 (similar to the sleeve 130 of FIG. 5) having cutout sections 252 where it is welded to the axle 244 and having cut wall sections 254 to which a downwardly and rearwardly inclined spring seat plate 256 is welded. The air spring 248 is mounted between the chassis 242 and the plate 256. The tubular member 50 is telescoped within and connected to the sleeve 250 by bolts 258 and 260 and spacer plates, like the spacer plate 262. This installation is similar to that illustrated in FIG. 5.
In FIGS. 16 through 21, a suspension system 270 is shown installed on a vehicle having a chassis 272 and an axle 274. The space between the chassis 272 and axle 274 is relatively great, calling for a longer hanger assembly 276 bolted to the chassis 272. As with the hanger assembly 47, the hanger assembly 276 has side walls 278 and 280 that are properly spaced to support a bushing assembly 46 which may be the same bushing assembly as is illustrated in FIGS. 14 and 15.
The axle seat assembly 281 is overslung. It is formed with an inverted U-channel 282 that has a top wall 284 and side walls 286 and 288. The side walls 286 and 288 terminate in outwardly extending flanges 290 and 292. When the beam member 50 is telescopingly received within the channel member 282, metal straps 294 and 296 can be fastened in place by bolts 298 to press the straps 294 and 296 against the bottom wall 54 of the tubular member 50.
The overslung axle seat assembly 281 includes cutout sections 300 in the side walls 286 and 288 where the axle seat assembly 281 is welded to the axle 274. Reinforcing straps 302 may be welded to the side walls 286 and 288 and to the axle. Rearwardly, the axle seat assembly 281 has a spring seat plate 304 that is downwardly and rearwardly inclined. An air spring 306 is connected by bolts to the spring seat plate 304 and to the chassis 274.
The connection between the torque beam 45 and the axle seat assembly 281 include two bolts 310 and 312 connected by nuts 314, spacer sleeves 316, and spacer plates 318 and 320. The spacer plate 320 may be welded to the side wall 288 of the channel member 282, but the spacer plate 318 is not welded so that, upon removal of the bolts 310 and 312, the spacer plate 318 can be knocked free to assist in the separation of the torque beam 45 from the axle seat assembly 281 even though the parts become rusted together. Similarly, the fact that the channel member 282 is open and that the straps 294 and 296 are removable, facilitates separation of the components.
The hanger assembly 276 incorporates a shock absorber bracket 322, and the axle seat assembly 281 incorporates a shock absorber bracket 324. A shock absorber 326 is connected between the brackets 322 and 324.
FIG. 21 illustrates a modification of the axle seat assembly 281. This modified axle seat assembly 281a is cut so it can be welded to a square axle 274a. In all other respects, the axle seat assembly 281a is identical to the axle seat assembly 281, and all the other components of the suspension system are unaffected.
Another suspension system embodiment 340 is shown in FIGS. 22 through 25. The vehicle on which the suspension system 340 is installed includes a chassis 342 and an axle 344 that is relatively close to the chassis 342. Consequently, the hanger 346 is relatively short, but nevertheless includes side walls 348 and 350 between which the bushing assembly 46 is mounted.
The suspension system 340 incorporates the same torque beam 45 (and the same bushing assembly 46) as do the other embodiments, but an axle seat assembly 352 is designed to accommodate a smaller air spring 354 and to accommodate the other parameters that are peculiar to the particular vehicle on which the system 340 is installed. More particularly, the axle seat assembly 352 has a sleeve 356 that receives the tubular member 50 with bolts 358 and 360 for connecting the components together. The sleeve 356 and the connections of the components may be as shown in FIGS. 5, 10 or 20. The axle seat assembly 340 is underslung relative to the axle 344 and therefore has cutout sections 362 where it is welded to the under side of the axle 344. Rearward of the axle 344 and generally aligned with the top of the sleeve 356, the axle seat assembly 340 supports a plate 364. The air spring 354 is mounted between the plate 364 and the chassis 342.
A sixth embodiment of the invention is illustrated in FIGS. 26 through 28 wherein a suspension system 370 is shown installed on a vehicle that has a chassis 372 and an axle 374. On this vehicle, the axle 374 is relatively close to the chassis 372, as with the vehicle illustrated in FIG. 22, but it is closer to the hanger assembly. In the suspension system 370, the hanger assembly 346 can be used to support a bushing like the bushing 46, and the torque beam 45 as already described. However, the air spring 376 is larger than the air spring 354 of the suspension system 340, whereas the ground clearance requirements are reduced.
To accommodate these particular parameters of the vehicle of FIG. 26, the suspension system 370 incorporates an axle seat assembly 378 that has a tubular section 380 with a tower section 382 welded to and extending above the sleeve section 380. The tower section 382 has cutout sections 384 where it is welded to the axle 374. This construction allows the bushing assembly 46 and the axle 374 to be at substantially the same elevation while inclining the sleeve 38 downwardly to a point at which it is connected to an axle seat section 384 that extends rearwardly and supports a spring seat plate 386 in a slightly downwardly inclined orientation. The air spring 376 is connected to the plate 386 and to a bracket 388 that is fastened to the chassis 372.
A shock absorber bracket 390 is supported by and projects upwardly from the hanger assembly 346. Another shock absorber bracket 392 is formed in the fabrication of the axle seat assembly 378. A shock absorber 394 is connected between the brackets 390 and 392.
Installation and Operation
It will now be understood that all of the embodiments represented by the suspension systems 40, 170, 240, 270, 340 and 370 can use the identical torque beam 45 and the identical bushing assembly 46. Some of the suspension systems (40, 170 and 270) can use the same hanger assembly 47. Other suspension systems (340 and 370) can use another hanger assembly 346. Each of the suspension systems has a different axle seat assembly and there are various forms of overslung and underslung connections to the axle.
In operation, all of the connections of the torque beam 45 to the axle seat assemblies are such that the connections are rigid, making the torque beam integral with the axle seat assembly. This produces a monopivot about the bushing assembly 46 as the axle moves up and down.
The recesses 90, 92, 94 and 96 located in the upper and lower quadrants of the bushing increase the compressibility of the bushing under changing vertical loads without significantly influencing the resistance of the bushing to longitudinal loads. These recesses, together with the annular groove 88 and the beveled ends 84 and 86 also improve flow of the bushing member under complex compression loading.
There are various changes and modifications which may be made to the invention as would be apparent to those skilled in the art. However, these changes or modifications are included in the teaching of the disclosure, and it is intended that the invention be limited only by the scope of the claims appended hereto. | A suspension system having a torque beam with a bushing for connecting the torque beams to a hanger. The torque beam can be telescopingly received in a sleeve of an axle seat assembly. There are a number of different axle seat assemblies for accommodating various vehicles but all have the sleeve so that one form of torque beam can be used with any one of the axle seat assemblies. The bushing has strategically located recesses to facilitate flow of the bushing member and to make it more yieldable in a vertical direction than in a longitudinal direction. An annular groove in the outer wall of the bushing also improves flow under compression of the bushing member. The telescoping connection between the torque beam and an axle seat assembly may include knock-away components to facilitate breaking the components apart in the event they become rusted together. | 1 |
RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35 USC §119(e) to U.S. Provisional Patent Application No. 61/790,519 filed Mar. 15, 2013, and is a Continuation-in-Part under 35 USC §365(c) of PCT Patent Application No. PCT/US13/23337 filed Jan. 27, 2013, which claims the benefit of priority under 35 USC §119(e) to U.S. Provisional Patent Application No. 61/591,816 filed Jan. 27, 2012, all of which are incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an integrated hydrotreating and steam pyrolysis process for direct processing of a crude oil to produce petrochemicals such as olefins and aromatics.
[0004] 2. Description of Related Art
[0005] The lower olefins (i.e., ethylene, propylene, butylene and butadiene) and aromatics (i.e., benzene, toluene and xylene) are basic intermediates which are widely used in the petrochemical and chemical industries. Thermal cracking, or steam pyrolysis, is a major type of process for forming these materials, typically in the presence of steam, and in the absence of oxygen. Feedstocks for steam pyrolysis can include petroleum gases and distillates such as naphtha, kerosene and gas oil. The availability of these feedstocks is usually limited and requires costly and energy-intensive process steps in a crude oil refinery.
[0006] Studies have been conducted using heavy hydrocarbons as a feedstock for steam pyrolysis reactors. A major drawback in conventional heavy hydrocarbon pyrolysis operations is coke formation. For example, a steam cracking process for heavy liquid hydrocarbons is disclosed in U.S. Pat. No. 4,217,204 in which a mist of molten salt is introduced into a steam cracking reaction zone in an effort to minimize coke formation. In one example using Arabian light crude oil having a Conradson carbon residue of 3.1% by weight, the cracking apparatus was able to continue operating for 624 hours in the presence of molten salt. In a comparative example without the addition of molten salt, the steam cracking reactor became clogged and inoperable after just 5 hours because of the formation of coke in the reactor.
[0007] In addition, the yields and distributions of olefins and aromatics using heavy hydrocarbons as a feedstock for a steam pyrolysis reactor are different than those using light hydrocarbon feedstocks. Heavy hydrocarbons have a higher content of aromatics than light hydrocarbons, as indicated by a higher Bureau of Mines Correlation Index (BMCI). BMCI is a measurement of aromaticity of a feedstock and is calculated as follows:
[0000] BMCI=87552/VAPB+473.5*(sp. gr.)−456.8 (1)
where: VAPB=Volume Average Boiling Point in degrees Rankine and sp. gr.=specific gravity of the feedstock.
[0011] As the BMCI decreases, ethylene yields are expected to increase. Therefore, highly paraffinic or low aromatic feeds are usually preferred for steam pyrolysis to obtain higher yields of desired olefins and to avoid higher undesirable products and coke formation in the reactor coil section.
[0012] The absolute coke formation rates in a steam cracker have been reported by Cai et al., “Coke Formation in Steam Crackers for Ethylene Production,” Chem. Eng . & Proc ., vol. 41, (2002), 199-214. In general, the absolute coke formation rates are in the ascending order of olefins>aromatics>paraffins, wherein olefins represent heavy olefins
[0013] To be able to respond to the growing demand of these petrochemicals, other type of feeds which can be made available in larger quantities, such as raw crude oil, are attractive to producers. Using crude oil feeds will minimize or eliminate the likelihood of the refinery being a bottleneck in the production of these petrochemicals.
[0014] While the steam pyrolysis process is well developed and suitable for its intended purposes, the choice of feedstocks has been very limited.
SUMMARY OF THE INVENTION
[0015] The system and process herein provides a steam pyrolysis zone integrated with a hydroprocessing zone including residual bypass to permit direct processing of crude oil feedstocks to produce petrochemicals including olefins and aromatics.
[0016] The integrated hydrotreating and steam pyrolysis process for the direct processing of a crude oil to produce olefinic and aromatic petrochemicals comprises separating the crude oil into light components and heavy components; charging the light components and hydrogen to a hydroprocessing zone operating under conditions effective to produce a hydroprocessed effluent having a reduced content of contaminants, an increased paraffinicity, reduced Bureau of Mines Correlation Index, and an increased American Petroleum Institute gravity; thermally cracking the hydroprocessed effluent in the presence of steam to produce a mixed product stream; separating the mixed product stream; purifying hydrogen recovered from the mixed product stream and recycling it to the hydroprocessing zone; recovering olefins and aromatics from the separated mixed product stream; and recovering a combined stream of pyrolysis fuel oil from the separated mixed product stream and heavy components from step (a) as a fuel oil blend.
[0017] As used herein, the term “crude oil” is to be understood to include whole crude oil from conventional sources, including crude oil that has undergone some pre-treatment. The term crude oil will also be understood to include that which has been subjected to water-oil separation; and/or gas-oil separation; and/or desalting; and/or stabilization.
[0018] Other aspects, embodiments, and advantages of the process of the present invention are discussed in detail below. Moreover, it is to be understood that both the foregoing information and the following detailed description are merely illustrative examples of various aspects and embodiments, and are intended to provide an overview or framework for understanding the nature and character of the claimed features and embodiments. The accompanying drawings are illustrative and are provided to further the understanding of the various aspects and embodiments of the process of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The invention will be described in further detail below and with reference to the attached drawings where:
[0020] FIG. 1 is a process flow diagram of an embodiment of an integrated process described herein;
[0021] FIGS. 2A-2C are schematic illustrations in perspective, top and side views of a vapor-liquid separation device used in certain embodiments of the integrated process described herein; and
[0022] FIGS. 3A-3C are schematic illustrations in section, enlarged section and top section views of a vapor-liquid separation device in a flash vessel used in certain embodiments of the integrated process described herein.
DETAILED DESCRIPTION OF THE INVENTION
[0023] A flow diagram including an integrated hydroprocessing and steam pyrolysis process and system including residual bypass is shown in FIG. 1 . The integrated system generally includes a feed separation zone, a selective hydroprocessing zone, a steam pyrolysis zone and a product separation zone.
[0024] Feed separation zone 20 includes an inlet for receiving a feedstock stream 1 , an outlet for discharging a rejected portion 22 and an outlet for discharging a remaining hydrocarbon portion 2 . The cut point in separation zone 20 can be set so that it is compatible with the residue fuel oil blend, e.g., about 540° C. Separation zone 20 can be a single stage separation device such a flash separator
[0025] In additional embodiments separation zone 20 can include, or consists essentially of (i.e., operate in the absence of a flash zone), a cyclonic phase separation device, or other separation device based on physical or mechanical separation of vapors and liquids. One example of a vapor-liquid separation device is illustrated by, and with reference to, FIGS. 2A-2C . A similar arrangement of a vapor-liquid separation device is also described in U.S. Patent Publication Number 2011/0247500 which is incorporated by reference in its entirety herein. In embodiments in which the separation zone includes or consist essentially of a separation device based on physical or mechanical separation of vapors and liquids, the cut point can be adjusted based on vaporization temperature and the fluid velocity of the material entering the device.
[0026] Selective hydroprocessing zone includes a hydroprocessing reaction zone 4 having an inlet for receiving a mixture 3 of hydrocarbon portion 21 and hydrogen 2 recycled from the steam pyrolysis product stream and make-up hydrogen as necessary. Hydroprocessing reaction zone 4 further includes an outlet for discharging a hydroprocessed effluent 5 .
[0027] Reactor effluents 5 from the hydroprocessing reactor(s) are cooled in a heat exchanger (not shown) and sent to a high pressure separator 6 . The separator tops 7 are cleaned in an amine unit 12 and a resulting hydrogen rich gas stream 13 is passed to a recycling compressor 14 to be used as a recycle gas 15 in the hydroprocessing reactor. A bottoms stream 8 from the high pressure separator 6 , which is in a substantially liquid phase, is cooled and introduced to a low pressure cold separator 9 in which it is separated into a gas stream 11 and a liquid stream 10 . Gases from low pressure cold separator include hydrogen, H 2 S, NH 3 and any light hydrocarbons such as C 1 -C 4 hydrocarbons. Typically these gases are sent for further processing such as flare processing or fuel gas processing. According to certain embodiments herein, hydrogen is recovered by combining stream gas stream 11 , which includes hydrogen, H 2 S, NH 3 and any light hydrocarbons such as C 1 -C 4 hydrocarbons, with steam cracker products 44 . All or a portion of liquid stream 10 serves as the feed to the steam pyrolysis zone 30
[0028] Steam pyrolysis zone 30 generally comprises a convection section 32 and a pyrolysis section 34 that can operate based on steam pyrolysis unit operations known in the art, i.e., charging the thermal cracking feed to the convection section in the presence of steam. In addition, in certain optional embodiments as described herein (as indicated with dashed lines in FIG. 1 ), a vapor-liquid separation section 36 is included between sections 32 and 34 . Vapor-liquid separation section 36 , through which the heated steam cracking feed from convection section 32 passes, and is fractioned, can be a flash separation device, a separation device based on physical or mechanical separation of vapors and liquids or a combination including at least one of these types of devices. In additional embodiments, a vapor-liquid separation zone 18 is included upstream of sections 32 , either in combination with a vapor-liquid separation zone 36 or in the absence of a vapor-liquid separation zone 36 . Stream 10 a is fractioned in separation zone 18 , which can be a flash separation device, a separation device based on physical or mechanical separation of vapors and liquids or a combination including at least one of these types of devices.
[0029] Useful vapor-liquid separation devices are illustrated by, and with reference to FIGS. 2A-2C and 3 A- 3 C. Similar arrangements of a vapor-liquid separation devices are described in U.S. Patent Publication Number 2011/0247500 which is herein incorporated by reference in its entirety. In this device vapor and liquid flow through in a cyclonic geometry whereby the device operates isothermally and at very low residence time. In general vapor is swirled in a circular pattern to create forces where heavier droplets and liquid are captured and channeled through to a liquid outlet as liquid residue, for instance, which is added to a pyrolysis fuel oil blend, and vapor is channeled through a vapor outlet as the charge 37 to the pyrolysis section 34 . In embodiments in which a vapor-liquid separation device 36 is provided, residue 38 is discharged and the vapor is the charge 37 to the pyrolysis section 34 . In embodiments in which a vapor-liquid separation device 18 is provided, residue 19 is discharged and the vapor is the charge 10 to the convection section 32 . The vaporization temperature and fluid velocity are varied to adjust the approximate temperature cutoff point, for instance in certain embodiments compatible with the residue fuel oil blend, e.g., about 540° C.
[0030] Rejected residuals derived from streams 19 and/or 38 have been subjected to the selective hydroprocessing zone and contain a reduced amount of heteroatom compounds including sulfur-containing, nitrogen-containing and metal compounds as compared to the initial feed. This facilitates further processing of these blends, or renders them useful as low sulfur, low nitrogen heavy fuel blends.
[0031] A quenching zone 40 includes an inlet in fluid communication with the outlet of steam pyrolysis zone 30 for receiving mixed product stream 39 , an inlet for admitting a quenching solution 42 , an outlet for discharging the quenched mixed product stream 44 and an outlet for discharging quenching solution 46 .
[0032] In general, an intermediate quenched mixed product stream 44 is converted into intermediate product stream 65 and hydrogen 62 , which is purified in the present process and used as recycle hydrogen stream 2 in the hydroprocessing reaction zone 4 . Intermediate product stream 65 is generally fractioned into end-products and residue in separation zone 70 , which can be one or multiple separation units such as plural fractionation towers including de-ethanizer, de-propanizer and de-butanizer towers, for example as is known to one of ordinary skill in the art. For example, suitable apparatus are described in “Ethylene,” Ullmann's Encyclopedia of Industrial Chemistry, Volume 12, Pages 531-581, in particular FIG. 24 , FIG. 25 and FIG. 26 , which is incorporated herein by reference.
[0033] In general product separation zone 70 includes an inlet in fluid communication with the product stream 65 and plural product outlets 73 - 78 , including an outlet 78 for discharging methane, an outlet 77 for discharging ethylene, an outlet 76 for discharging propylene, an outlet 75 for discharging butadiene, an outlet 74 for discharging mixed butylenes, and an outlet 73 for discharging pyrolysis gasoline. Additionally an outlet is provided for discharging pyrolysis fuel oil 71 . The rejected portion 22 from the feed separation zone 20 and optionally the rejected portion 38 from vapor-liquid separation section 36 are combined with pyrolysis fuel oil 71 and the mixed stream can be withdrawn as a pyrolysis fuel oil blend 72 , e.g., a low sulfur fuel oil blend to be further processed in an off-site refinery or used as fuel for optional power generation zone 120 . Note that while six product outlets are shown, fewer or more can be provided depending, for instance, on the arrangement of separation units employed and the yield and distribution requirements.
[0034] An optional power generation zone 120 can be provided, includes an inlet for receiving fuel oil 72 and an outlet for discharging a remaining portion, e.g., a hydrogen deficient sub-standard quality feedstock. An optional fuel gas desulfurization zone 120 includes an inlet for receiving the remaining portion from the power generation zone 110 , and an outlet for discharging a desulfurized fuel gas.
[0035] In an embodiment of a process employing the arrangement shown in FIG. 1 , a crude oil feedstock 1 is introduced into the feed separation zone 20 to produce a rejected portion 22 and a remaining hydrocarbon fraction 21 . The hydrocarbon fraction 21 is mixed with an effective amount of hydrogen 2 and 15 (and if necessary a source of make-up hydrogen) to form a combined stream 3 and the admixture 3 is charged to the inlet of selective hydroprocessing reaction zone 4 at a temperature in the range of from 300° C. to 450° C. In certain embodiments, hydroprocessing reaction zone 4 includes one or more unit operations as described in commonly owned United States Patent Publication Number 2011/0083996 and in PCT Patent Application Publication Numbers WO2010/009077, WO2010/009082, WO2010/009089 and WO2009/073436, all of which are incorporated by reference herein in their entireties. For instance, a hydroprocessing zone can include one or more beds containing an effective amount of hydrodemetallization catalyst, and one or more beds containing an effective amount of hydroprocessing catalyst having hydrodearomatization, hydrodenitrogenation, hydrodesulfurization and/or hydrocracking functions. In additional embodiments hydroprocessing zone 200 includes more than two catalyst beds. In further embodiments hydroprocessing reaction zone 4 includes plural reaction vessels each containing one or more catalyst beds, e.g., of different function.
[0036] Hydroprocessing reaction zone 4 operates under parameters effective to hydrodemetallize, hydrodearomatize, hydrodenitrogenate, hydrodesulfurize and/or hydrocrack the crude oil feedstock. In certain embodiments, hydroprocessing is carried out using the following conditions: operating temperature in the range of from 300° C. to 450° C.; operating pressure in the range of from 30 bars to 180 bars; and a liquid hour space velocity in the range of from 0.1 h −1 to 10 h −1 . Notably, using crude oil as a feedstock in the hydroprocessing zone advantages are demonstrated, for instance, as compared to the same hydroprocessing unit operation employed for atmospheric residue. For instance, at a start or run temperature in the range of 370° C. to 375° C. the deactivation rate is around 1° C./month. In contrast, if residue were to be processed, the deactivation rate would be closer to about 3° C./month to 4° C./month. The treatment of atmospheric residue typically employs pressure of around 200 bars whereas the present process in which crude oil is treated can operate at a pressure as low as 100 bars. Additionally to achieve the high level of saturation required for the increase in the hydrogen content of the feed, this process can be operated at a high throughput when compared to atmospheric residue. The LHSV can be as high as 0.5 hr −1 while that for atmospheric residue is typically 0.25 hr −1 . An unexpected finding is that the deactivation rate when processing crude oil is going in the inverse direction from that which is usually observed. Deactivation at low throughput (0.25 hr −1 ) is 4.2° C./month and deactivation at higher throughput (0.5 hr −1 ) is 2.0° C./month. With every feed which is considered in the industry, the opposite is observed. This can be attributed to the washing effect of the catalyst.
[0037] Reactor effluents 5 from the hydroprocessing zone 4 are cooled in an exchanger (not shown) and sent to a high pressure cold or hot separator 6 . Separator tops 7 are cleaned in an amine unit 12 and the resulting hydrogen rich gas stream 13 is passed to a recycling compressor 14 to be used as a recycle gas 15 in the hydroprocessing reaction zone 4 . Separator bottoms 8 from the high pressure separator 6 , which are in a substantially liquid phase, are cooled and then introduced to a low pressure cold separator 9 . Remaining gases, stream 11 , including hydrogen, H 2 S, NH 3 and any light hydrocarbons, which can include C 1 -C 4 hydrocarbons, can be conventionally purged from the low pressure cold separator and sent for further processing, such as flare processing or fuel gas processing. In certain embodiments of the present process, hydrogen is recovered by combining stream 11 (as indicated by dashed lines) with the cracking gas, stream 44 , from the steam cracker products. The bottoms 10 from the low pressure separator 9 are optionally sent to separation zone 20 or passed directly to steam pyrolysis zone 30 .
[0038] The hydroprocessed effluent 10 a contains a reduced content of contaminants (i.e., metals, sulfur and nitrogen), an increased paraffinicity, reduced BMCI, and an increased American Petroleum Institute (API) gravity.
[0039] The hydroprocessed effluent 10 a is conveyed to the inlet of a convection section 32 as feed 10 in the presence of an effective amount of steam, e.g., admitted via a steam inlet. In additional embodiments as described herein a separation zone 18 is incorporated upstream of the convection section 32 whereby the feed 10 is the light portion of said pyrolysis feed. The steam cracking feed can have, for instance, an initial boiling point corresponding to that of the stream 10 a and a final boiling point in the range of about 370° C. to about 600° C.
[0040] The steam pyrolysis zone 30 operates under parameters effective to crack effluent 10 a or a light portion 10 thereof derived from the optional separation zone 18 , into desired products, including ethylene, propylene, butadiene, mixed butenes and pyrolysis gasoline. In the convection section 32 the mixture is heated to a predetermined temperature, e.g., using one or more waste heat streams or other suitable heating arrangement. The heated mixture of the pyrolysis feedstream and steam is passed to the pyrolysis section 34 to produce a mixed product stream 39 . In certain embodiments the heated mixture of from section 32 is passed through a vapor-liquid separation section 36 in which a portion 38 is rejected as a fuel oil component suitable for blending with pyrolysis fuel oil 71 . In certain embodiments, steam cracking is carried out using the following conditions: a temperature in the range of from 400° C. to 900° C. in the convection section and in the pyrolysis section; a steam-to-hydrocarbon ratio in the convection section in the range of from 0.3:1 to 2:1 (wt.:wt.); and a residence time in the convection section and in the pyrolysis section in the range of from 0.05 seconds to 2 seconds.
[0041] In certain embodiments, the vapor-liquid separation section 36 includes one or a plurality of vapor liquid separation devices 80 as shown in FIGS. 2A-2C . The vapor liquid separation device 80 is economical to operate and maintenance free since it does not require power or chemical supplies. In general, device 80 comprises three ports including an inlet port for receiving a vapor-liquid mixture, a vapor outlet port and a liquid outlet port for discharging and the collection of the separated vapor and liquid, respectively. Device 80 operates based on a combination of phenomena including conversion of the linear velocity of the incoming mixture into a rotational velocity by the global flow pre-rotational section, a controlled centrifugal effect to pre-separate the vapor from liquid (residue), and a cyclonic effect to promote separation of vapor from the liquid (residue). To attain these effects, device 80 includes a pre-rotational section 88 , a controlled cyclonic vertical section 90 and a liquid collector/settling section 92 .
[0042] As shown in FIG. 2B , the pre-rotational section 88 includes a controlled pre-rotational element between cross-section (S 1 ) and cross-section (S 2 ), and a connection element to the controlled cyclonic vertical section 90 and located between cross-section (S 2 ) and cross-section (S 3 ). The vapor liquid mixture coming from inlet 32 having a diameter (D 1 ) enters the apparatus tangentially at the cross-section (S 1 ). The area of the entry section (S 1 ) for the incoming flow is at least 10% of the area of the inlet 82 according to the following equation:
[0000]
π
*
(
[
D
1
)
]
2
4
(
2
)
[0043] The pre-rotational element 88 defines a curvilinear flow path, and is characterized by constant, decreasing or increasing cross-section from the inlet cross-section S 1 to the outlet cross-section S 2 . The ratio between outlet cross-section from controlled pre-rotational element (S 2 ) and the inlet cross-section (S 1 ) is in certain embodiments in the range of 0.7≦S 2 /S 1 ≦1.4.
[0044] The rotational velocity of the mixture is dependent on the radius of curvature (R 1 ) of the center-line of the pre-rotational element 88 where the center-line is defined as a curvilinear line joining all the center points of successive cross-sectional surfaces of the pre-rotational element 88 . In certain embodiments the radius of curvature (R 1 ) is in the range of 2≦R 1 /D 1 ≦6 with opening angle in the range of 150°≦αR 1 ≦250°.
[0045] The cross-sectional shape at the inlet section S 1 , although depicted as generally square, can be a rectangle, a rounded rectangle, a circle, an oval, or other rectilinear, curvilinear or a combination of the aforementioned shapes. In certain embodiments, the shape of the cross-section along the curvilinear path of the pre-rotational element 88 through which the fluid passes progressively changes, for instance, from a generally square shape to a rectangular shape. The progressively changing cross-section of element 88 into a rectangular shape advantageously maximizes the opening area, thus allowing the gas to separate from the liquid mixture at an early stage and to attain a uniform velocity profile and minimize shear stresses in the fluid flow.
[0046] The fluid flow from the controlled pre-rotational element 88 from cross-section (S 2 ) passes section (S 3 ) through the connection element to the controlled cyclonic vertical section 90 . The connection element includes an opening region that is open and connected to, or integral with, an inlet in the controlled cyclonic vertical section 90 . The fluid flow enters the controlled cyclonic vertical section 90 at a high rotational velocity to generate the cyclonic effect. The ratio between connection element outlet cross-section (S 3 ) and inlet cross-section (S 2 ) in certain embodiments is in the range of 2≦S 3 /S 1 ≦5.
[0047] The mixture at a high rotational velocity enters the cyclonic vertical section 90 . Kinetic energy is decreased and the vapor separates from the liquid under the cyclonic effect. Cyclones form in the upper level 90 a and the lower level 90 b of the cyclonic vertical section 90 . In the upper level 90 a , the mixture is characterized by a high concentration of vapor, while in the lower level 90 b the mixture is characterized by a high concentration of liquid.
[0048] In certain embodiments, the internal diameter D 2 of the cyclonic vertical section 90 is within the range of 2≦D 2 /D 1 ≦5 and can be constant along its height, the length (LU) of the upper portion 90 a is in the range of 1.2≦LU/D 2 ≦3, and the length (LL) of the lower portion 90 b is in the range of 2≦LL/D 2 ≦5.
[0049] The end of the cyclonic vertical section 90 proximate vapor outlet 84 is connected to a partially open release riser and connected to the pyrolysis section of the steam pyrolysis unit. The diameter (DV) of the partially open release is in certain embodiments in the range of 0.05≦DV/D 2 ≦0.4.
[0050] Accordingly, in certain embodiments, and depending on the properties of the incoming mixture, a large volume fraction of the vapor therein exits device 80 from the outlet 84 through the partially open release pipe with a diameter DV. The liquid phase (e.g., residue) with a low or non-existent vapor concentration exits through a bottom portion of the cyclonic vertical section 90 having a cross-sectional area S 4 , and is collected in the liquid collector and settling pipe 92 .
[0051] The connection area between the cyclonic vertical section 90 and the liquid collector and settling pipe 92 has an angle in certain embodiment of 90°. In certain embodiments the internal diameter of the liquid collector and settling pipe 92 is in the range of 2≦D 3 /D 1 ≦4 and is constant across the pipe length, and the length (LH) of the liquid collector and settling pipe 92 is in the range of 1.2≦LH/D 3 ≦5. The liquid with low vapor volume fraction is removed from the apparatus through pipe 86 having a diameter of DL, which in certain embodiments is in the range of 0.05≦DL/D 3 ≦0.4 and located at the bottom or proximate the bottom of the settling pipe.
[0052] In certain embodiments, a vapor-liquid separation device is provided similar in operation and structure to device 80 without the liquid collector and settling pipe return portion. For instance, a vapor-liquid separation device 180 is used as inlet portion of a flash vessel 179 , as shown in FIGS. 3A-3C . In these embodiments the bottom of the vessel 179 serves as a collection and settling zone for the recovered liquid portion from device 180 .
[0053] In general a vapor phase is discharged through the top 194 of the flash vessel 179 and the liquid phase is recovered from the bottom 196 of the flash vessel 179 . The vapor-liquid separation device 180 is economical to operate and maintenance free since it does not require power or chemical supplies. Device 180 comprises three ports including an inlet port 182 for receiving a vapor-liquid mixture, a vapor outlet port 184 for discharging separated vapor and a liquid outlet port 186 for discharging separated liquid. Device 180 operates based on a combination of phenomena including conversion of the linear velocity of the incoming mixture into a rotational velocity by the global flow pre-rotational section, a controlled centrifugal effect to pre-separate the vapor from liquid, and a cyclonic effect to promote separation of vapor from the liquid. To attain these effects, device 180 includes a pre-rotational section 188 and a controlled cyclonic vertical section 190 having an upper portion 190 a and a lower portion 190 b . The vapor portion having low liquid volume fraction is discharged through the vapor outlet port 184 having a diameter (DV). Upper portion 190 a which is partially or totally open and has an internal diameter (DII) in certain embodiments in the range of 0.5<DV/DII<1.3. The liquid portion with low vapor volume fraction is discharged from liquid port 186 having an internal diameter (DL) in certain embodiments in the range of 0.1<DL/DII<1.1. The liquid portion is collected and discharged from the bottom of flash vessel 179 .
[0054] In order to enhance and to control phase separation, heating steam can be used in the vapor-liquid separation device 80 or 180 , particularly when used as a standalone apparatus or is integrated within the inlet of a flash vessel.
[0055] While the various members are described separately and with separate portions, it will be understood by one of ordinary skill in the art that apparatus 80 and apparatus 180 can be formed as a monolithic structure, e.g., it can be cast or molded, or it can be assembled from separate parts, e.g., by welding or otherwise attaching separate components together which may or may not correspond precisely to the members and portions described herein.
[0056] It will be appreciated that although various dimensions are set forth as diameters, these values can also be equivalent effective diameters in embodiments in which the components parts are not cylindrical. Mixed product stream 39 is passed to the inlet of quenching zone 40 with a quenching solution 42 (e.g., water and/or pyrolysis fuel oil) introduced via a separate inlet to produce an intermediate quenched mixed product stream 44 having a reduced temperature, e.g., of about 300° C., and spent quenching solution 46 is discharged. The gas mixture effluent 39 from the cracker is typically a mixture of hydrogen, methane, hydrocarbons, carbon dioxide and hydrogen sulfide. After cooling with water or oil quench, mixture 44 is compressed in a multi-stage compressor zone 51 , typically in 4-6 stages to produce a compressed gas mixture 52 . The compressed gas mixture 52 is treated in a caustic treatment unit 53 to produce a gas mixture 54 depleted of hydrogen sulfide and carbon dioxide. The gas mixture 54 is further compressed in a compressor zone 55 , and the resulting cracked gas 56 typically undergoes a cryogenic treatment in unit 57 to be dehydrated, and is further dried by use of molecular sieves.
[0057] The cold cracked gas stream 58 from unit 57 is passed to a de-methanizer tower 59 , from which an overhead stream 60 is produced containing hydrogen and methane from the cracked gas stream. The bottoms stream 65 from de-methanizer tower 59 is then sent for further processing in product separation zone 70 , comprising fractionation towers including de-ethanizer, de-propanizer and de-butanizer towers. Process configurations with a different sequence of de-methanizer, de-ethanizer, de-propanizer and de-butanizer can also be employed.
[0058] According to the processes herein, after separation from methane at the de-methanizer tower 59 and hydrogen recovery in unit 61 , hydrogen 62 having a purity of typically 80-95 vol % is obtained. Recovery methods in unit 61 include cryogenic recovery (e.g., at a temperature of about −157° C.). Hydrogen stream 62 is then passed to a hydrogen purification unit 64 , such as a pressure swing adsorption (PSA) unit to obtain a hydrogen stream 2 having a purity of 99.9%+, or a membrane separation units to obtain a hydrogen stream 2 with a purity of about 95%. The purified hydrogen stream 2 is then recycled back to serve as a major portion of the requisite hydrogen for the hydroprocessing zone. In addition, a minor proportion can be utilized for the hydrogenation reactions of acetylene, methylacetylene and propadienes (not shown). In addition, according to the processes herein, methane stream 63 can optionally be recycled to the steam cracker to be used as fuel for burners and/or heaters.
[0059] The bottoms stream 65 from de-methanizer tower 59 is conveyed to the inlet of product separation zone 70 to be separated into methane, ethylene, propylene, butadiene, mixed butylenes and pyrolysis gasoline discharged via outlets 78 , 77 , 76 , 75 , 74 and 73 , respectively. Pyrolysis gasoline generally includes C5-C9 hydrocarbons, and benzene, toluene and xylenes can be extracted from this cut. The rejected portion 22 from the feed separation zone 100 and optionally the unvaporized heavy liquid fraction 38 from the vapor-liquid separation section 36 are combined with pyrolysis fuel oil 71 (e.g., materials boiling at a temperature higher than the boiling point of the lowest boiling C10 compound, known as a “C10+” stream) from separation zone 70 , and this is withdrawn as a pyrolysis fuel oil blend 72 , e.g., to be further processed in an off-site refinery (not shown).
[0060] In certain optional embodiments, fuel oil 72 can be passed to power generation zone 110 to generate power (e.g., one or more steam turbines that can employ fuel oil 72 as a fuel source), and a remaining portion is conveyed to a fuel gas desulfurization zone 120 to produce a desulfurized fuel gas.
[0061] Advantages of the system described with respect to FIG. 1 include improvements in hydroprocessing, in which the process can be efficiently utilized to improve the hydrogen content of the products. For example, the system described herein uses hydrotreating catalyst having smaller pore size which contributes to significantly more active hydrotreating reactions. In addition, the overall hydrogen consumption of the hydrotreating zone is significantly reduced. Hydrogen is not consumed for upgrading unsatureated heavy residue, but rather is utilized for the fraction undergoing pyrolysis reaction, e.g., fractions boiling below 540° C. The heavier fraction, e.g., boiling above 540° C., is used to generate power for the plant, while the remaining portion is recovered as fuel oil.
[0062] In certain embodiments, selective hydroprocessing or hydrotreating processes can increase the paraffin content (or decrease the BMCI) of a feedstock by saturation followed by mild hydrocracking of aromatics, especially polyaromatics. When hydrotreating a crude oil, contaminants such as metals, sulfur and nitrogen can be removed by passing the feedstock through a series of layered catalysts that perform the catalytic functions of demetallization, desulfurization and/or denitrogenation.
[0063] In one embodiment, the sequence of catalysts to perform hydrodemetallization (HDM) and hydrodesulfurization (HDS) is as follows:
[0064] A hydrodemetallization catalyst. The catalyst in the HDM section are generally based on a gamma alumina support, with a surface area of about 140-240 m 2 /g. This catalyst is best described as having a very high pore volume, e.g., in excess of 1 cm 3 /g. The pore size itself is typically predominantly macroporous. This is required to provide a large capacity for the uptake of metals on the catalysts surface and optionally dopants. Typically the active metals on the catalyst surface are sulfides of Nickel and Molybdenum in the ratio Ni/Ni+Mo<0.15. The concentration of Nickel is lower on the HDM catalyst than other catalysts as some Nickel and Vanadium is anticipated to be deposited from the feedstock itself during the removal, acting as catalyst. The dopant used can be one or more of phosphorus (see, e.g., United States Patent Publication Number US 2005/0211603 which is incorporated by reference herein), boron, silicon and halogens. The catalyst can be in the form of alumina extrudates or alumina beads. In certain embodiments alumina beads are used to facilitate un-loading of the catalyst HDM beds in the reactor as the metals uptake will range between 30 to 100% at the top of the bed.
[0065] An intermediate catalyst can also be used to perform a transition between the HDM and HDS function. It has intermediate metals loadings and pore size distribution. The catalyst in the HDM/HDS reactor is essentially alumina based support in the form of extrudates, optionally at least one catalytic metal from group VI (e.g., molybdenum and/or tungsten), and/or at least one catalytic metals from group VIII (e.g., nickel and/or cobalt). The catalyst also contains optionally at least one dopant selected from boron, phosphorous, halogens and silicon. Physical properties include a surface area of about 140-200 m 2 /g, a pore volume of at least 0.6 cm 3 /g and pores which are mesoporous and in the range of 12 to 50 nm.
[0066] The catalyst in the HDS section can include those having gamma alumina based support materials, with typical surface area towards the higher end of the HDM range, e.g. about ranging from 180-240 m 2 /g. This required higher surface for HDS results in relatively smaller pore volume, e.g., lower than 1 cm 3 /g. The catalyst contains at least one element from group VI, such as molybdenum and at least one element from group VIII, such as nickel. The catalyst also comprises at least one dopant selected from boron, phosphorous, silicon and halogens. In certain embodiments cobalt is used to provide relatively higher levels of desulfurization. The metals loading for the active phase is higher as the required activity is higher, such that the molar ratio of Ni/Ni+Mo is in the range of from 0.1 to 0.3 and the (Co+Ni)/Mo molar ratio is in the range of from 0.25 to 0.85.
[0067] A final catalyst (which could optionally replace the second and third catalyst) is designed to perform hydrogenation of the feedstock (rather than a primary function of hydrodesulfurization), for instance as described in Appl. Catal. A General, 204 (2000) 251. The catalyst will be also promoted by Ni and the support will be wide pore gamma alumina. Physical properties include a surface area towards the higher end of the HDM range, e.g., 180-240 m 2 /g gr. This required higher surface for HDS results in relatively smaller pore volume, e.g., lower than 1 cm 3 /g.
[0068] The method and system herein provides improvements over known steam pyrolysis cracking processes:
[0069] use of crude oil as a feedstock to produce petrochemicals such as olefins and aromatics;
[0070] the hydrogen content of the feed to the steam pyrolysis zone is enriched for high yield of olefins;
[0071] coke precursors are significantly removed from the initial whole crude oil which allows a decreased coke formation in the radiant coil; and
[0072] additional impurities such as metals, sulfur and nitrogen compounds are also significantly removed from the starting feed which avoids post treatments of the final products.
[0073] In addition, hydrogen produced from the steam cracking zone is recycled to the hydroprocessing zone to minimize the demand for fresh hydrogen. In certain embodiments the integrated systems described herein only require fresh hydrogen to initiate the operation. Once the reaction reaches the equilibrium, the hydrogen purification system can provide enough high purity hydrogen to maintain the operation of the entire system.
[0074] The method and system of the present invention have been described above and in the attached drawings; however, modifications will be apparent to those of ordinary skill in the art and the scope of protection for the invention is to be defined by the claims that follow. | A process is provided that is directed to a steam pyrolysis zone integrated with a hydroprocessing zone including residual bypass to permit direct processing of crude oil feedstocks to produce petrochemicals including olefins and aromatics. The integrated hydrotreating and steam pyrolysis process for the direct processing of a crude oil to produce olefinic and aromatic petrochemicals comprises separating the crude oil into light components and heavy components; charging the light components and hydrogen to a hydroprocessing zone operating under conditions effective to produce a hydroprocessed effluent reduced having a reduced content of contaminants, an increased paraffinicity, reduced Bureau of Mines Correlation Index, and an increased American Petroleum Institute gravity; thermally cracking the hydroprocessed effluent in the presence of steam to produce a mixed product stream; separating the mixed product stream; purifying hydrogen recovered from the mixed product stream and recycling it to the hydroprocessing zone; recovering olefins and aromatics from the separated mixed product stream; and recovering a combined stream of pyrolysis fuel oil from the separated mixed product stream and heavy components from step (a) as a fuel oil blend. | 2 |
BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates to a power supply circuit for supplying power to universal serial bus (USB) interfaces.
[0003] 2. Description of Related Art
[0004] Generally, a front USB interface and a rear USB interface are respectively mounted on front and rear sides of a motherboard. Because the front USB interface is further away from the motherboard power connector than the rear USB interface, the transmission lines from the connector to the front USB interface is longer and hence must be more robust and larger. This is an inconvenience to designers and manufacturers because of the trend towards miniaturization.
BRIEF DESCRIPTION OF THE DRAWING
[0005] Many aspects of the embodiments can be better understood with reference to the following drawing. The components in the drawing are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present embodiments.
[0006] The FIGURE is a circuit diagram of an exemplary embodiment of a power supply circuit for universal serial bus (USB) interfaces.
DETAILED DESCRIPTION
[0007] The disclosure, including the accompanying drawing, is illustrated by way of examples and not by way of limitation. It should be noted that references to “an” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and such references mean “at least one.”
[0008] The FIGURE shows an embodiment of a power supply circuit for universal serial bus (USB) interfaces. In the embodiment, the USB interfaces include a front USB interface 1 and a rear USB interface 2 . The power supply circuit includes three metal oxide semiconductor field effect transistors (MOSFETs) Q1, Q2, and Q3. In the embodiment, the MOSFETs Q1-Q3 are n-channel MOSFETs.
[0009] A gate of the MOSFET Q1 is connected to a USB controller 10 on a motherboard 5 to receive a control signal VCCGATE from the USB controller 10 . A source of the MOSFET Q1 is connected to a system power supply 5V_SYS. A gate of the MOSFET Q2 is connected to the gate of the MOSFET Q1. A source of the MOSFET Q2 is connected to the source of the MOSFET Q1. A drain of the MOSFET Q1 outputs a 5V_USB power supply for the front USB interface 1 . A drain of the MOSFET Q2 outputs a 5V_USB power supply for the rear USB interface 2 .
[0010] A gate of the MOSFET Q3 is connected to the USB controller 10 to receive a control signal DUALGATE_USB. A drain of the MOSFET Q3 is connected to a standby power supply 5V_SB. A source of the MOSFET Q3 outputs the USB power 5V_USB for the front USB interface 1 and the rear USB interface 2 . The source of the MOSFET Q3 is further grounded through a capacitor C1.
[0011] According to specification of the USB controller 10 , when the motherboard 5 is in the work mode, the control signal VCCGATE from the USB controller 10 is at a high level, and the control signal DUALGATE_USB from the USB controller 10 is at a low level. When the motherboard 5 is in the sleep mode, or when the motherboard 5 is powered off, the control signal VCCGATE from the USB controller 10 is at a low level, and the control signal DUALGATE_USB is at a high level.
[0012] Accordingly, when the motherboard 5 is in the work mode, the MOSFETs Q1 and Q2 are turned on, and the MOSFET Q3 is turned off. In this state, the system power supply 5V_SYS supplies the 5V_USB power supply for the front USB interface 1 and for the rear USB interface 2 through the MOSFETs Q1 and Q2.
[0013] When the motherboard 5 is in the sleep mode or when the motherboard 5 is powered off, the MOSFETs Q1 and Q2 are turned off, and the MOSFETs Q3 is turned on. In this state, the 5V_SB standby power supply supplies the 5V_USB power supply for the front USB interface 1 and for the rear USB interface 2 .
[0014] According to wiring rules of the motherboard, there are to be power layers near the front USB interface 1 and near the rear USB interface 2 . The MOSFET Q1 is thus mounted near the front USB interface 1 , and the MOSFET Q2 is mounted near the rear USB interface 2 , to provide the shortest power lines between the system power supply 5V_SYS, the MOSFET Q1, and the front USB interface 1 , and also the shortest power lines between the system power supply 5V_SYS, the MOSFET Q2, and the rear USB interface 2 . In other words, the lines which carry electrical power can be shorter. With regard to the lines for data transmission between the USB controller 10 and the MOSFETs Q1-Q3, a width of these transmission lines can be 20 millimeters because these transmission lines just transmit the control signals.
[0015] With regard to the standby power supply of 5V_SB, according to the specification of the USB, the front USB interface 1 and the rear USB interface 2 may only consume large quantities of current when the motherboard 5 is in the work mode. When the motherboard 5 is in the sleep mode, or when the motherboard 5 is powered off, the front USB interface 1 and the rear USB interface 2 consume insignificant, or very little, current. As a result, a width of the transmission lines between the MOSFET Q3, the front USB interface 1 , and the rear USB interface 2 , need only be 20 millimeters.
[0016] In the embodiment, the MOSFETs Q1-Q3 function as electronic switches.
[0017] The foregoing description of the exemplary embodiments of the disclosure has been presented only for the purposes of illustration and description and is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Many modifications and variations are possible in light of disclosure above. The embodiments were chosen and described in order to explain the principles of the disclosure and their practical application so as to enable others of ordinary skill in the art to utilize the disclosure and various embodiments, and with such various modifications as are suited to the particular use contemplated. Alternative embodiments will become apparent to those of ordinary skills in the art to which the present disclosure pertains without departing from its spirit and scope. Accordingly, the scope of the present disclosure is defined by the appended claims rather than by the foregoing description and the exemplary embodiments described therein. | A power supply circuit includes a first electronic switch mounted near a front universal serial bus (USB) interface, a second electronic switch mounted near a rear USB interface, and a third electronic switch. The first electronic switch supplies power for the front USB interface. The second electronic switch supplies power for the rear USB interface. The third electronic switch supplies power for the front USB interface and the rear USB interface when the first and second electronic switches are off. | 8 |
[0001] This application claims priority from European Patent Application No. 08 044 580.0, filed Mar. 12, 2008, the entire disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the dispersal of liquids having a relatively high-viscosity, such as insecticides and fragrance solutions, and gel or lotion-like formulations by ejecting a cloud or mist of small droplets of the liquid from a liquid droplet spray device into the atmosphere and allowing the droplets to evaporate well before they fall back through the atmosphere.
BACKGROUND OF THE INVENTION
[0003] Such liquids may be for example fragrance compositions such as described in US 2005/0037945, or insecticides or still other liquids having a relatively high viscosity.
[0004] Such liquid droplet spray devices are also sometimes called piezoelectric spray devices, aerosol generators, nebulizers and the like. They normally contain a nozzle body on a support part, in particular, a nozzle body of a liquid droplet spray device which dispenses a liquid substance as a liquid droplet spray. They further consist of a piezoelectric actuator used as vibrating means for causing the liquid to vibrate so as to be accelerated and expelled as droplets. They further consist of elements such as a liquid space, liquid feed and fluid interface linked to a reservoir, a reservoir as well as electrical connections between the ultrasound generating means and a corresponding electronic circuitry. The liquid may be for example an ambient fragrance, a perfume, an insecticide, an aromatherapy essence, a liquid pharmaceutical formulation, aqueous based liquids and flammable or combustible liquids.
[0005] Such nozzle bodies are sometimes called aperture plates, nozzle arrays, dosing aperture, orifice plate, vibratable membrane member, dosing aperture arrangement, aerosol generator and the like. Such terms are hence to be understood as being interchangeable throughout the present document.
[0006] In fact such nozzle bodies and droplet spray devices are well known. For example see the document EP 1 129 741 in the name of the present Applicant. This document describes a liquid droplet spray device having a top substrate formed of a main body and of a nozzle body. The nozzle body contains a nozzle array of liquid droplet outlet means allowing a liquid substance contained in the liquid droplet spray device to exit the device, in this case as a spray of droplets. A piezoelectric actuator is used to cause the liquid to undergo a vibration so as to generate the droplet spray.
[0007] It is well known to disperse fragrances and insecticides into the atmosphere by such device to form a mist or cloud of small droplets of a liquid substance containing the fragrance or insecticide and to eject the mist or cloud into the atmosphere in the form of minute liquid droplets. As the mist or cloud settles, the fragrance or insecticide evaporates from the droplets. Examples of devices for doing this are shown in U.S. Pat. No. 4,085,893, U.S. Pat. No. 5,173,274, U.S. Pat. No. 5,601,235 and U.S. Pat. No. 5,894,001. In general these devices supply the liquid fragrance or insecticide to a vibrating atomization plate which, due to its vibrations, breaks up the liquid into fine droplets and ejects them upwardly in the form of a mist or a cloud. As the droplets fall back down, the fragrance or insecticide evaporates from the droplets and disperses into the atmosphere.
[0008] Document WO 2008/015394 describes a spray device without an atomiser plate, but instead uses a wick fixedly attached to a vibrating element. When the vibrating element is activated, the wick will vibrate together with the vibrating element so that any liquid absorbed by the wick will be dispersed therefrom. Such device may avoid clogging, due to the absence of an atomiser plate, but the disclosure is totally silent about fallback.
[0009] Document WO 00/47335 describes another example of such a device, and a corresponding method for dispensing liquids of relatively low viscosity. The described device uses a dome-shaped vibrating orifice plate that is actuated by a piezoelectric vibrating element to vibrate the plate. Once the plate vibrates, liquid is supplied to the plate by capillary action so as to be expelled there from as a spray of droplets. As described in this document, liquids having a viscosity of less than 5 centipoises may be used, but at higher viscosity, the device stops functioning.
[0010] A problem occurs in the operation of these known devices in that there is no means to be sure that all of the liquid which is ejected will indeed evaporate before the droplets fall back onto surrounding surfaces. As a result, an often destructive liquid residue of unevaporated liquid builds up on these surfaces. This problem is particularly difficult where the liquid to be ejected is a fragrance or an insecticide having a relatively high viscosity. This is because fragrance and insecticide compositions are generally quite complex; and there has been no way to know in advance that a particular composition will fully evaporate when subjected to atomization in a vibrating plate atomizer.
[0011] Document WO 2007/054920 describes a further example of such device having a vibratable atomizer plate. Here, an air disturbance generator, such as a fan, is proposed to increase the ability of the ejected mist of droplets to remain airborne so as to increase the time allowing for increased vaporization of the droplet mist. The ejected droplets are compositions having lower and higher volatile components, and only the highly volatile components remain airborne, but the other components fall back down onto the surrounding surface. Further, a fan constitutes an additional component that needs to be placed correctly and adds to the constructional costs of the device.
[0012] A solution has been proposed in view of these problems by analysing the vapour pressure of the components of the sprayed liquid. Indeed, according to U.S. Pat. No. 6,793,149 and U.S. Pat. No. 7,070,121, when liquid compositions are broken up into small droplets and ejected into the atmosphere above a surrounding surface, such as a tabletop, for example, the ability of those droplets to become fully evaporated before they fall back onto the surrounding surface, does not depend on the vapour pressure of the liquid composition itself. Instead the ability of the droplets to evaporate depends upon the vapour pressures of the individual components of the liquid composition. This document thus describes a method of nebulising a multi-component liquid solution having a high-viscosity, such as a multi-component liquid insecticide or a perfume in a manner such that the amount of liquid deposited on adjacent surfaces is minimized. The liquid solution comprises a plurality of components having respective vapour pressures. The described method is based on the discovery that the vapour pressure of the lowest vapour pressure component of the liquid composition must be such that this component will evaporate before the liquid droplet containing this component reaches the surrounding surface.
[0013] However, according to this same document, the composition of liquids is not always exactly known. Where liquid compositions, such as fragrances or insecticides, comprise large numbers of components, it is often not practical to ascertain the vapour pressures of each of the individual components in order to determine the evaporation characteristics of nebulised droplets of the liquid. Further, often, the liquid components themselves and their respective concentrations are not known because the fragrance or insecticide is maintained by the supplier as a trade secret.
[0014] In such cases, it is thus impossible to use the described method.
[0015] It is, therefore, an object of the present invention to provide an innovative method and liquid droplet spray device for controlling the evaporation of the droplet cloud resulting from nebulising a liquid that overcome the inconveniences and limitations presented by the prior art documents, and that allow to minimise the fall back for liquids such as fragrances or the like.
SUMMARY OF THE INVENTION
[0016] Thus, the present invention concerns a method and liquid droplet spray device in accordance with various embodiments. For example, in accordance with a first embodiment of the present invention, a method of controlling the evaporation of the droplets of a liquid nebulised as a spray of droplets from a liquid droplet spray device is provided, wherein the liquid droplet spray device comprises a reservoir ( 3 ) for containing the liquid, a perforate membrane plate ( 5 ), fluid interface means ( 9 ) for feeding the liquid from the reservoir ( 3 ) to the membrane plate ( 5 ), ultrasound generating means ( 13 ) for acting on the supplied liquid to cause it to be expelled as a spray of droplets through orifices ( 7 ) of the membrane plate ( 5 ) and electronic control means ( 15 ) for controlling the activation of the ultrasound generating means ( 13 ), and the method includes the steps of: (a) providing the liquid droplet spray device; (b) supplying the liquid to a space ( 12 ) below the perforated membrane plate ( 5 ); (c) providing a pulsed driving signal having a period T for activating the ultrasound generating means ( 13 ); (d) activating the ultrasound generating means ( 13 ) for a period of time T on so as to cause the spray of droplets to be expelled at a maximum spray cloud height, T on consisting of T ona and T onb ; and (e) de-activating the ultrasound generating means for a period of time T off , where T off ≧T on +T evap , wherein T evap is the time that is required for the sprayed cloud of a given liquid produced during T on to fully evaporate, and wherein T ona is the time required to ultrasonically energise the liquid, T onb is the time to spray the liquid, and T ona lasts from less than tens of milliseconds to several seconds, whereby the amount of unevaporated liquid that falls back on a surface surrounding the liquid droplet spray device is minimised.
[0017] In accordance with a second embodiment of the present invention, the first embodiment is further modified so that T off >T on +T evap . In accordance with a third embodiment of the present invention, the first embodiment is modified to further include the step of (f) providing a fan, wherein the fan is activated for a time T onf and where T onf starts several milliseconds before T onb and lasts several milliseconds longer than T onb .
[0018] In accordance with a fourth embodiment of the present invention, a liquid droplet spray device for nebulising a liquid expelled from the liquid droplet spray device is provided, wherein the device includes: (a) a reservoir ( 3 ) for containing the liquid; (b) a perforate membrane plate ( 5 ); (c) a space ( 12 ) for containing the liquid to be expelled, the space being positioned adjacent the membrane plate ( 5 ) and arranged to receive liquid from the reservoir ( 3 ); (d) fluid interface means ( 9 ) for feeding the liquid from the reservoir ( 3 ) to the space ( 12 ); (e) ultrasound generating means ( 13 ) for acting on the supplied liquid to cause it to be expelled as a spray of droplets through orifices ( 7 ) of the membrane plate ( 5 ); and (f) electronic control means ( 15 ) for controlling the activation of the ultrasound generating means ( 13 ), wherein the electronic control means ( 15 ) is configured to drive the ultrasound generating means ( 13 ) with a pulsed driving signal having a period T, wherein the electronic control means ( 15 ) is configured to activate the ultrasound generating means ( 13 ) for a period of time T on so as to cause a spray of droplets to be expelled at a maximum spray cloud height, T on consisting of T ona and T onb , wherein the electronic control means ( 15 ) is configured to not to activate the ultrasound generating means ( 13 ) for a period of time T off , where T off ≧T on +T evap , wherein T evap is the time that is required for the sprayed cloud of a given liquid produced during T on to fully evaporate, and wherein T ona is the time required to ultrasonically energise the liquid, T onb is the time to spray the liquid, and T ona lasts from less than tens of milliseconds to several seconds, whereby the amount of unevaporated liquid that falls back on a surface surrounding the liquid droplet spray device is minimised.
[0019] In accordance with a fifth embodiment of the present invention, the fourth embodiment is modified so that T off >T on +T evap . In accordance with a sixth embodiment of the present invention, the fourth embodiment is modified so that the electronic control means ( 15 ) includes memory means for storing fabrication parameters of the ultrasound generating means ( 13 ). In accordance with a seventh embodiment of the present invention, the fourth embodiment is modified so that the memory means further stores external parameters comprising ranges of viscosities of liquids at specific temperatures to be used with the liquid droplet spray device. In accordance with an eighth embodiment of the present invention, the fourth embodiment is modified so that the fluid interface means are sized in such a way that their capillary action for a given viscosity is such that the space ( 12 ) is filled in an optimal way in order to further reduce fall out. In accordance with a ninth embodiment of the present invention, the fourth embodiment is modified so as to further include a fan, wherein the fan is arranged to be activated for a time T onf where T onf starts several milliseconds before T onb and lasts several milliseconds longer than T onb .
[0020] Thanks to the features of the method and liquid droplet spray device according to the present invention, it is possible to reliably minimise the fall back for liquids of relatively high-viscosity.
[0021] The method works independently of the vapour pressure of liquid components, so that even for unknown compositions of a liquid substance, it is possible to avoid fallback on surrounding surfaces.
[0022] In fact, liquid droplets are ejected sufficiently high to avoid fallback, i.e. the droplets fully evaporate well before they may fall back close to the surface near the spray device. Further, the present invention ejects the droplets in a controlled manner to avoid that a too high-density cloud of droplets is created. By having a relatively low-density cloud, the fallback can be further minimised.
[0023] Indeed, in the liquid droplet spray device, the ultrasound generating means, such as a piezoelectric actuator, is controlled by electronic means that control the turning on and off of the actuator, thereby effectively controlling the spraying.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Other features and advantages of the method and liquid droplet spray device according to the present invention will become clear from reading the following description, which is given solely by way of a non-limitative example thereby referring to the attached drawings in which:
[0025] FIG. 1 shows an example of a liquid droplet spray device according to the present invention,
[0026] FIG. 2 shows an example of a pulsed drive signal for driving an ultrasound generating means in a liquid droplet spray device according to the present invention, and
[0027] FIG. 3 shows in more detail the relative durations of timings T ona , T onb and T onf .
DETAILED DESCRIPTION OF THE INVENTION
[0028] A general overview of flow principles is first briefly explained.
[0029] It is known that the flow rate of ejected liquids depends on the diameter of the liquid droplets as well as on the density of outlet nozzles through which the liquid is ejected. This diameter directly depends on the diameter of an outlet nozzle through which the liquid passes to be ejected as a spray. Further, the flow rate is inversely proportional to the viscosity of the liquid and the pressure drop across the outlet nozzles. Thus, persons skilled in the art will readily recognise that the physical dimensions of the atomizer, in particular its outlet means, will be matched to the physical properties of the liquid to be expelled to ensure efficient spraying of the liquid.
[0030] For example, all other nozzle dimensions remaining equal, the diameter D 0 of an outlet nozzle is 4 μm, and, the diameter D 1 is 4.5 μm. For a given liquid viscosity of 4 cp we obtain the following:
[0000] Qv 1 (4.5)=(1 +x ) QV 0 (4)
[0031] Experimental measurements have shown that x is 0.3 in this case, so that the flow rate increases by 30%, whilst the diameter size has increased from 4 to 4.5 μm, i.e. by 12.5% for a same density of outlet nozzles. The size of the expelled droplets has increased by about 10%.
[0032] The Dv50 (as measured in a well-known manner for example on a Malvern Mastersizer) increased by 3.3% which does not have any impact on the fall-back, i.e. on the amount of droplets that do not evaporate but fall back onto the surface surrounding the spray device.
[0033] An example of a preferred embodiment will now be described while referring to FIG. 1 .
[0034] FIG. 1 show a schematic representation of a liquid droplet spray device according to the present invention. However, the shown structure is merely an example of a suitable device. Other structures, known as such in the art, may be used instead, as the main aspect of this present invention is the controlling of the ejection of droplets from the device. Thus, in the example, the liquid droplet spray device 1 comprises a reservoir 3 for containing liquid to be expelled. Such reservoir may be internal to the device, or external, and may be a disposable reservoir or not. Such reservoir may be a bottle, or a collapsible bag, or any other suitable liquid recipient.
[0035] The device has a perforated membrane plate 5 having a plurality of outlet means 7 through which the liquid is to be expelled as a spray of droplets. In this example, the perforated membrane plate is included in a first substrate 8 arranged above a second substrate 10 , thereby enclosing a space 12 , or pressure chamber, for containing liquid to be expelled. Other arrangements may be used instead, and are well known in the art. Important here is that liquid is provided to the space 12 adjacent to a perforated membrane plate so as to allow for ejection of the liquid through the nozzles of the plate to obtain a mist of expelled droplets.
[0036] Thus, liquid supply means 9 are provided for feeding liquid from the reservoir by capillary action to the space and thus the membrane plate. In this example, an optional valve 11 is further shown controlling the feed from the reservoir to the membrane plate. In an alternative, wicking means may be provided for feeding the liquid from the reservoir, in a manner well known in the art.
[0037] The liquid supply means 9 are preferably sized in such a way that their capillary action for a given viscosity is such that space 12 is filled in an optimal way in order to avoid fall out. Partial filling because of insufficient capillarity would leave room for air inclusions in space 12 , hence reducing the efficiency of ultrasonic energy transmitted to the liquid by ultrasound generating means 13 and thus reducing spray height which may result in fall-out. For this reason, for a given viscosity, the capillarity lift height of the liquid supply means 9 need to improve on the liquid supply capability furnished by wicking means and the reservoir.
[0038] Ultrasound generating means 13 are further provided and arranged to act on the liquid so that the liquid undergoes a vibration due to which it is expelled through the nozzles of the perforated membrane plate. For example, a piezoelectric element may be used as the ultrasound generating means. In this example, the ultrasound generating means are shown to be below the spray device, but such means may be arranged on the top surface, near the perforated membrane plate, as is known as such in the art.
[0039] Electronic control means 15 are further provided for controlling the actuation of the ultrasound generating means. Such electronic control means may comprise an analogue circuit, a microcontroller, a timer and the like components in suitable combinations. A driving signal generator may also be included, or such may be provided separately. By controlling the “on” and “off” time, respectively called T on and T off , of the ultrasound generating means 13 , the amount of liquid ejected by the liquid droplet spray device may be controlled.
[0040] The total duration of operation for expelling a predetermined amount of liquid is thus T=T on +T off . An example of a drive signal for actuating the ultrasound generating means is shown in FIG. 2 .
[0041] Indeed, it has been found that by using a pulsed drive of the ultrasound generating means in a particularly advantageous way, a more efficient operation may be obtained thus resulting in a reduced power consumption of the liquid droplet spray device while eliminating or minimising fall-back.
[0042] By further adjusting the energy supplied to the ultrasound generating means, the amount of expelled droplets can also be influenced. Basically, more energy input means that more droplets will be expelled.
[0043] This energy adjustment relates to the on and off time, T on and T off , as well as to the amplitude of a pulsed drive signal of the electronic control means. The longer T on during which the ultrasound generating means is actuated, the more energy is provided and thus the more droplets are expelled during a period T. T on will be chosen to obtain a maximum height of the sprayed cloud of droplets for a given liquid. By also controlling the off time T off , i.e. by controlling the distance in time of the driving signal, the height of the expelled spray cloud can be controlled.
[0044] In fact, T on consists of T ona and T onb , where T ona is the time required to ultrasonically energise the liquid, and T onb is the time to spray the liquid. T ona may last from less than 1 second to several seconds. As will be explained further, both T ona and T onb contribute to generate a maximum height of the sprayed cloud of droplets for a given liquid.
[0045] It was found that if too many droplets are expelled, i.e. if the number of sequences of sprays of droplets expelled are in quick succession, i.e. T off is relatively small compared to T on , the ejected sprays tend towards becoming a large and dense cloud, as the earlier expelled droplets will not yet have fully evaporated before newly expelled droplets arrive. The droplets may then interfere with each other, thus possibly preventing each other from fully evaporating before falling back to the surface surrounding the spray device and thus leading to a certain amount of fallback.
[0046] On the other hand, if T off is increased with respect to T on , for a same period T, the hovering cloud of expelled droplets is much less dense and the droplets may all evaporate before falling back to the surrounding surface.
[0047] Indeed, it has been found that by measuring the evaporating time T evap that is required for a sprayed cloud of a given liquid produced during T on to fully evaporate, and by controlling the time T off so as to be longer than T evap , fallback can be effectively controlled.
[0048] Thus, by controlling the ratio between T off , T on and T evap the fallback may be further avoided.
[0049] Indeed, it has been found that T off ≧T on +T evap .
[0050] For example, for a given liquid having a viscosity of 4 cps, T on =50 ms, T evap =950 ms, and thus T off is at least 1 sec.
[0051] For some liquids, like glycerine or aqueous solutions of glycerine, where the viscosity at 30° C. may be higher than 30 cps, for example 33.9 cps at a concentration of 80% glycerine in water (H 2 O), it may be an advantage to use the energy produced by the ultrasound generating means to heat this aqueous solution during a short period of time from ambient to 80° C. where the viscosity of the solution will drop to 5.13 cps and where it can be dispensed as droplets easily.
[0052] As said before, T on therefore consists of T ona and T onb , where T ona is the time required to ultrasonically energise the liquid in the way described above, and T onb is the time to spray the liquid. Thus, a maximum height of the sprayed cloud of droplets for the solution can be reached by lowering the flow resistance of the liquid T ona and then dispensing it during T onb .
[0053] T ona may last from less than tens of milliseconds to 1 second and to several seconds depending on the liquid and the volume to be energized and sprayed to a maximum height of the sprayed cloud of droplets for a given liquid.
[0054] It is known that the viscosity of a liquid changes with the temperature. It is therefore desirable to allow adjusting the operation of the ultrasound generating means to adapt to the temperature change so as to ensure correct operation of the liquid droplet spray device, and thus to minimise fall-back, even with varying ambient temperature, and varying viscosities.
[0055] In this respect, it should be noted that the present Applicant has conceived an electronic control system for a liquid droplet spray device that allows such adjustment. This has been described in co-pending application EP 07 118 212.5. For example, due to ambient temperature changes, the liquid droplet spray device might operate at a different frequency in a more efficient manner, so that by checking an envelope of a system response signal, the new peak can be detected which thus gives the new optimum operating frequency.
[0056] Further, memory means may be provided for storing parameters from the ultrasound generating means. Upon fabrication, several parameters may be measured, and then stored, for different ambient temperatures. Thus, physical characteristics of the ultrasound generating means at different temperatures may be stored. Likewise, reference characteristics at different temperature and for different viscosities may be stored. Once the liquid droplet spray device is activated, the optimum operating frequency is determined. This frequency will thus correspond to a certain ambient temperature. By comparing the frequency with one pre-stored in the memory means, it is thus possible to determine the corresponding ambient temperature, as explained in detail in the above-mentioned co-pending application.
[0057] It should be noted that such memory means may also store information relating to liquids to be used for spraying by the liquid droplet spray device. For example, for several perfumes, a certain viscosity at a certain temperature may also be pre-stored.
[0058] It is thus possible to operate the liquid droplet spray device at the determined optimum operating frequency, for the given ambient temperature, and possibly also for a given viscosity of a liquid to be sprayed.
[0059] By using a periodic monitoring, it is possible to ensure a correct operation of the liquid droplet spray device with time. Thus, even if there is a temperature change, the operating frequency of the atomiser is further controlled to remain at an optimum operating frequency. As such, also the fallback can be controlled even with a varying ambient temperature.
[0060] In some cases, it may be useful to further provide a fan, which may be suitably arranged with respect to the membrane plate. For instance when spraying a dense cloud of relatively large droplets that may be close to or in excess of 10 μm in diameter, for example, it may be necessary to operate a fan at least temporarily in order to increase the lift height of the cloud. In such case it may be advantageous to adapt the timing of the fan operation T onf with respect to T onb as shown in FIG. 3 . T onf starts preferably a few tens of milliseconds, for example 50 ms, before T onb starts, and also lasts a few milliseconds longer than T onb , for example also 50 ms. This allows accelerating the expelled cloud and thus to increase the lift height as well as avoiding the fall back of heavier droplets at the end of T onb .
[0061] Having described now the preferred embodiments of this invention, it will be apparent to one of skill in the art that other embodiments incorporating its concept may be used. It is felt, therefore, that this invention should not be limited to the disclosed embodiments, but rather should be limited only by the scope of the appended claims. | A method of controlling evaporation of droplet cloud resulting from nebulization of a liquid expelled from a liquid droplet spray device is disclosed, wherein the liquid droplet spray device comprises a reservoir containing liquid, a perforate membrane plate, fluid interface means for feeding liquid from the reservoir to the membrane plate, ultrasound generating means for acting on the supplied liquid to cause it to be expelled as a spray of droplets through orifices of the membrane plate, and electronic control means for controlling activation of the ultrasound generating means. | 1 |
CROSS-REFERENCES TO RELATED APPLICATIONS
The present application claims priority to U.S. Provisional Application Ser. No. 60/373,176, filed on Apr. 16, 2002, the disclosure of which is incorporated herein by reference in its entirety.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable
REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISK.
Not applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to a novel process for preparing heteroaryl and unsaturated heterocycloalkylmagnesium reagents that are useful in the synthesis of a variety of pharmaceuticals, in particular certain cysteine protease inhibitors.
2. State of the Art
Heteroaryl and unsaturated heterocycloalkylmagnesium reagents are useful in the synthesis of a variety of pharmaceuticals, such as renin inhibitors and cysteine protease inhibitors. For example, heteroarylmagnesium reagents are used in the synthesis of 1-hydroxy-1-(heteroaryl or unsaturated heterocycloalkyl)-2-N-protected-aminoethyl intermediates which are then used in the synthesis of a number of peptidic pharmaceutically active agents (see EP 0376012 which discloses the use of 1-hydroxy-1-(heteroaryl)-2-aminoethyl in the synthesis of renin inhibitors and PCT Application Publication No. WO 00/55144 and Ohmoto, K. et. al., J. Med. Chem. 2001, 44, 1268 which disclose the use of 1-hydroxy-1-(heteroaryl or heterocycloalkyl)-2-aminoethyl in the synthesis of protease inhibitors). At present, 1-hydroxy-1-(heteroaryl)-2-N-protected-aminoethyl intermediates used are prepared by reacting an aldehyde with a heteroarylmagnesium reagent or by assembly of the heterocyclic/heteroaryl ring. The heteroarylmagnesium reagent used in this process is prepared by first treating a heteroaryl with an organolithium reagent and then converting the resulting lithiated species into a Grignard reagent under transmetallation reaction conditions. The drawbacks of these procedures are that they require very low reaction temperatures, typically −78° C., or are not the most economical or expedient route.
In order to avoid low temperature chemistry, the heteroarylmagnesium reagent can be prepared by reacting the corresponding heteroaryl halide with magnesium turnings in the presence of an initiation mixture containing ethyl bromide and iodine crystals. The drawback of this procedure is that the initiation of the reaction is very unpredictable and the reaction is highly exothermic and hence requires appropriate set up to keep the reaction temperature under control. Additionally, this method can be subject to undesirable side reactions, such as Wurtz coupling. These drawbacks make the use of heteroaryl or unsaturated heterocycloalkylmagnesium reagents unattractive for large-scale synthesis of pharmaceuticals.
Accordingly, there is a need for a synthetic process that would be amenable to large-scale synthesis of these compounds without the limitations discussed above. The present invention fulfills this and related needs.
BRIEF SUMMARY OF THE INVENTION
The present invention is directed to a novel process for preparing heteroaryl and unsaturated heterocycloalkylmagnesium reagents and their use in the synthesis of certain cysteine protease inhibitors. As discussed above, the current synthesis of these reagents makes their use in large-scale synthesis unattractive. Applicants have surprisingly discovered that heteroaryl or unsaturated heterocycloalkylmagnesium reagents can be prepared under mild reaction conditions by treating a corresponding heteroaryl or unsaturated heterocycloalkyl compound directly with a Grignard reagent.
Accordingly, in one aspect, this invention is directed to a process of preparing a nucleophilic heteroaryl or unsaturated heterocycloalkylmagnesium reagent comprising reacting a compound of formula (I):
wherein:
X is —O— or —S—;
Y is nitrogen or —CR 3a —;
Y′ is nitrogen or —CR 2a — provided that Y and Y′ are not simultaneously nitrogen;
one of R 2 and R 3 is hydrogen, (C 1-6 )alkyl, (C 1-6 )alkoxy, (C 1-6 )alkoxy(C 1-6 )alkyl, (C 1-6 )alkylthio, (C 5-6 )cycloalkyl, (C 5-6 )cycloalkylalkyl, halo, nitro, halo(C 1-3 )alkyl, (C 6-12 )aryl, heteroaryl, heterocycloalkyl, (C 6-12 )aryl(C 1-6 )alkyl, heteroaryl(C 1-6 )alkyl, (C 1-6 )alkylsulfonyl, (C 6-12 )arylsulfonyl, (C 6-12 )aryl(C 1-6 )alkylsulfonyl, heteroarylsulfonyl, heteroaryl (C 1-6 )alkylsulfonyl, aminosulfonyl, (C 1-6 )alkylaminosulfonyl, (C 1-6 )dialkylaminosulfonyl, —CONR 4 R 5 (where R 4 and R 5 are independently of each other hydrogen, (C 1-6 )alkyl, (C 1-6 )alkoxy, aryl, aryl(C 1-6 )alkyl, heteroaryl, heteroaryl(C 1-6 )alkyl, (C 5-6 )cycloalkyl, (C 5-6 )cycloalkyl(C 1-6 )alkyl, heterocycloalkyl, or heterocycloalkyl(C 1-6 )alkyl, or R 4 and R 5 together with the nitrogen atom to which they are attached form heterocycloamino), —NHCOR 6 (where R 6 is (C 1-6 )alkyl, (C 6-12 )aryl, aryl(C 1-6 )alkyl, heteroaryl, heteroaryl (C 1-6 )alkyl, (C 5-6 )cycloalkyl, (C 5-6 )cycloalkyl(C 1-6 )alkyl, heterocycloalkyl, or heterocycloalkyl(C 1-6 )alkyl), —SO 2 NR 7 R 8 (where R 7 and R 8 are independently of each other hydrogen, (C 1-6 )alkyl, (C 6-12 )aryl, (C 6-12 )aryl(C 1-6 )alkyl, heteroaryl, heteroarylalkyl, (C 5-6 )cycloalkyl, (C 5-6 )cycloalkyl(C 1-6 )alkyl, heterocycloalkyl, or heterocycloalkyl(C 1-6 )alkyl, or R 7 and R 8 together with the nitrogen atom to which they are attached form heterocycloamino), -alkylene-CONR 4 R 5 (where R 4 and R 5 are as defined above), -alkylene-NHCOR 6 (where R 6 is as defined above), or -alkylene-SO 2 NR 7 R 8 (where R 7 and R 8 are as defined above); and
the other of R 2 and R 3 is hydrogen or (C 1-6 )alkyl wherein within R 2 or R 3 said aryl, heteroaryl, or heterocycloalkyl is optionally substituted further with one, two, or three substituents independently selected from the group consisting of (C 1-6 )alkoxy, (C 1-6 )alkyl, (C 6-12 )aryl(C 1-6 )alkyl, halo, nitro, and halo(C 1-3 )alkyl; or
when Y and Y′ are carbon, then R 2 and R 3 together with the atoms to which they are attached form an optionally substituted benzene, napthyl, (C 3-6 )cycloalkyl, or an aromatic or non-aromatic heterocyclic ring;
R 2a and R 3a are independently hydrogen or alkyl; or R 2a and R 3a together form a covalent bond, provided that when Y or Y′ is nitrogen, R 2a and R 3 or R 2 and R 3a together form a covalent bond;
with a Grignard reagent provided that (I) is not 1,2,4- or 1,3,4-oxadiazole.
In the context of the present invention, functional groups when present on (I) are those that are compatible with the general use of a Grignard reagent and are well known to those of skill in the art. Certain functional groups, whose presence might lead to reduced yields can be suitably protected prior to contacting the compound of formula (I) with the Grignard reagent. Again, suitable protecting groups are known to those of skill in the art and can be found in, for example, Greene and Wuts, Protective Groups in Organic Synthesis, 2nd ed., John Wiley & Sons, Inc. 1991.
Preferably, a compound of formula (I) where Y′ is —CR 2a —.
Preferably, the Grignard reagent has an empirical formula R 1 MgZ where R 1 is alkyl or optionally substituted phenyl and Z is halo, preferably Z is chloro or bromo and the reaction is carried out in a suitable organic solvent. Preferably the Grignard reagent is selected from the group consisting of n-butylmagnesium chloride, isopropylmagnesium chloride, phenylmagnesium chloride, n-butylmagnesium bromide, isopropylmagnesium bromide, or phenylmagnesium bromide. More preferably the Grignard reagent is isopropylmagnesium chloride in tetrahydrofuran.
Preferably, the reaction solvent is an ethereal organic solvent such as tetrahydrofuran and the like, or a mixture of ethereal and an aromatic organic solvent. Preferably, it is carried out in a 1:1 mixture of tetrahydrofuran and toluene.
Preferably the reaction is carried out from about −78° to about 40° C., more preferably from about −10° to about 40° C. More preferably from about −10° to about 10° C., most preferably at about −5° C.
Preferably,
ring in (I) is 4,5-dihydrooxazole, thiazole, or oxazole wherein one of R 2 and R 3 is hydrogen or (C 1-4 )alkyl and the other of R 2 and R 3 is selected from the group consisting of hydrogen, halo, (C 1-4 )alkyl, (C 6-12 )aryl, —CONR 4 R 5 (where R 4 and R 5 are independently of each other hydrogen, (C 1-6 )alkyl, (C 1-4 )alkoxy, (C 6-12 )aryl, (C 6-12 )aryl(C 1-6 )alkyl, heteroaryl, heteroaryl(C 1-6 )alkyl, (C 5-6 )cycloalkyl, (C 5-6 )cycloalkyl(C 1-6 )alkyl, heterocycloalkyl, or heterocycloalkyl(C 1-6 )alkyl, or R 4 and R 5 together with the nitrogen atom to which they are attached form heterocycloamino), —SO 2 NR 7 R 8 (where R 7 and R 8 are independently of each other hydrogen, (C 1-6 )alkyl, (C 6-12 )aryl, (C 6-12 )aryl(C 1-6 )alkyl, heteroaryl, heteroaralkyl, (C 5-6 )cycloalkyl, (C 5-6 )cycloalkyl(C 1-6 )alkyl, heterocycloalkyl, or heterocycloalkyl(C 1-6 )alkyl, or R 7 and R 8 together with the nitrogen atom to which they are attached form heterocycloamino), nitro, and trifluoromethyl wherein within R 2 or R 3 said aryl, heteroaryl, or heterocycloalkyl is optionally substituted further with one, two, or three substituents independently selected from the group consisting of (C 1-6 )alkoxy, (C 1-6 )alkyl, (C 6-12 )aryl(C 1-6 )alkyl, halo, nitro, and halo(C 1-3 )alkyl. Preferably, one of R 2 and R 3 is hydrogen or methyl and the other of R 2 and R 3 is selected from the group consisting of hydrogen, phenyl, phenylaminocarbonyl, benzylaminocarbonyl, aminosulfonyl, 2-phenylethylaminocarbonyl, 3-phenylpropylaminocarbonyl, aminocarbonyl, methylaminocarbonyl, 4-benzylpiperidin-1-ylcarbonyl, furan-2-ylmethylaminocarbonyl, pyridin-2-ylmethylaminocarbonyl, pyridin-3-ylmethyl-aminocarbonyl, pyridin-4-yl-methylaminocarbonyl, 2-,3-, or 4-chlorobenzylamino-carbonyl, isopropylaminocarbonyl, 1-phenylethylaminocarbonyl, N-methyl-N-benzylaminocarbonyl, pyrrolidin-1-yl-carbonyl, piperidin-1-ylcarbonyl, 1,2,3,4-tetrahydroquinolin-1-ylcarbonyl, napthyl-1-yl-methylamino-carbonyl, 1,2,3-tetrahydroindol-1-ylcarbonyl, and admant-1-ylmethylaminocarbonyl.
Preferebly, (I) is a compound where R 2 and R 3 together with the atoms to which they are attached form an optionally substituted benzene ring. Preferably, the benzene ring is optionally subsituted with (C 1-4 )alkyl, halo, (C 1-4 )alkoxy, (C 6-12 )aryl, —CONR a R b (where R a and R b are independently of each other hydrogen, (C 1-6 )alkyl, (C 1-4 )alkoxy, (C 6-12 )aryl, (C 6-12 )aryl(C 1-6 )alkyl, heteroaryl, heteroaryl(C 1-6 )alkyl, (C 5-6 )cycloalkyl, (C 5-6 )cycloalkyl-(C 1-6 )alkyl, heterocycloalkyl, or heterocycloalkyl(C 1-6 )alkyl, or R a and R b together with the nitrogen atom to which they are attached form heterocycloamino), —SO 2 NR a R b (where R a and R b are independently of each other hydrogen, (C 1-6 )alkyl, (C 6-12 )aryl, (C 6-12 )aryl(C 1-6 )alkyl, heteroaryl, heteroaralkyl, (C 5-6 )cycloalkyl, (C 5-6 )cycloalkyl(C 1-6 )alkyl, heterocycloalkyl, or heterocycloalkyl(C 1-6 )alkyl, or R a and R b together with the nitrogen atom to which they are attached form heterocycloamino), nitro, or trifluoromethyl.
Preferebly, (I) is benzoxazole, benzothiazole, 5-phenylbenzoxazole, 5, or 6-methoxybenzoxazole, 5-trifluorobenzoxazole, 5-nitrobenzoxazole, 5-chloro-benzoxazole, oxazolo[4,5-b]pyridine, or 5-aminosulfonylbenzoxazole, most preferably benzoxazole.
Preferably, the nucleophilic heteroaryl or unsaturated heterocycloalkylmagnesium reagent generated by the above process has the structure (Ia):
wherein X, Y, Y′, R 2 , and R 3 are as defined in formula (I) above, including the preferred embodiments and Z is halo, preferably chloro or bromo.
Preferebly,
in (Ia) is benzoxazol-2-yl, benzothiazol-2-yl, 5-phenylbenzoxazol-2-yl, 5- or 6-methoxybenzoxazol-2-yl, 5-trifluorobenzoxazol-2-yl, 5-nitrobenzoxazol-2-yl, 5-chloro-benzoxazol-2-yl, oxazolo[4,5-b]pyridin-2-yl, or 5-aminosulfonylbenzoxazol-2-yl, most preferably benzoxazol-2-yl.
This invention also provides a process as described above, which further comprises reacting the nucleophilic heteroaryl or unsaturated heterocycloalkylmagnesium reagent prepared as described above (including the preferred embodiments) with an aldehyde of formula (II):
where:
PG is an amino protecting group;
R 1 is hydrogen or (C 1-6 )alkyl, or R 1 together with R 10 and the atoms to which they are attached form heterocycloamino;
R 9 is hydrogen or (C 1-6 )alkyl; and
R 10 is:
(i) (C 1-6 )alkyl optionally substituted with halo, nitro, —SR 11 , —C(O)NR 11 R 11 , —P(O)(OR 11 )OR 11 , —OP(O)(OR 11 )OR 11 , —S(O)R 12 , or —S(O) 2 R 12 wherein R 11 at each occurrence independently is hydrogen, (C 1-6 )alkyl or halo-substituted (C 1-3 )alkyl and R 12 is alkyl or halo-substituted (C 1-3 )alkyl; or
(ii) (C 5-6 )cycloalkyl(C 2-3 )alkyl, hetero(C 3-6 )cycloalkyl(C 2-3 )alkyl, (C 6-12 )aryl(C 2-3 )alkyl or hetero(C 5-6 )aryl(C 2-3 )alkyl, wherein said cycloalkyl, heterocycloalkyl, aryl or heteroaryl optionally is substituted further with 1 to 5 radicals independently selected from the group consisting of alkyl, alkylidene, halo, halo-substituted (C 1-4 )alkyl, nitro, —X 1 NR 14 C(O)OR 14 , —X 1 NR 14 C(O)NR 14 R 14 , —X 1 NR 14 C(NR 14 )NR 14 R 14 , —X 1 OR 14 , —X 1 SR 14 , —X 1 C(O)NR 14 R 14 ,—X 1 S(O) 2 NR 14 R 14 , —X 1 P(O)(OR 14 )OR 14 , —X 1 OP(O)(OR 14 )OR 14 , —X 1 NR 14 C(O)R 15 , —X 1 S(O)R 15 , and —X 1 S(O) 2 R 15 wherein X 1 is a bond or (C 1-6 )alkyl, R 14 at each occurrence independently is hydrogen, (C 1-6 )alkyl or halo-substituted (C 1-3 )alkyl, and R 15 is (C 1-6 )alkyl, halo-substituted (C 1-3 )alkyl, or halo; or
(iii) R 9 and R 10 taken together with the carbon atom to which both R 9 and R 10 are attached form (C 3-8 )cycloalkylene or heterocycloalkylene, wherein said cycloalkylene or heterocycloalkylene is optionally substituted with 1 to 3 radicals independently selected from the group consisting of (C 1-6 )alkyl, (C 1-6 )alkylidene, halo, halo-substituted (C 1-4 )alkyl, nitro, —X 2 NR 14 C(O)OR 14 , —X 2 NR 14 C(O)NR 14 , —X 2 NR 14 C(NR 14 )NR 14 R 14 ,—X 2 OR 14 , —X 2 SR 14 , —X 2 C(O)NR 14 R 14 , —X 2 S(O) 2 NR 14 R 14 , —X 2 P(O)(OR 14 )OR 14 , —X 2 OP(O)(OR 14 )OR 14 , —X 2 NR 14 C(O)R 15 , —X 2 S(O)R 15 , and —X 2 S(O) 2 R 15 wherein X 2 is a bond or (C 1-6 )alkylene, R 14 at each occurrence independently is hydrogen, (C 1-6 )alkyl or halo-substituted (C 1-3 )alkyl, and R 15 is (C 1-6 )alkyl, halo-substituted (C 1-3 )alkyl, or halo; to provide a compound of formula
where:
X, Y, Y′, PG, R 2 , R 3 , R 9 , and R 10 are as defined above;
(i) optionally removing the amino protecting group;
(ii) optionally converting the compound obtained in step (i) above, to an acid addition salt;
(iii) optionally converting a salt form of a compound of formula (III) to a free base;
(iv) optionally separating individual isomers;
(v) optionally modifying any of the PG, R 2 , R 3 , R 9 and R 10 groups.
Preferably the moiety,
in compound (III) is as defined in the preferred embodiments for formula (I) above; R 9 is hydrogen or (C 1-6 )alkyl and R 10 is (C 1-6 )alkyl or (C 6-12 )aryl(C 2-3 )alkyl, or R 9 and R 10 taken together with the carbon atom to which both R 9 and R 10 are attached form (C 3-8 )cycloalkylene. More preferably, R 9 is hydrogen or methyl, more preferably hydrogen and R 10 is methyl, ethyl, propyl, butyl, phenylmethyl, or 2-phenylethyl, or R 9 and R 10 taken together with the carbon atom to which both R 9 and R 10 are attached form cyclopropylene, cyclopentylene or cyclohexylene. Even more preferably, R 10 is ethyl and the stereochemistry at the carbon atom to which R 10 is attached is (S).
Preferably, the reaction is carried out in an aromatic organic solvent such as toluene, benzene, and the like.
This invention also provides a process as described in the immediately above, additionally comprising:
removing the amino protecting group in compound (III) to provide a compound of formula (IV):
where Y, X, R 2 , R 3 , R 9 and R 10 are as defined above (including the preferred embodiments) and optionally forming an acid addition salt; and
reacting (IV) with a compound of formula (V):
where:
R 25 and R 27 are independently of each other hydrogen or (C 1-6 )alkyl;
R 28 is:
(i) (C 1-6 )alkyl optionally substituted by cyano, halo, nitro, —NR 14 R 14 , —NR 14 C(O)OR 14 , —NR 14 C(O)NR 14 R 14 , —NR 14 C(NR 14 )NR 14 R 14 , —OR 14 , —SR 14 , —C(O)NR 14 R 14 , —S(O) 2 NR 14 R 14 , —P(O)(OR 14 )OR 14 , —OP(O)(OR 14 )OR 14 , —NR 14 C(O)R 15 , —S(O)R 15 , —S(O) 2 R 15 , —C(O)R 15 , —OR 16 , —SR 16 , —S(O)R 16 , —S(O) 2 R 16 , —C(O)NR 16 R 17 , —NR 16 R 17 , —NR 17 C(O)R 16 , —NR 17 C(O)OR 16 , —NR 17 C(O)NR 16 R 17 or NR 17 C(NR 17 )NR 16 R 17 , wherein R 14 and R 15 are as defined above, R 16 is (C 3-12 )cycloalkyl(C 0-6 )alkyl, heterocycloalkyl(C 0-6 )alkyl, (C 6-12 )aryl(C 0-6 )alkyl, heteroaryl(C 0-6 )alkyl, (C 9-12 )bicycloaryl(C 0-6 )alkyl or heterobicycloaryl(C 0-6 )alkyl and R 17 at each occurrence independently is hydrogen or (C 1-6 )alkyl; or
(ii) (C 3-12 )cycloalkyl(C 0-6 )alkyl, hetero(C 3-12 )cycloalkyl(C 0-6 )alkyl, (C 6-12 )aryl(C 0-6 )alkyl, hetero(C 5-12 )aryl(C 0-6 )alkyl, (C 9-12 )bicycloaryl(C 0-6 )alkyl or hetero(C 8-12 )bicycloaryl(C 0-6 )alkyl; or
(iii) (C 3-6 )cycloalkyl(C 0-6 )alkyl, hetero(C 3-6 )cycloalkyl(C 0-6 )alkyl, phenyl(C 0-6 )alkyl or hetero(C 5-6 )aryl(C 0-6 )alkyl, wherein said cycloalkyl, heterocycloalkyl, phenyl or heteroaryl is substituted by —R 18 , —X 3 OR 18 , —X 3 SR 18 , —X 3 S(O)R 18 , —X 3 S(O) 2 R 18 , —X 3 C(O)R 18 , —X 3 C(O)OR 18 , —X 3 C(O)NR 18 R 19 , —X 3 NR 18 R 19 , —X 3 NR 19 C(O)R 18 , —X 3 NR 19 C(O)OR 18 , —X 3 NR 19 C(O)NR 18 R 19 or —X 3 NR 19 C(NR 19 )NR 18 R 19 , wherein X 3 is a bond or (C 1-6 )alkylene, R 18 is (C 3-6 )cycloalkyl(C 0-6 )alkyl, hetero(C 3-6 )cycloalkyl(C 0-6 )alkyl, phenyl(C 0-6 )alkyl or hetero(C 5-6 )aryl(C 0-6 )alkyl and R 19 at each occurrence independently is hydrogen or (C 1-6 )alkyl;
wherein within R 28 any alicyclic or aromatic ring system present may be substituted further by 1 to 5 radicals independently selected from the group consisting of (C 1-6 )alkyl, (C 1-6 )alkylidene, cyano, halo, halo-substituted (C 1-4 )alkyl, nitro, —X 4 NR 14 R 14 , —X 4 NR 14 C(O)OR 14 , —X 4 NR 14 C(O)NR 14 R 14 , —X 4 NR 14 C(NR 14 )NR 14 R 14 , —X 4 OR 14 , —X 4 SR 14 , —X 4 C(O)OR 14 , —X 4 C(O)NR 14 R 14 , —X 4 S(O) 2 NR 14 R 14 , —X 4 P(O)(OR 14 )OR 14 , —X 4 OP(O)(OR 14 )OR 14 , —X 4 NR 14 C(O)R 15 , —X 4 S(O)R 15 , —X 4 S(O) 2 R 15 and —X 4 C(O)R 15 , wherein X 4 is a bond or (C 1-6 )alkylene, and R 14 and R 15 are as defined above; and
R 26 is:
(i) (C 1-6 )alkyl optionally substituted with cyano, aryl, halo, nitro, —NR 14 R 14 , —NR 14 C(O)OR 14 , —NR 14 C(O)NR 14 R 14 , —NR 14 C(NR 14 )NR 14 R 14 , —OR 14 , —SR 14 , —C(O)NR 14 R 14 , —S(O) 2 NR 14 R 14 , —P(O)(OR 14 )OR 14 , —OP(O)(OR 14 )OR 14 , —NR 14 C(O)R 15 , —NR 14 SO 2 R 15 , —S(O)R 15 , —S(O) 2 R 15 , —C(O)R 15 , —OR 16 , —SR 16 , —S(O)R 16 , —S(O) 2 R 16 , —OC(O)R 16 , —NR 16 R 17 , —NR 17 C(O)R 16 , NR 17 C(O)OR 16 , —C(O)NR 16 R 17 , —S(O) 2 NR 16 R 17 , —NR 17 C(O)NR 16 R 17 or —NR 17 C(NR 17 )NR 16 R 17 , wherein R 14 , R 15 , R 16 and R 17 are as defined above, and wherein within R 16 said cycloalkyl, heterocycloalkyl, aryl, heteroaryl, bicycloaryl or heterobicycloaryl ring optionally is substituted by a group selected from —R 20 , —X 5 OR 20 , —X 5 SR 20 , —X 5 S(O)R 20 , —X 5 S(O) 2 R 20 , —X 5 C(O)R 20 , —X 5 C(O)OR 20 , —X 5 OC(O)R 20 , —X 5 NR 20 R 21 , —X 5 NR 21 C(O)R 20 , —X 5 NR 21 C(O)OR 20 , —X 5 C(O)NR 20 R 21 , —X 5 S(O) 2 NR 20 R 21 , —X 5 NR 19 C(O)NR 20 R 21 and —X 5 NR 21 C(NR 21 )NR 20 R 21 , wherein X 5 is a bond or (C 1-6 )alkylene, R 20 is hydrogen or (C 1-6 )alkyl and R 21 is (C 3-12 )cycloalkyl(C 0-6 )alkyl, hetero(C 3-12 )cycloalkyl-(C 0-6 )alkyl, (C 6-12 )aryl(C 0-6 )alkyl, hetero(C 5-12 )aryl(C 0-6 )alkyl, (C 9-12 )polycycloaryl(C 0-6 )alkyl or hetero(C 8-12 )polycycloaryl(C 0-6 )alkyl; or
(ii) a group selected from (C 3-12 )cycloalkyl(C 0-6 )alkyl, hetero(C 3-12 )cycloalkyl(C 0-6 )alkyl, (C 6-12 )aryl(C 0-6 )alkyl, hetero(C 5-12 )aryl(C 0-6 )alkyl, (C 9-12 )polycycloaryl(C 0-6 )alkyl and hetero(C 8-12 )polycycloaryl(C 0-6 )alkyl, wherein said cycloalkyl, heterocycloalkyl, aryl, heteroaryl, polycycloaryl or heterpolycycloaryl ring optionally is substituted by a group selected from —R 20 , —X 6 OR 20 , —X 6 SR 20 , —X 6 S(O)R 20 , —X 6 S(O) 2 R 20 , —X 6 C(O)R 20 , —X 6 C(O)OR 20 , —X 6 OC(O)R 20 , —X 6 NR 20 R 21 , —X 6 NR 21 C(O)R 20 , —X 6 NR 21 C(O)OR 20 , —X 6 C(O)NR 20 R 21 , —X 6 S(O) 2 NR 20 R 21 , —X 6 NR 19 C(O)NR 20 R 21 and
—X 6 NR 21 C(NR 21 )NR 20 R 21 , wherein X 6 is a bond or (C 1-6 )alkylene, R 20 and R 21 are as defined above;
wherein within R 26 any alicyclic or aromatic ring system present may be substituted further by 1 to 5 radicals independently selected from the group consisting of (C 1-6 )alkyl, (C 1-6 )alkylidene, cyano, halo, halo-substituted (C 1-4 )alkyl, nitro, —X 7 NR 14 R 14 , —X 7 NR 14 C(O)OR 14 , —X 7 NR 14 C(O)NR 14 R 14 , —X 7 NR 14 C(NR 14 )NR 14 R 14 , —X 7 OR 14 , —X 7 SR 14 , —X 7 C(O)OR 14 , —X 7 C(O)NR 14 R 14 , —X 7 S(O) 2 NR 14 R 14 , —X 7 P(O)(OR 14 )OR 14 , —X 7 OP(O)(OR 14 )OR 14 , —X 7 NR 14 C(O)R 15 , —X 7 S(O)R 15 , —X 7 S(O) 2 R 15 and —X 7 C(O)R 15 , wherein X 7 is a bond or (C 1-6 )alkylene, and R 14 and R 15 are as defined above; or
R 26 together with R 27 form trimethylene, tetramethylene or phenylene-1,2-dimethylene, optionally substituted with 1 to 3 radicals independently selected from the group consisting of (C 1-6 )alkyl, (C 1-6 )alkylidene, cyano, halo, halo-substituted (C 1-4 )alkyl, nitro, oxo, —X 8 NR 14 C(O)OR 14 , —X 8 NR 14 C(O)NR 14 R 14 , —X 8 NR 14 C(NR 14 )NR 14 R 14 , —X 8 OR 14 , —X 8 SR 14 , —X 8 C(O)OR 14 , —X 8 C(O)NR 4 R 14 , —X 8 S(O) 2 NR 14 R 14 , —X 8 R 14 S(O) 2 R 15 , —X 8 P(O)(OR 14 )OR 14 , —X 8 OP(O)(OR 14 )OR 14 , —X 8 NR 14 C(O)R 15 , —X 8 S(O)R 15 , —X 8 S(O) 2 R 15 and —X 8 C(O)R 15 , wherein X 8 is a bond or (C 1-6 )alkylene, R 14 and R 15 are as defined above;
under coupling reaction conditions to provide a compound of formula (VI):
where X, Y, Y′, R 2 , R 3 , R 9 , R 10 , R 25 -R 28 are as defined above;
(i) optionally protecting the hydroxy group;
(ii) optionally converting a compound of formula (VI) to. an acid addition salt;
(iii) optionally converting a salt form of a compound of formula (VI) to a free base;
(iv) optionally separating individual isomers;
(v) optionally modifying any of the X, R 2 , R 3 , R 9 , R 10 , and R 25 —R 28 groups.
Preferably, the moiety,
R 9 and R 10 are as defined in preferred embodiments above;
R 27 represents hydrogen;
R 25 represents hydrogen or methyl, preferably hydrogen; and
R 26 represents (i) (C 1-6 )alkyl optionally substituted with —SR 14 , —S(O)R 14 —S(O) 2 R 14 or —S(O) 2 R 16 wherein R 14 is (C 1-6 )alkyl and R 16 is (C 3-6 )cycloalkyl(C 1-6 )alkyl, (C 6-12 )aryl(C 0-6 )alkyl or hetero(C 5-12 )aryl(C 0-6 )alkyl; or (ii) (C 3-12 )cycloalkyl(C 0-6 )alkyl or (C 6-12 )aryl(C 0-6 )alkyl; wherein within R 26 any alicyclic or aromatic ring system present may be substituted further by 1 to 5 radicals independently selected from the group consisting of (C 1-6 )alkyl, (C 1-6 )alkylidene, cyano, halo, halo-substituted (C 1-4 )alkyl, nitro, —X 5 NR 14 R 14 , —X 5 NR 14 C(O)OR 14 , —X 5 NR 14 C(O)NR 14 R 14 , —X 5 NR 14 C(NR 14 )NR 14 R 14 , —X 5 OR 14 , —X 5 SR 14 , —X 5 C(O)OR 14 , —X 5 C(O)NR 14 R 14 , —X 5 S(O) 2 NR 14 R 14 , —X 5 P(O)(OR 14 )OR 14 , —X 5 OP(O)(OR 4 )OR 14 , —X 5 NR 14 C(O)R 15 , —X 5 S(O)R 15 , —X 5 S(O) 2 R 15 and —X 5 C(O)R 15 , wherein X 5 is a bond or (C 1-6 )alkylene, R 14 at each occurrence independently is hydrogen, (C 1-6 )alkyl or halo-substituted (C 1-3 )alkyl and R 15 is (C 1-6 )alkyl or halo-substituted (C 1-3 )alkyl. Preferably R 26 is cyclohexylmethyl, isobutyl, sec-butyl, 2-fluorobenyl, benzyl, phenylethyl, 2-chlorobenzyl, 2-trifluoromethylbenzyl, 2-cyanobenzylsulfanylmethyl, benzylsulfanylmethyl, 2-cyanobenzylsulfanylmethyl, benzylsulfanylmethyl, 2-phenylsulfanylethyl, trifluoromethylbenzylsulfonylmethyl, 2-phenylsulfonylethyl, thien-3-ylmethylsulfonylmethyl, benzylsulfonylmethyl, 2-chlorobenzylsulfonylmethyl, 2-cyanobenzylsulfonylmethyl, 2-difluoromethoxybenzylsulfonylmethyl, 3,5-dimethylisoxazol-4-ylmethylsulfonylmethyl, 2-methoxybenzylsulfonylmethyl, 6-methylpyrid-2-ylmethylsulfonylmethyl, 2-methylpyrid-3-ylmethylsulfonylmethyl, pyrid-3-ylmethylsulfonylmethyl, pyrid-2-ylmethylsulfonylmethyl, 2-nitrobenzylsulfonylmethyl, pyrid-2-ylmethylsulfonylmethyl, o-tolylmethylsulfonyl-methyl, isopropylmethylsulfonylmethyl, cyclopropylmethylsulfonylmethyl, 2-trifluoromethylbenzylsulfonylmethyl. More preferably R 26 is cyclopropylmethylsulfonylmethyl or isopropylmethylsulfonylmethyl; and
R 28 is methyl, azetidin-3-yl, 1-benzyloxycarbonylpiperidin-4-yl, bicyclo[2.2.2]hept-2-yl, bicyclo[2.2.1]hept-2-yl, tert-butoxy, carboxymethyl, 2-carboxyethyl, cyclohexylmethyl, 3-cyclohexylpropyl, 2-cyclohexylethyl, 2-cyclopentylethyl 6-hydroxypyrid-3-yl, 1H-imidazol-4-yl, morpholin-4-yl, 2-morpholin-4-ylethyl, naphth-1-ylmethyl, naphth-1-ylmethyl, 2-phenylethyl, piperazin-1-yl, piperidin-4-yl, pyrazin-2-yl, pyrid-3-yl, pyrid-4-yl, or tetrahydropyran-4-yl. More preferably, R 28 represents morpholin-4-yl, piperidin-4-yl, pyrazin-2-yl, pyrid-3-yl, pyrid-4-yl, or tetrahydropyran-4-yl and most preferably, morpholin-4-yl.
The deprotection conditions employed in the removal of the amino protecting group depend on the nature of the protecting group. If the group is tert-butoxycarbonyl, it is removed under acidic reaction conditions. Preferably acids are trifluoroacetic acid, hydrochloric acid, and the like. Preferably, the removal of the tert-butoxycarbonyl group is carried out by treating (III) with dioxane/HCl or trimethylsilyl chloride in an ethanolic solvent such as ethanol, isopropanol, and the like.
Preferably, the coupling reaction is carried out with a coupling agent such as benzotriazole-1-yloxytrispyrrolidino-phosphonium hexafluorophosphate (PyBOP®), O-benzotriazol-1-yl-N,N,N′,N′-tetramethyluronium hexafluorophosphate (HBTU), O-(7-azabenzotriazol-1-yl)-1,1,3,3-tetramethyluronium hexafluorophosphate (HATU), or 1-hydroxybenzotriazole (HOBT) in the presence of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDC), or 1,3-dicyclohexylcarbodiimide (DCC), a base such as N,N-diisopropylethylamine, triethylamine, or N-methylmorpholine. Suitable solvents are dichloromethane, dichloroethane, dimethylformamide, dioxane, tetrahydrofuran, or acetonitrile.
This invention also provides a process as described above additionally comprising converting a compound of formula (VI) to a compound of formula (VII):
where X, Y, Y′, R 2 , R 3 , R 9 , R 10 , R 25 –R 28 are as defined above, with a suitable oxidizing agent; and
(i) optionally converting a compound of formula (VII) to an acid addition salt;
(ii) optionally converting a salt form of a compound of formula (VII) to a free base;
(iii) optionally separating individual isomers; and
(iv) optionally modifying any of the X, R 2 , R 3 , R 9 , R 10 , R 25 –R 28 groups.
Preferably the moiety,
R 10 , R 25 –R 28 are as discussed in the preferred embodiments above.
Preferably, the oxidizing agent is selected from the group NaOCl/TEMPO®, Dess-Martin Periodinane, and the like.
The compounds of formula (VII) are cysteine protease inhibitors.
Reference to the preferred embodiments set forth above is meant to include all combinations of particular and preferred groups.
Preferably, this invention is directed to a process of preparing a compound of formula (VIIa):
wherein:
R 30 is isopropylmethyl or cyclopropylmethyl which process comprises:
(i) reacting benzoxazole with a Grignard reagent in a suitable solvent to provide a benzoxazolyl Grignard reagent;
(ii) reacting benzoxazolyl Grignard reagent obtained in Step (i) above with an aldehyde of formula (IIa):
where PG is an amino-protecting group to provide a compound of formula (IIIa):
(iii) deprotecting the amino group in (IIIa) with a suitable acid to provide a compound of formula (IVa) and optionally converting the free base to an acid addition salt;
(iv) reacting (IVa) or an acid addition salt thereof with a compound of formula (Va):
where R 30 is cyclopropylmethyl or isopropylmethyl, under coupling reaction conditions to provide a compound of formula (VIa):
and;
(v) oxidizing (VIa) with a suitable oxidizing agent to provide a compound of formula (VIIa);
(vi) optionally converting a compound of formula (VIIa) to an acid addition salt;
(vii) optionally converting a salt form of a compound of formula (VIIa) to a free base; and
(viii) optionally separating individual isomers.
Preferably, Step (i) is carried out at about −10° to 20° C., more preferably from about −10 to about 0° C., even more preferably at about —5° C.
Preferably, in Step (i), the Grignard reagent is n-butylmagnesium chloride/bromide, isopropylmagnesium chloride/bromide or phenylmagnesium chloride/bromide. Preferably, the Grignard reagent is isopropylmagnesium chloride in tetrahydrofuran. Preferably, the reaction solvent is ethereal organic solvent or a mixture of ethereal and aromatic organic solvent. Preferably, the reaction is carried out in aa 1:1 mixture of tetrahydrofuran and toluene.
Preferably, in Step (ii) the reaction is carried out in aromatic organic solvent such as toluene, benzene, and the like or a mixture of ethereal and aromatic organic solvent. Preferably, the amino protecting group is tert-butoxycarbonyl, benzyl, benzyloxycarbonyl, more preferably tert-butoxycarbonyl.
Preferably, the amino protecting group in Step (iii) is removed with hydrochloric acid or trifluoroacetic acid. Preferably, the removal of the tert-butoxycarbonyl group is by treating (IIIa) with trimethylsilyl chloride in an ethanolic solvent such as ethanol, isopropanol, and the like.
Preferably, the coupling reaction in Step (iv) is carried out with a coupling agent such as benzotriazole-1-yloxytrispyrrolidino-phosphonium hexafluorophosphate (PyBOP®), O-benzotriazol-1-yl-N,N,N′,N′-tetramethyluronium hexafluorophosphate (HBTU), O-(7-azabenzotriazol-1-yl)-1,1,3,3-tetramethyluronium hexafluorophosphate (HATU), 1-hydroxybenzotriazole (HOBT), and the like. The reaction is carried out in the presence of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDC.HCl), 1,3-dicyclohexylcarbodiimide (DCC), and the like, and a base such as N,N-diisopropylethylamine, triethylamine, N-methylmorpholine, and the like. Suitable solvents are dichloromethane, dichloroethane, dimethylformamide, dioxane, tetrahydrofuran, acetonitrile, and the like. Preferably, catalytic amount of HOBT is used.
Preferably, the oxidizing agent in Step (v) is selected from the group NaOCl/TEMPO®, Dess-Martin Periodinane, and the like.
In a second aspect, this invention is directed to 1-hydroxy-1-(heteroaryl or unsaturated heterocycloalkyl)-2-N-protected-aminoethyl intermediates of formula (III):
where:
X is —O— or —S—;
Y is nitrogen or —CR 3a —;
Y′ is nitrogen or —CR 2a — provide that Y and Y′ are not simultaneously nitrogen;
one of R 2 and R 3 is hydrogen, (C 1-6 )alkyl, (C 1-6 )alkoxy, (C 1-6 )alkoxy(C 1-6 )alkyl, amino(C 1-6 )alkyl, carboxy(C 1-6 )alkyl, hydroxy, (C 1-6 )alkylthio, (C 5-6 )cycloalkyl, (C 5-6 )cycloalkylalkyl, halo, nitro, halo(C 1-3 )alkyl, (C 6-12 )aryl, heteroaryl, heterocycloalkyl, (C 6 -12 )aryl(C 1-6 )alkyl, heteroaryl(C 1-6 )alkyl, (C 1-6 )alkylsulfonyl, (C 6-12 )arylsulfonyl, (C 6-12 )aryl(C 1-6 )alkylsulfonyl, heteroarylsulfonyl, heteroaryl(C 1-6 )alkylsulfonyl, aminosulfonyl, (C 1-6 )alkylaminosulfonyl, (C 1-6 )dialkylaminosulfonyl, —CONR 4 R 5 (where R 4 and R 5 are independently of each other hydrogen, (C 1-6 )alkyl, (C 1-6 )alkoxy, aryl, aryl(C 1-6 )alkyl, heteroaryl, heteroaryl(C 1-6 )alkyl, (C 5-6 )cycloalkyl, (C 5-6 )cycloalkyl(C 1-6 )alkyl, heterocycloalkyl, or heterocycloalkyl(C 1-6 )alkyl, or R 4 and R 5 together with the nitrogen atom to which they are attached form heterocycloamino), —NHCOR 6 (where R 6 is (C 1-6 )alkyl, (C 6-12 )aryl, aryl(C 1-6 )alkyl, heteroaryl, heteroaryl(C 1-6 )alkyl, (C 5-6 )cycloalkyl, (C 5-6 )cycloalkyl(C 1-6 )alkyl, heterocycloalkyl, or heterocycloalkyl(C 1-6 )alkyl), —SO 2 NR 7 R 8 (where R 7 and R 8 are independently of each other hydrogen, (C 1-6 )alkyl, (C 6-12 )aryl, (C 6-12 )aryl(C 1-6 )alkyl, heteroaryl, heteroarylalkyl, (C 5-6 )cycloalkyl, (C 5-6 )cycloalkyl(C 1-6 )alkyl, heterocycloalkyl, or heterocycloalkyl(C 1-6 )alkyl, or R 7 and R 8 together with the nitrogen atom to which they are attached form heterocycloamino), -alkylene-CONR 4 R 5 (where R 4 and R 5 are as defined above), -alkylene-NHCOR 6 (where R 6 is as defined above), or -alkylene-SO 2 NR 7 R 8 (where R 7 and R 8 are as defined above); and
the other of R 2 and R 3 is hydrogen or (C 1-6 )alkyl wherein within R 2 or R 3 said aryl, heteroaryl, or heterocycloalkyl is optionally substituted further with one, two, or three substituents independently selected from the group consisting of hydroxy, (C 1-6 )alkoxy, (C 1-6 )alkyl, (C 6-12 )aryl(C 1-6 )alkyl, halo, nitro, and halo(C 1-3 )alkyl; or R 2 and R 3 together with the atoms to which they are attached form an optionally substituted benzene or napthyl, (C 3-6 )cycloalkyl, or an aromatic or non-aromatic heterocyclic ring;
R 2a and R 3a are independently hydrogen or alkyl; or R 2a and R 3a together form a covalent bond, provided that when Y or Y′ is nitrogen, R 2a and R 3 or R 2 and R 3a together form a covalent bond;
R 9 is hydrogen or (C 1-6 )alkyl; and
R 10 is:
(i) (C 1-6 )alkyl optionally substituted with cyano, halo, nitro, —SR 11 , —C(O)OR 11 , —C(O)NR 11 R 11 , —NR 13 C(NR 13 )NR 13 R 13 , —P(O)(OR 11 )OR 11 , —OP(O)(OR 11 )OR 11 , —S(O)R 12 , —S(O) 2 R 12 or —C(O)R 12 , wherein R 11 at each occurrence independently is hydrogen, (C 1-6 )alkyl or halo-substituted (C 1-3 )alkyl, R 12 is alkyl or halo-substituted alkyl, and R 13 at each occurrence independently is hydrogen or (C 1-6 )alkyl; or
(ii) (C 5-6 )cycloalkyl(C 2-3 )alkyl, hetero(C 3-6 )cycloalkyl(C 2-3 )alkyl, (C 6-12 )aryl(C 2-3 )alkyl or hetero(C 5-6 )aryl(C 2-3 )alkyl, wherein said cycloalkyl, heterocycloalkyl, aryl or heteroaryl optionally is substituted further with 1 to 5 radicals independently selected from the group consisting of (C 1-6 )alkyl, alkylidene, cyano, halo, halo-substituted (C 1-4 )alkyl, nitro, —X 1 NR 14 C(O)OR 14 , —X 1 NR 14 C(O)NR 14 R 14 , —X 1 NR 14 C(NR 14 )NR 14 R 14 , —X 1 OR 14 , —X 1 SR 14 , —X 1 C(O)OR 14 , —X 1 C(O)NR 14 R 14 , —X 1 S(O) 2 NR 14 R 14 , —X 1 P(O)(OR 14 )OR 14 , —X 1 OP(O)(OR 14 )OR 14 , —X 1 NR 14 C(O)R 15 , —X 1 S(O)R 15 , —X 1 S(O) 2 R 15 and —X 1 C(O)R 15 , wherein X 1 is a bond or (C 1-6 )alkylene, R 14 at each occurrence independently is hydrogen, (C 1-6 )alkyl or halo-substituted (C 1-3 )alkyl, and R 15 is (C 1-6 )alkyl, halo-substituted (C 1-3 )alkyl, or halo; or
(iii) R 9 and R 10 taken together with the carbon atom to which both R 9 and R 10 are attached form (C 3-8 )cycloalkylene or heterocycloalkylene, wherein said cycloalkylene or heterocycloalkylene is optionally substituted with 1 to 3 radicals independently selected from the group consisting of (C 1-6 )alkyl, (C 1-6 )alkylidene, cyano, halo, halo-substituted (C 1-4 )alkyl, nitro, —X 2 NR 14 C(O)OR 14 , —X 2 NR 14 C(O)NR 14 R 14 , —X 2 NR 14 C(NR 14 )NR 14 R 14 , —X 2 OR 14 , —X 2 SR 14 , —X 2 C(O)OR 14 , —X 2 C(O)NR 14 R 14 , —X 2 S(O) 2 NR 14 R 14 , —X 2 P(O)(OR 14 )OR 14 , —X 2 OP(O)(OR 14 )OR 14 , —X 2 NR 14 C(O)R 15 , —X 2 S(O)R 15 , —X 2 S(O) 2 R 15 and —X 2 C(O)R 15 , wherein X 2 is a bond or (C 1-6 )alkylene, R 14 and R 15 are as defined above; and individual isomers, mixture of isomers, or a salt thereof; provided that:
when X is O or S, R 2a and R 3a together form a covalent bond, R 9 is hydrogen, R 10 is (C 1-6 )alkyl optionally substituted with —SR 11 where R 11 is (C 1-6 )alkyl, and one of R 2 and R 3 is hydrogen, then the other of R 2 and R 3 is not hydrogen, alkyl, or —COR where R is amino, alkylamino or dialkylamino, or pyridin-2-ylmethylamino;
when
is a benzothiazol-2-yl ring, and one of R 9 and R 10 is hydrogen, then the other of R 9 and R 10 is not methyl;
when PG is benzyloxycarbonyl,
is a benzoxazol-2-yl, 4-azabenzoxazol-2-yl, or 4-, 5-, 6-, or 7-methylbenzoxazol-2-yl, and one of R 9 and R 10 is hydrogen, then the other of R 9 and R 10 is not methyl; and
when PG is benzyloxycarbonyl,
is benzoxazol-2-yl, and one of R 9 and R 10 is hydrogen, then the other of R 9 and R 10 is not isopropyl.
In the above compounds of formula (III), a preferred group of compounds is that wherein the moiety:
is thiazol-2-yl, 4,5-dihydrooxazol-2-yl, or oxazol-2-yl wherein one of R 2 and R 3 is hydrogen or (C 1-4 )alkyl and the other of R 2 and R 3 is selected from the group consisting of halo, (C 1-4 )alkyl, nitro, trifluoromethyl, —CONR 4 R 5 (where R 4 and R 5 are independently of each other hydrogen, (C 1-6 )alkyl, (C 1-4 )alkoxy, (C 6-12 )aryl, (C 6-12 )aryl(C 1-6 )alkyl, heteroaryl, heteroaryl(C 1-6 )alkyl, (C 5-6 )cycloalkyl, (C 5-6 )-cycloalkyl(C 1-6 )alkyl, heterocycloalkyl, or heterocycloalkyl(C 1-6 )alkyl, or R 4 and R 5 together with the nitrogen atom to which they are attached form heterocycloamino), and —SO 2 NR 7 R 8 (where R 7 and R 8 are independently of each other hydrogen, (C 1-6 )alkyl, (C 6-12 )aryl, (C 6-12 )aryl(C 1-6 )alkyl, heteroaryl, heteroaralkyl, (C 5-6 )cycloalkyl, (C 5-6 )cycloalkyl(C 1-6 )alkyl, heterocycloalkyl, or heterocycloalkyl(C 1-6 )alkyl, or R 7 and R 8 together with the nitrogen atom to which they are attached form heterocycloamino) wherein within R 2 or R 3 said aryl, heteroaryl, or heterocycloalkyl is optionally substituted further with one, two, or three substituents independently selected from the group consisting of hydroxy, (C 1-6 )alkoxy, (C 1-6 )alkyl, (C 6-12 )aryl(C 1-6 )alkyl, halo, nitro, and halo(C 1-3 )alkyl.
Preferably, one of R 2 and R 3 is hydrogen or methyl and the other of R 2 and R 3 is selected from the group consisting of phenyl, phenylaminocarbonyl, benzylaminocarbonyl, aminosulfonyl, 2-phenylethylaminocarbonyl, 3-phenylpropylaminocarbonyl, aminocarbonyl, methylaminocarbonyl, 4-benzylpiperidin-1-ylcarbonyl, furan-2-ylmethylaminocarbonyl, pyridin-2-ylmethylaminocarbonyl, pyridin-3-ylmethylaminocarbonyl, pyridin-4-yl-methylaminocarbonyl, 2-, 3-, or 4-chlorobenzylaminocarbonyl, isopropylaminocarbonyl, 1-phenylethylaminocarbonyl, N-methyl-N-benzylaminocarbonyl, pyrrolidin-1-yl-carbonyl, piperidin-1-ylcarbonyl, 1,2,3 ,4-tetrahydroquinolin-1-ylcarbonyl, napthyl-1-ylmethyl-aminocarbonyl, 2,3-dihydroindol-1-ylcarbonyl, and admant-1-ylmethylaminocarbonyl.
Another preferred group of compounds of formula (III) is that wherein R 2 and R 3 together with the carbon atoms to which they are attached form an optionally substituted benzene ring. Preferably, the benzene ring is optionally subsituted with (C 1-4 )alkyl, halo, (C 1-4 )alkoxy, (C 6-12 )aryl, —CONR a R b (where R a and R b are independently of each other hydrogen, (C 1-6 )alkyl, (C 1-4 )alkoxy, (C 6-12 )aryl, (C 6-12 )aryl(C 1-6 )alkyl, heteroaryl, heteroaryl(C 1-6 )alkyl, (C 5-6 )cycloalkyl, (C 5-6 )cycloalkyl(C 1-6 )alkyl, heterocycloalkyl, or heterocycloalkyl(C 1-6 )alkyl, or R a and R b together with the nitrogen atom to which they are attached form heterocycloamino), —SO 2 NR 1 R b (where R a and R b are independently of each other hydrogen, (C 1-6 )alkyl, (C 6-12 )aryl, (C 6-12 )aryl(C 1-6 )alkyl, heteroaryl, heteroaralkyl, (C 5-6 )cycloalkyl, (C 5-6 )cycloalkyl(C 1-6 )alkyl, heterocycloalkyl, or heterocycloalkyl(C 1-6 )alkyl, or R a and R b together with the nitrogen atom to which they are attached form heterocycloamino), (C 1-4 )alkoxycarbonyl, nitro, or trifluoromethyl.
More preferably, the moiety:
is benzoxazol-2-yl, benzothiazol-2-yl, 5-phenylbenzoxazol-2-yl, 5, or 6-methoxybenzoxazol-2-yl, 5-trifluorobenzoxazol-2-yl, 5-nitrobenzoxazol-2-yl, 5-chlorobenzoxazol-2-yl, 4-azabenzoxazol-2-yl, or 5-aminosulfonylbenzoxazol-2-yl, most preferably benzoxazol-2-yl.
Within these preferred and more preferred groups of compounds, an even more preferred group of compounds of formula (III) is that wherein:
R 9 is hydrogen or (C 1-6 )alkyl; preferably hydrogen or methyl, most preferably hydrogen; and
R 10 is (C 1-6 )alkyl; preferably R 10 is methyl, ethyl, propyl, or butyl, or
R 9 and R 10 together with the carbon atom to which they are attached form (C 3-6 )cycloalkylene, preferably R 9 and R 10 together with the carbon atom to which they are attached form cyclopropylene.
Most preferably, R 10 is ethyl and the stereochemistry at the carbon atom to which it is attaches is (S).
Within the above preferred groups, a more preferred group of compounds is that wherein PG is tert-butoxycarbonyl, benzyloxycarbonyl, or benzyl, more preferably tert-butoxycarbonyl.
A representative preferred compounds of formula (III) are listed below:
2-(tert-butoxycarbonyl)amino-1-benzoxazol-2-yl-2-methyl-propan-1-ol;
(S)-2-(tert-butoxycarbonyl)amino-1-benzoxazol-2-yl-hexan-1-ol;
1-(1-(tert-butoxycarbonyl)aminocyclopropyl)-1-benzoxazol-2-yl-methanol;
(S)-2-(tert-butoxycarbonyl)amino-1-benzoxazol-2-yl-propan-1-ol;
(S)-2-(tert-butoxycarbonyl)amino-1-benzoxazol-2-yl-4-methanesulfonyl-butan-1-ol;
(S)-2-(tert-butoxycarbonyl)amino-1-benzoxazol-2-yl-pentan-1-ol;
(S)-2-(tert-butoxycarbonyl)amino-1-benzoxazol-2-yl-butan-1-ol;
(S)-2-(tert-butoxycarbonyl)amino-1-benzoxazol-2-yl-4-phenylbutan-1-ol;
(S)-2-(tert-butoxycarbonyl)amino-1-(oxazol-[4,5-b]pyridin-2-yl)-butan-1-ol; and
2-(tert-butoxycarbonyl)-amino-1-benzoxazol-2-yl-3-methoxy-propan-1-ol; more preferably (S)-2-(tert-butoxycarbonyl)amino-1-benzoxazol-2-yl-propan-1-ol.
In the present invention, it is often beneficial to consider of functional group/reagent compatibility. In some embodiments, functional groups that are incompatible with particular reagents or conditions can be protected prior to reaction, using well known protecting groups. Alternatively, one of skill in the art can select equivalent reagents to be used, for example, in oxidation procedures that are mild, less deleterious to the reactants and products, or generally provide greater yields.
BRIEF DESCRIPTION OF THE DRAWINGS
DETAILED DESCRIPTION OF THE INVENTION
Definitions:
Unless otherwise stated, the following terms used in the specification and claims are defined for the purposes of this Application and have the meanings given this Section:
“Alicyclic” means a moiety characterized by arrangement of the carbon atoms in closed non-aromatic ring structures having properties resembling those of aliphatics and may be saturated or partially unsaturated with two or more double or triple bonds. Representative examples include but are not limited to cycloalkyl, cycloalkenyl, and the like.
“Aliphatic” means a moiety characterized by straight or branched saturated chain arrangement of the constituent carbon atoms. Representative examples include but are not limited to alkyl, alkylene, and the like.
“Alkyl” represented by itself means a straight or branched, saturated, aliphatic radical having one to six carbon atoms unless otherwise indicated (e.g. (C 1-6 )alkyl includes methyl, ethyl, propyl, isopropyl, butyl, sec-butyl, isobutyl, tert-butyl, and the like).
“Alkylthio” means the radical —SR, wherein R is alkyl as defined in this Application, having the number of carbon atoms indicated (e.g., (C 1-6 )alkylthio includes the radicals methylthio, ethylthio, propylthio (including all its isomeric forms), and the like).
“Alkoxy” means the radical —OR, wherein R is alkyl as defined in this Application, having the number of carbon atoms indicated (e.g., (C 1-6 )alkoxy includes the radicals methoxy, ethoxy, propoxy, isopropoxy, butoxy, sec-butoxy, isobutoxy, tert-butoxy, and the like).
“Alkoxycarbonyl” means the radical —C(O)OR, wherein R is alkoxy as defined in this Application.
“Alkoxyalkyl” means the radical -(alkylene)-OR, wherein R is alkyl as defined in this Application, having the number of carbon atoms indicated (e.g., (C 1-6 )alkoxy(C 1-6 )alkyl includes the radicals methoxymethyl, methoxyethyl, ethoxyethyl, and the like).
“Aminoalkyl” means the radical -(alkylene)-NRR′, wherein R and R′ are independently hydrogen, (C 1-6 )alkyl, (C 6-12 )aryl, (C 6-12 )aryl(C 1-6 )alkyl, heteroaryl, heteroaryl(C 1-6 )alkyl as defined in this Application, having the number of carbon atoms indicated (e.g., amino(C 1-6 )alkyl includes the radicals aminomethyl, methylaminomethyl, dimethylaminoethyl, phenylaminoethyl, and the like).
“Alkylsulfonyl” means the radical —SO 2 R, wherein R is alkyl as defined in this Application, having the number of carbon atoms indicated (e.g., (C 1-6 )alkylsulfonyl includes the radicals methylsulfonyl, ethylsulfonyl, propylsulfonyl, (including all its isomeric forms), and the like).
“Alkylene”, unless indicated otherwise, means a straight or branched, saturated aliphatic, divalent radical having one to six carbon atoms unless otherwise indicated, (e.g. (C 1-6 )alkylene includes methylene (—CH 2 —), ethylene (—CH 2 CH 2 —), trimethylene (—CH 2 CH 2 CH 2 —), 2-methyltrimethylene (—CH 2 CH(CH 3 )CH 2 —), tetramethylene (—CH 2 CH 2 CH 2 CH 2 —), 2-methyltetramethylene (—CH 2 CH(CH 3 )CH 2 CH 2 —), pentamethylene (—CH 2 CH 2 CH 2 CH 2 CH 2 —) and the like). For example, a compound of formula I, wherein R 26 is hydrogen and R 12 taken together with R 27 forms optionally substituted trimethylene is depicted by the following illustration:
“Alkylidene” means a straight or branched saturated or unsaturated, aliphatic, divalent radical having the number of carbon atoms indicated (e.g. (C 1-6 )alkylidene includes methylene (═CH 2 ), ethylidene (═CHCH 3 ), isopropylidene (═C(CH 3 ) 2 ), propylidene (═CHCH 2 CH 3 ), allylidene (═CHCH═CH 2 ), and the like).
“Amino” means the radical —NH 2 . Unless indicated otherwise, the compounds of the invention containing amino moieties include protected derivatives thereof. Suitable protecting groups for amino moieties include acetyl, tert-butoxycarbonyl, benzyloxycarbonyl, and the like.
“Aryl” means a monocyclic or bicyclic aromatic ring (fused or linked by a single bond) containing six to twelve carbon atoms unless otherwise indicated. For example, (C 6-12 )aryl as used in this Application to define R′ includes phenyl, naphthyl and biphenylyl.
“Arylsulfonyl” means a radical —SO 2 R where R is aryl as defined above. For example,(C 6-12 )arylsulfonyl includes phenylsulfonyl, naphthylsulfonyl, and the like.
“Arylalkyl” means an alkyl group as defined above that is substituted with an aryl group as defined above, e.g. (C 6-12 )aryl(C 1-6 )alkyl includes benzyl, phenethyl, 1-phenylethyl 3-phenylpropyl, and the like.
“Arylalkylsulfonyl” means a radical —SO 2 R where R is arylalkyl as defined above. For example, (C 6-12 )aryl(C 1-6 )alkylsulfonyl includes benzylsulfonyl, 2-phenylethylsulfonyl, 1-phenylethylsulfonyl, naphthylmethylsulfonyl, and the like.
“Aminosulfonyl” means a radical —SO 2 NH 2 .
“Alkylaminosulfonyl” means a radical —SO 2 NHR where R is alkyl as defined above. Representative examples, but are not limited to, methylaminosulfonyl, ethylaminosulfonyl, n- or isopropylaminosulfonyl, and the like.
“Aromatic” means a moiety wherein the constituent atoms make up an unsaturated ring system, all atoms in the ring system are sp2 hybridized and the total number of pi electrons is equal to 4n+2.
“Aromatic heterocyclic ring” means an aromatic ring containing five or six ring atoms wherein one or two of the ring atoms is a heteroatom selected from the group consisting of N, O or S(O) n where n is 0 to 2, the remaining ring atoms being carbon. The heterocyclic ring may be optionally fused to an aryl or heteroaryl ring. For example, compounds of formula I where R 2 and R 3 together with the carbon atoms to which they are attached form an aromatic heterocyclic ring includes rings such as:
and the like.
The aromatic heterocyclic ring as defined above, is optionally substituted with one or two substituents independently selected from the group consisting of alkyl, alkoxy, trifluoromethyl, halo, haloalkoxy, nitro, aminosulfonyl, alkylaminosulfonyl, dialkylaminosulfonyl, aminoprotected group, and phenyl.
“Amino-protecting group” refers to those organic groups intended to protect nitrogen atoms against undesirable reactions during synthetic procedures. Said protecting group is readily attached and removed under mild conditions e.g., benzyl, benzyloxycarbonyl (CBZ), tert-butoxycarbonyl (BOC), trifluoroacetyl, and the like. Other suitable amino protecting groups are disclosed in Greene and Wuts, Protective Groups in Organic Synthesis, 2nd ed., John Wiley & Sons, Inc. 1991.
“Dialkylaminosulfonyl” means a radical —SO 2 NRR′ where R and R′ are independently alkyl as defined above. Representative examples, but are not limited to, dimethylaminosulfonyl, diethylaminosulfonyl, di-n- or isopropylaminosulfonyl, methylethylamino, and the like.
“Carbamoyl” means the radical —C(O)NH 2 . Unless indicated otherwise, the compounds of the invention containing carbamoyl moieties include protected derivatives thereof. Suitable protecting groups for carbamoyl moieties include acetyl, tert-butoxycarbonyl, benzyloxycarbonyl, and the like and both the unprotected and protected derivatives fall within the scope of the invention.
“Cycloalkyl” means a saturated or partially unsaturated, monocyclic ring, bicyclic ring (directly linked by a single bond or fused) or bridged polycyclic ring containing three to ten carbon atoms, unless otherwise indicated, e.g. (C 3-12 )cycloalkyl includes cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, bicyclohexylyl, bicyclo[2.2.2]octyl, adamantan-1-yl, and the like).
“Cycloalkylalkyl” means an alkyl radical as defined above that is substituted with a cycloalkyl group as defined above e.g., cyclopropylmethyl, cyclopropylethyl, cyclohexylmethyl, cyclohexylethyl, and the like.
“Cycloalkylene” means a saturated or partially unsaturated, monocyclic ring or bridged polycyclic ring containing three to eight carbon atoms, unless otherwise indicated. For example, the instance wherein R 9 and R 10 together with the carbon atom to which both R 9 and R 10 are attached form (C 3-8 )cycloalkylene” includes, but is not limited to, the following:
“Fused heteropolycyclic ring system” means a saturated, partially saturated or aromatic moiety containing two or more rings, wherein at least two ring member atoms of one ring are common to a second ring containing the number of ring member atoms indicated in which at least one of the ring member atoms is a heteroatom and any carbocyclic ketone, thioketone, iminoketone or substituted derivative thereof. For example, the term “a fused heteropolycyclic radical containing 8 to 14 ring member atoms” as used in this Application to define A may include acridinyl, benzofuryl, benzooxazolyl, benzothiazolyl, carbazolyl, carbolinyl, chromanyl, chromenyl, cinnolinyl, indazolyl, indolinyl, indolyl, indolizinyl, isobenzofuryl, isochromenyl, isochromanyl, isoindolinyl, isoquinolyl, naphthyridinyl, perimidinyl, phenanthridinyl, phenanthrolinyl, phenazinyl, phenothiazinyl, phenoxathiinyl, phenoxazinyl, phthalazinyl, pteridinyl, purinyl, pyrrolizinyl, quinazolinyl, quinolizinyl, quinolyl, quinoxalinyl, quinuclidinyl, xanthenyl, and the like.
“Halo” means fluoro, chloro, bromo or iodo.
“Halo-substituted alkyl” or “haloalkyl”, as a group or part of a group, means alkyl as defined above, unless otherwise indicated, substituted by one or more “halo” atoms. Halo-substituted alkyl includes monohaloalkyl, dihaloalkyl, trihaloalkyl, perhaloalkyl and the like (e.g. halo-substituted (C 1-3 )alkyl includes chloromethyl, dicloromethyl, difluoromethyl, trifluromethyl, 2,2,2-trifluoroethyl, perfluoroethyl, 2,2,2-trifluoro-1,1-dichloroethyl, and the like).
“Heteroaryl” means a monovalent monocyclic ring or bicyclic ring (directly linked by a single bond or fused) aromatic radical of 5 to 12 ring atoms containing one or more, preferably one, two, or three ring heteroatoms selected from N, O, or S, the remaining ring atoms being C. For example, heteroaryl as used in this Application includes benzofuryl, benzoxazolyl, benzothiazolyl, [2,4′]bipyridinylyl, carbazolyl, carbolinyl, cinnolinyl, furazanyl, furyl, imidazolyl, indazolyl, indolyl, indolizinyl, isobenzofuryl, isoxazolyl, isoquinolyl, isothiazolyl, naphthyridinyl, oxazolyl, perimidinyl, pteridinyl, purinyl, pyrazinyl, pyradazinyl, pyrazolyl, pyridyl, pyrimidinyl, pyrrolizinyl, pyrrolyl, pyranyl, quinazolinyl, quinolizinyl, quinolyl, quinoxalinyl, tetrazolyl, thiazolyl, thienyl, and the like.
“Heteroarylalkyl” means an alkyl group as defined above that is substituted with a heteroaryl group as defined above, e.g. heteroaryl(C 1-6 )alkyl includes pyridylmethyl, furanylmethyl, and the like.
“Heteroarylsulfonyl” means a radical —SO 2 R where R is heteroaryl as defined above. For example, heteroarylsulfonyl includes 2-benzooxazolylsulfonyl, 2-benzothiazolylsulfonyl, 2- or 3-furylsulfonyl, 2-imidazolylsulfonyl, 2-, 3-pyridylsulfonyl, 2-pyrimidinylsulfonyl, and the like.
“Heteroarylalkylsulfonyl” means —SO 2 R where R is heteroarylalkyl group as defined above, e.g. 2-benzooxazolylmethylsulfonyl, 2-benzothiazolylmethylsulfonyl, 2- or 3-furylmethylsulfonyl, 2-imidazolylethylsulfonyl, 2-, 3-pyridylethyl or methylsulfonyl, 2-pyrimidinyl-methyl or -ethylsulfonyl, and the like.
“Heteroatom moiety” includes —N═, —NR—, —O—, —S— and —S(O) 2 —, wherein R is hydrogen, (C 1-6 )alkyl or a protecting group.
“Heterocycloalkyl” means a saturated or partially saturated monovalent monocyclic ring or bicyclic ring (directly linked by a single bond or fused) of 3 to 12 ring atoms in which one or two ring atoms are heteroatoms selected from the group consisting of N, O, and S(O)n, where n is an integer from 0 to 2, the remaining ring atoms being C where one or two carbon atoms may optionally be replaced by a —C═O group e.g. the term heterocycloalkyl includes [1,4′]bipiperidinylyl, dihydrooxazolyl, morpholinyl, 1-morpholin-4-ylpiperidinyl, piperazinyl, piperidyl, pyrrolinyl, pyrrolidinyl, quinuclidinyl, and the like). The heterocycloalkyl may optionally be substituted with a amino protecting group. Suitable protecting groups include tert-butoxycarbonyl, benzyloxycarbonyl, benzyl, 4-methoxybenzyl, 2-nitrobenzyl, and the like. For example, a compound of formula I wherein R 1 is piperidin-4-ylcarbonyl may exist as either the unprotected or a protected derivative, e.g. wherein R 1 is 1-tert-butoxycarbonylpiperidin-4-ylcarbonyl, and both the unprotected and protected derivatives fall within the scope of the invention.
“Heterocycloalkylalkyl” means an alkyl group that is substituted with a heterocycloalkyl group as defined above. Representative examples include, but are not limited to, morpholinomethyl or ethyl, piperazin-1-ylmethyl or ethyl, piperidin-1-ylmethyl, ethyl, or propyl, and the like.
“Heterocycloalkylene” means a saturated or partially unsaturated, monocyclic ring or bridged polycyclic ring containing three to eight carbon ring atoms, unless otherwise indicated, in which one or two of the carbon ring atoms are replaced by a heteroatom selected from the group consisting of —N═, —NR—, —O—, —S— and —S(O) 2 —, wherein R is hydrogen or (C 1-6 )alkyl. For example, the instance wherein R 9 and R 10 together with the carbon atom to which both R 9 and R 10 are attached form heterocycloalkylene” includes, but is not limited to tetrahydropyranyl, piperidinyl, and the like.
“Heterocycloamino” means a-saturated monovalent cyclic group of 3 to 8 ring atoms, wherein at least one ring atom is N and optionally contains a second ring heteroatom selected from the group consisting of N, O and S(O)n (where n is an integer from 0 to 2), the remaining ring atoms being C. The heterocycloamino ring may be optionally fused to a benzene ring or it may be optionally substituted independently with one or more substituents, preferably one or two substituents, selected from (C 1-6 )alkyl, halo(C 1-6 )alkyl, (C 5-6 )cycloalkyl, (C 5-6 )cycloalkyl(C 1-6 )alkyl, (C 6-12 )aryl, (C 6-12 )aryl(C 1-6 )alkyl, heteroaryl, heteroaryl(C 1-6 )alkyl, or halo. For example, a compound of formula I, wherein R 2 is —SO 2 NR 7 R 8 where R 7 and R 8 together with the nitrogen atom to which they are attached form heterocycloamino includes, but are not limited to groups such as:
where X is C, N, O, or S and the derivatives thereof.
“Heteropolycycloaryl” means polycycloaryl, as defined herein, except one or more of the ring member carbon atoms indicated are replaced by a heteroatom moiety selected from the group consisting of —N═, —NR—, —O— and —S—, wherein R is hydrogen, (C 1-6 )alkyl or a protecting group. For example, hetero(C 8-12 )polycycloaryl includes 1′,2′-dihydro-2H-[1,4′]bipyridinylyl, imidazolinyl, indolinyl, isochromanyl, isoindolinyl, and the like.
“Heteropolycycloarylalkyl” means an alkyl group as defined above that is substituted with a heteropolycycloaryl group as defined above.
“Hydroxy” means the radical —OH. Unless indicated otherwise, the compounds of the invention containing hydroxy radicals include protected derivatives thereof. Suitable protecting groups for hydroxy moieties include benzyl and the like and both the unprotected and protected derivatives fall within the scope of the invention.
“Isomers” mean compounds of formula I having identical molecular formulae but differ in the nature or sequence of bonding of their atoms or in the arrangement of their atoms in space. Isomers that differ in the arrangement of their atoms in space are termed “stereoisomers”. Stereoisomers that are not mirror images of one another are termed “diastereomers” and stereoisomers that are nonsuperimposable mirror images are termed “enantiomers” or sometimes “optical isomers”. A carbon atom bonded to four nonidentical substituents is termed a “chiral center”. A compound with one chiral center has two enantiomeric forms of opposite chirality is termed a “racemic mixture”. A compound that has more than one chiral center has 2 n−1 enantiomeric pairs, where n is the number of chiral centers. Compounds with more than one chiral center may exist as ether an individual diastereomer or as a mixture of diastereomers, termed a “diastereomeric mixture”. When one chiral center is present a stereoisomer may be characterized by the absolute configuration of that chiral center. Absolute configuration refers to the arrangement in space of the substituents attached to the chiral center. Enantiomers are characterized by the absolute configuration of their chiral centers and described by the R- and S-sequencing rules of Cahn, Ingold and Prelog. Conventions for stereochemical nomenclature, methods for the determination of stereochemistry and the separation of stereoisomers are well known in the art (e.g. see “Advanced Organic Chemistry”, 3rd edition, March, Jerry, John Wiley & Sons, New York, 1985). It is understood that the names and illustration used in this Application to describe compounds of formula I are meant to be encompassed all possible stereoisomers and any mixture, racemic or otherwise, thereof.
“Nitro” means the radical —NO 2 .
“Nonaromatic heterocyclic ring” means a saturated or unsaturated ring containing five or six ring atoms wherein one or two of the ring atoms is a heteroatom selected from the group consisting of N, O or S(O)n where n is 0 to 2, the remaining ring atoms being carbon. The heterocyclic ring may be optionally fused to aryl or heteroaryl ring. For example, compounds of formula I where R 2 and R 3 together with the carbon atoms to which they are attached form nonaromatic heterocyclic ring includes rings such as:
and the like.
The nonaromatic heterocyclic ring can be optionally substituted with one or two substituents independently selected from the group consisting of (C 1-6 )alkyl, (C 1-6 )alkoxy, trifluoromethyl, nitro, aminosulfonyl, (C 1-6 )alkylaminosulfonyl, di(C 1-6 )alkylaminosulfonyl, aminoprotected group, and phenyl.
“Nucleophilic” means a substance that has an electron pair available for donation. A nucleophilic reagent can undergo numerous reactions such as nucleophilic addition to an aldehyde to form an alcohol, and the like (see Jerry March, 4 th Edition, Wiley). Therefore in order to determine whether the organomagnesium compound of this invention is nucleophilic it can be reacted with an aldehyde, such as benzaldehyde, under standard nucleophilic addition reaction conditions to determine whether it adds to the aldehyde to form a secondary alcohol. The term nucleophilic is intended as a claim limitation.
“Optionally substituted benzene” means benzene ring that is optionally substituted with one or more, preferably one or two substituents independently selected from the group consisting of (C 1-4 )alkyl, (C 1-4 )alkoxy, (C 6-12 )aryl, halo, —CONR a R b (where R a and R b are independently of each other hydrogen, (C 1-6 )alkyl, (C 1-4 )alkoxy, (C 6-12 )aryl, (C 6-12 )aryl(C 1-6 )alkyl, heteroaryl, heteroaryl(C 1-6 )alkyl, (C 5-6 )cycloalkyl, (C 5-6 )cycloalkyl(C 1-6 )alkyl, heterocycloalkyl, or heterocycloalkyl(C 1-6 )alkyl, or R a and R b together with the nitrogen atom to which they are attached form heterocycloamino), —SO 2 NR a R b (where R a and R b are independently of each other hydrogen, (C 1-6 )alkyl, (C 6-12 )aryl, (C 6-12 )aryl(C 1-6 )alkyl, heteroaryl, heteroaralkyl, (C 5-6 )cycloalkyl, (C 5-6 )cycloalkyl(C 1-6 )alkyl, heterocycloalkyl, or heterocycloalkyl(C 1-6 )alkyl, or R a and R b together with the nitrogen atom to which they are attached form heterocycloamino), (C 1-4 )alkoxycarbonyl, nitro, or trifluoromethyl or it can be a tetrafluoro or pentafluorobenzene ring. For example, in compounds of formula I when R 2 and R 3 together with the carbon atoms to which they are attached form an optionally substituted benzene ring it means the following structure which is optionally substituted:
and derivatives thereof.
“Optionally substituted phenyl” means benzene ring that is optionally substituted with one or two substituents independently selected from the group consisting of halo, alkoxy or alkyl.
“Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event or circumstance occurs and instances in which it does not. For example, the phrase “(C 1-6 )alkyl optionally substituted with cyano, halo, nitro,” means that the alkyl group referred to may or may not be substituted in order to fall within the scope of the invention.
“Salt” as used herein includes acid and base addition salts. Acid addition salts are salts formed with inorganic acids such as hydrochloric acid, hydrobromic acid, sulfuric acid, nitric acid, phosphoric acid, and the like; or with organic acids such as acetic acid, propionic acid, hexanoic acid, heptanoic acid, cyclopentanepropionic acid, glycolic acid, pyruvic acid, lactic acid, malonic acid, succinic acid, malic acid, maleic acid, fumaric acid, tartatic acid, citric acid, benzoic acid, o-(4-hydroxybenzoyl)benzoic acid, cinnamic acid, madelic acid, methanesulfonic acid, ethanesulfonic acid, 1,2-ethanedisulfonic acid, 2-hydroxyethanesulfonic acid, benzenesulfonic acid, p-chlorobenzenesulfonic acid, 2-naphthalenesulfonic acid, p-toluenesulfonic acid, camphorsulfonic acid, 4-methylbicyclo[2.2.2]oct-2-ene-1-carboxylic acid, glucoheptonic acid, 4,4′-methylenebis(3-hydroxy-2-ene-1-carboxylic acid), 3-phenylpropionic acid, trimethylacetic acid, tertiary butylacetic acid, lauryl sulfuric acid, gluconic acid, glutamic acid, hydroxynaphthoic acid, salicylic acid, stearic acid, muconic acid and the like.
Base addition salts are salts which may be formed when acidic protons present are capable of reacting with inorganic or organic bases. Acceptable inorganic bases include sodium hydroxide, sodium carbonate, potassium hydroxide, ammonium hydroxide, aluminum hydroxide and calcium hydroxide. Acceptable organic bases include ethanolamine, diethanolamine, triethanolamine, tromethamine, N-methylglucamine and the like.
“Phenylene-1,2-dimethylene” means the divalent radical —CH 2 C 6 H 4 CH 2 —, wherein the methylene moieties are attached at the 1- and 2-positions of the phenylene moiety.
“Polycycloaryl” or “bicycloaryl” means a bicyclic ring assembly (directly linked by a single bond or fused) containing the number of ring member carbon atoms indicated, wherein at least one, but not all, of the fused rings comprising the radical is aromatic (e.g. (C 9-12 )polycycloaryl includes indanyl, indenyl, 1,2,3,4-tetrahydronaphthalenyl, 1,2-dihydronaphthalenyl, cyclohexylphenyl, phenylcyclohexyl, 2,4-dioxo-1,2,3,4-tetrahydronaphthalenyl, and the like).
“Polycycloarylalkyl” means an alkyl group as defined above that is substituted with a polycycloaryl group as defined above.
“Suitable solvent” refers to any solvent, preferably organic solvent” which does not interact with starting materials, reagents, intermediates or products in a manner which adversely affects the reaction or the yield of the desired product. Further, the term reaction inert solvent or suitable solvent may refer to a single, dual or multiple solvent systems depending upon the nature of the reaction and the solubility of the substrate and/or reagents being disclosed.
General Synthetic Sheme
Compounds of formula, (III), and (VII) can be prepared by methods described below.
Processes for Making Compounds of Formula (III)
Compounds of formula (III) where X, Y, PG, R 2 , R 3 , R 9 and R 10 are as defined in the Summary of the Invention can be prepared by proceeding as in the following Scheme 1 below:
Treatment of a compound a heteroaryl or unsaturated heterocycloalkyl compound of formula (I) with a Grignard reagent, preferably a Grignard reagent of the formula RMgZ where R is alkyl or optionally substituted phenyl, preferably n-butyl, isopropyl, or phenyl and Z is halo, preferably chloro or bromo provides a heteroaryl or unsaturated heterocycloalkyl Grignard reagent respectively, of formula (la). The reaction is typically carried out in an ethereal organic solvent such as tetrahydrofuran, diethyl ether, dioxane, and the like, preferably tetrahydrofuran, or a mixture of ethereal and aromatic organic solvent at a temperature from about −78° to about 40° C. Preferably, the reaction is carried out from about −10° C. to about 40° C., more preferably from about −10° to about 10° C. The reaction typically requires an hour to complete. Once the reaction is complete, an aldehyde of formula (II) where PG, R 9 and R 10 are as defined in the Summary of the Invention is added to the reaction mixture to provide a compound of formula (III) after treatment with an aqueous acid or buffer. Preferably, PG is tert-butyoxycarbonyl, benzyloxycarbonyl, or benzyl, more preferably tert-butoxycarbonyl. The nucleophilic additon reaction is typically carried out from about −10° C. to about room temperature. The term “complete” as used herein means that there is no further appreciable conversion of starting material to the desired product as determined by traditional means such as thin layer chromatograph, NMR, HPLC, and the like. Compounds of formula (I) and (II) are either commercially available or they can be prepared by methods well known in the art.
Processes for Making Compounds of Formula (VII)
Compounds of formula (VII) where X, Y, R 2 , R 3 , R 9 , R 10 , and R 25 –R 28 are as defined in the Summary of the Invention can be prepared as shown in Scheme 2 below.
Removal of the amino protecting group in the compound of formula (III) provides a compound of formula (IV). The reaction conditions employed for removal the amino protecting group depends on the nature of the protecting group. For example, if the protecting group is tert-butoxycarbonyl, it is removed under acid reaction conditions. Suitable acids are trifluoroacetic acid, hydrochloric acid, trimethylsilane in alcoholic organic solvent, and the like. If the protecting group is benzyl it is removed under catalytic hydrogenation reaction conditions. Suitable catalyst are palladium, platinum, rodium based catalysts and others known in the art. Other suitable reaction conditions for their removal can be found in T. W. Greene, Protecting Groups in Organic Synthesis , John Wiley & Sons, Inc. 1981. The reaction is carried out in an inert organic solvent methylene chloride, tetrahydrofuran, dioxane, dimethylformamide, and the like.
Reaction of a compound of formula (IV) with an acid of formula (V) provides a compound of formula (VI). The reaction is carried out under suitable coupling reaction conditions. Typically, the reaction is carried out in the presence of a suitable coupling agent such as benzotriazole-1-yloxytrispyrrolidinophosphonium hexafluorophosphate (PyBOP®), O-benzotriazol-1-yl-N,N,N′,N′-tetramethyluronium hexafluorophosphate (HBTU), O-(7-azabenzotriazol-1-yl)-1,1,3,3-tetramethyluronium hexafluorophosphate (HATU), 1-hydroxybenzotriazole (HOBT), and the like, in the presence of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDC), 1,3-dicyclohexylcarbodiimide (DCC), and the like, and a base such as N,N-diisopropylethylamine, triethylamine, N-methylmorpholine, and the like. The reaction is typically carried out at 20 to 30° C., preferably at about 25° C., and requires 2 to 4 hours to complete. Suitable reaction solvents are inert organic solvents such as halogenated organic solvents (e.g., methylene chloride, chloroform, and the like), acetonitrile, dimethylformamide, ethereal solvents such as tetrahydrofuran, dioxane, and the like. Preferably, the reaction is carried out with EDC in the presence of a catalytic amount of HOBt in acetonitrile.
Alternatively, this reaction can be carried out by first converting (V) into an active acid derivative such as acid chloride or succinate ester and then reacting it with an amine of formula (IV). The reaction typically requires 2 to 3 hours to complete. The reaction conditions utilized in this reaction depend on the nature of the active acid derivative. For example, if it an acid chloride derivative of (V), the reaction is carried out in the presence of a suitable base (e.g. triethylamine, diisopropylethylamine, pyridine, and the like). Suitable reaction solvents are polar organic solvents such as acetonitrile, N,N-dimethylformamide (DMF), dichloromethane, or any suitable combination thereof.
Compounds of formula (V) can be prepared by methods well known in the art. Some such procedures are described in PCT Application Publication No. WO 00/55144 the disclosure of which is incorporated herein in its entirety. For example a compound of formula (V) where R 25 and R 27 are hydrogen, R 26 is cyclopropylmethylsulfonylmethyl and R 28 is morpholin-4-yl can be prepared as illustrated and described in Scheme 3 below.
Reaction of cysteine with bromomethylcyclopropane in the presence of an aqueous base such as sodium hydroxide provides 2-amino-2-cyclopropylmethylsulfanylmethylacetic acid. The reaction is carried out in a polar organic solvent such as dioxane or an alcoholic solvent such as methanol, ethanol, and the like. Preferably the reaction is carried out in ethanol.
Treatment of 2-amino-2-cyclopropylmethylacetic acid with morpholin-4-ylcarbonyl chloride in the presence of base such as triethylamine, pyridine, and the like and in a suitable organic solvent such as acetonitrile, and the like provides 2-(morpholin-4-ylcarbonylamino)-2-cyclopropylmethylsulfanyl-methylacetic acid. This reaction can alternatively be carried out by treating 2-amino-2-cyclopropylmethylacetic acid sequentially with N-methyl-N-(trimethylsilyl)trifluoroacetamide and morpholinecarbonyl chloride. This reaction is carried out in halogenated solvent such as dichloromethane, and the like.
Oxidation of 2-(morpholin-4-ylcarbonylamino)-2-cyclopropylmethylsulfanyl-methylacetic acid with an aqueous solution of Oxone® in an alcoholic organic solvent such as methanol, ethanol, and the like, or hydrogen peroxide in acetic acid or hydrogen peroxide and tungstic acid in water then provides the desired compound.
2-(Morpholin-4-ylcarbonylamino)-2-isopropylmethylsulfonylmethylacetic acid can be prepared by following the procedure described above but substituting bromomethylcyclo-propane with 3-methylpropyl bromide.
Oxidation of the hydroxy group in (VI) then provides a compound of formula (VII). The reaction is carried out at room temperature. Suitable solvents are halogenated organic solvent such as methylene chloride, chloroform, carbon tetrachloride, and the like. Suitable oxidizing agent are Dess-Martin Periodinane (DMP) (supplier Lancaster), TEMPO/bleach, and the like.
Additional Processes for Preparing Compounds of Formula (VII):
Compounds of formula (VII) can be optionally converted to other compounds of formula (VII) by methods well known in the art. Some such examples are provided below.
Compounds of formula (VII) in which the moiety
is optionally substituted oxazol-2-yl can be prepared by oxidizing a corresponding compound of formula (VII) in which it is 4,5-dihydrooxazol-2-yl. The oxidation is carried out by first treating (VII) with bromine followed by a base such as 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU) or the like, in a suitable solvent (e.g. dichloromethane, or the like) at 20 to 25° C. and requires 6 to 12 hours to complete.
Compounds of formula (VII) in which R 28 carries a —C(O)OH can be prepared from a corresponding compound of formula (VII) in which R 28 carries methoxycarbonyl. The conversion can be effected by treating the methyl ester with sodium hydroxide in a suitable solvent (e.g., ethanol, or the like) at 20 to 25° C. and requires 6 to 12 hours to complete.
Compounds of formula (VII) in which R 28 carries a —C(O)NR 18 R 19 can be prepared by reacting a corresponding compound of formula (VII) in which R 28 carries —C(O)OH with a compound of the formula NHR 18 R 19 . The reaction is carried out in the presence of a suitable coupling agent (PyBOP®, EDC, HBTU, DCC, or the like) and base (e.g., N,N-diisopropylethylamine, triethylamine, or the like) in a suitable solvent (e.g., DMF, or the like) at 20 to 25° C. and requires 2 to 4 hours to complete.
Compounds of formula (VII) in which R 26 contains a sulfonyl moiety can be prepared by oxidizing a corresponding compound of formula (VII) containing a sulfanyl moiety. The oxidation is carried out with a suitable oxidizing agent (e.g. potassium peroxymonosulfate (OXONE®, or the like) in a suitable solvent (e.g. methanol, water, or the like, or any suitable combination thereof) at ambient temperature and requires 16 to 24 hours to complete.
A compound of formula (VII) in which the moiety
is 1,1-dioxo-1H-1λ 6 -benzo[b]thien-2-yl can be prepared by oxidizing a corresponding compound of formula (VII)) in which it is benzo[b]thien-2-yl.
A compound of formula (VII) can be prepared as a pharmaceutically acceptable acid addition salt by reacting the free base form of the compound with a pharmaceutically acceptable inorganic or organic acid. Alternatively, a pharmaceutically acceptable base addition salt of a compound of formula (VII) can be prepared by reacting the free acid form of the compound with a pharmaceutically acceptable inorganic or organic base. Inorganic and organic acids and bases suitable for the preparation of the pharmaceutically acceptable salts of compounds of formula (VII) are set forth in the definitions section of this application. Alternatively, the salt forms of the compounds of formula (I) can be prepared using salts of the starting materials or intermediates.
The free acid or free base forms of the compounds of formula (VII) can be prepared from the corresponding base addition salt or acid addition salt form. For example, a compound of formula (VII) in an acid addition salt form can be converted to the corresponding free base by treating with a suitable base (e.g. ammonium hydroxide solution, sodium hydroxide, or the like). A compound of formula (VII) in a base addition salt form can be converted to the corresponding free acid by treating with a suitable acid (e.g. hydrochloric acid, etc).
The N-oxides of compounds of formula (VII) can be prepared by methods known to those of ordinary skill in the art. For example, N-oxides can be prepared by treating an unoxidized form of the compound of formula (VII) with an oxidizing agent (e.g. trifluoroperacetic acid, permaleic acid, perbenzoic acid, peracetic acid, meta-chloroperoxybenzoic acid, or the like) in a suitable inert organic solvent (e.g. a halogenated hydrocarbon such as dichloromethane) at approximately 0° C. Alternatively, the N-oxides of the compounds of formula (VII) can be prepared from the N-oxide of an appropriate starting material.
Compounds of formula (VII) in unoxidized form can be prepared from N-oxides of compounds of formula (VII) by treating with a reducing agent (e.g. sulfur, sulfur dioxide, triphenyl phosphine, lithium borohydride, sodium borohydride, phosphorus trichloride, tribromide, or the like) in an suitable inert organic solvent (e.g. acetonitrile, ethanol, aqueous dioxane, or the like) at 0 to 80° C.
Prodrug derivatives of the compounds of formula (VII) can be prepared by methods known to those of ordinary skill in the art (e.g. for further details see Saulnier et al. (1994), Bioorganic and Medicinal Chemistry Letters. 4:1985). For example, appropriate prodrugs can be prepared by converting an acid group in a compound of formula (VII) to an ester group.
Protected derivatives of the compounds of formula (VII) can be made by means known to those of ordinary skill in the art. A detailed description of the techniques applicable to the creation of protecting groups and their removal can be found in T. W. Greene, Protecting Groups in Organic Synthesis , John Wiley & Sons, Inc. 1981.
SYNTHETIC EXAMPLES
The following preparations and examples are given to enable those skilled in the art to more clearly understand and to practice the present invention. They should not be considered as limiting the scope of the invention, but merely as being illustrative and representative thereof.
Example 1
Synthesis of (S)-2-amino-1-benzoxazol-2-yl-propan-1-ol hydrochloride
Step 1
To a solution of benzoxazole (28.6 g, 240 mmol) in toluene (150 mL) was added during ca 20 min., at ca −4° C. a 2M solution of isopropyl-magnesium chloride in THF (120 mL, 240 mmol). The red-brown mixture was stored at ca −4° C. and used as needed.
Step 2
To a solution of (S)-2-Boc-aminobutanol (50 g; 264 mmol) in dichloromethane (500 mL) and water (350 mL) were added at 20° C. TEMPO (0.01 eq), sodium bromide (1 eq) and sodium hydrogencarbonate (3 eq). The reaction mixture was stirred at 0° C. and diluted bleach (1.3 eq, 450 mL) was added over 40 min. The reaction mixture was stirred for 30 min. at 0° C. and then quenched with aq. thiosulfate. After decantation and extractions (dichloromethane), the organic phase was washed with brine, dried and concentrated in vacuo to dryness, giving (S)-2-(tert-butoxycarbonyl)-amino-butyraldehyde as a low-melting solid (38.1 g; yield: 77%). C 9 H 17 NO 3 ; MW=187.2; T melt =44° C.; NMR (CDCl 3 , ppm): 0.97 (t, J=7 Hz, 3H), 1.45 (s, 9H), 1.68 (m, 1H), 1.91 (m, 1H), 4.20 (lq, J=6.5 Hz, 1H), 5.09 (1s, 1H (mobile)) and 9.59 (s, 1H); SM (EI; m/z): 158 (M + —CHO), 102, 57.
Step 3
A solution of (S)-2-(tert-butoxycarbonyl)amino-butyraldehyde (30 g; 160 mmol) in toluene (150 mL) was added over 30 min. at −5° C. to a solution of Grignard reagent of benzoxazole (prepared as described in Step 1 above). The reaction mixture was stirred for 0.5 h at 0° C., then 2.5 h at RT. Quenching with 5% aq. acetic acid, washings with 5% aq. sodium carbonate, then brine and concentration to dryness gave crude (S)-2-(tert-butoxycarbonyl)-amino-1-benzoxazol-2-yl-propan-1-ol. The residue was diluted with toluene, and silica gel was added. The slurry was filtered. Elution by toluene removed the non-polar impurities. Then an 8/2 mixture of toluene and ethyl acetate desorbed the (S)-2-(tert-butoxycarbonyl) amino-1-benzoxazol-2-yl-propan-1-ol. Concentration to dryness gave a red resin (37 g ; yield=75% ; 7/3 mixture of diastereomers). C 16 H 22 N 2 O 4 ; MW=306.4 ; NMR (DMSO, ppm): 0.86 (t, J=7.5 Hz, 3H), 1.14 (s, 2.7H), 1.27 (s, 6.3H), 1.40 (m, 1H), 1.56 (m, 0.7H), 1.79 (m, 0.3H), 3.75 (m, 1H), 4.60 (dd, J=8 and 5.5 Hz, 0.3H), 4.84 (t, J=5.5 Hz, 0.7H), 5.94 (d, J=5.5 Hz, 0.7H (mobile)), 6.14 (d, J=5.5 Hz, 0.3H (mobile)), 6.54 (d, J=9.5 Hz, 0.7H (mobile)), 6.71 (d, J=9.5 Hz, 0.3H (mobile)), 7.35 (m, 2H) and 7.69 (m, 2H); SM (ESP; m/z): 307 (MH + ).
Step 3
To a solution of (S)-2-(tert-butoxycarbonyl)amino-1-benzoxazol-2-yl-propan-1-ol (26.3 g; 86 mmol) in isopropanol (118 mL) at 20–25° C. was added trimethylchlorosilane (1.4 eq). The solution was stirred for 5 h at 50° C. Concentration of the reaction mixture to 52 mL followed by addition of isopropyl ether (210 mL), filtration and drying under vacuum afforded (S)-2-amino-1-benzoxazol-2-yl-propan-1-ol hydrochloride salt as a grey solid (16.4 g; yield=79%; mixture of diastereomers). C 11 H 15 CIN 2 O 2 ; MW=242.7; T melt =138° C.; NMR (DMSO, ppm): 0.91 (t, J=7 Hz, 0.9H), 0.93 (t, J=7 Hz, 2.1H), 1.66 (m, 2H), 3.54 (m, 1H), 5.02 (t, J=5 Hz, 0.7 H), 5.24 (m, 0.3 H), 6.89 (m, 0.3H (mobile)), 7.06 (d, J=5.5 Hz, 0.7H (mobile)), 7.42 (m, 2H), 7.77 (m, 2H), 8.24 (m, 2.1H) and 8.35 (m, 0.9H); SM (ESP; m/z): 207 (MH + ), 150, 132.
Example 2
Synthesis of (S)-2-(tert-butoxycarbonyl)amino-1-(oxazolo[4,5-b]pyridin-2-yl)propan-1-ol
Step 1
A mixture of 2-amino-3-hydroxypyridine (11 g, 100 mmol), triethylorthoformate (80 ml) and p-toluenesulfonic acid (61 mg) was heated at 140° C. for 8 hours. Excess triethylorthoformate was removed under vacuum and oxazolo[4,5-b]pyridine was crystalized from ethyl acetate (9 g).
Step 2
In a clean roundbottom flask equipped with stir bar was placed oxazolo[4,5-b]pyridine (600 mg, 5 mmol) in 30 mL THF and the reaction mixture was cooled to 0° C. under N 2 atmosphere. Isopropylmagnesium chloride (2M in THF, 2.5 ml, 5 mmol ) was added. After stirring for 1 h at 0° C., (S)-2-(tert-butoxycarbonyl)aminobutyraldehyde (573 mg, 3 mmol) in 20 ml THF was added. The ice bath was removed and the reaction mixture was allowed to warm to room temperature. After 2 h, the reaction mixture was quenched with saturated ammonium chloride solution and concentrated to dryness. The residue was extracted with EtOAc, then washed with brine, dried with anhyd. MgSO 4 , filtered and concentrated. The crude product was purified by chromatograph to yield 383 mg of the desired compound.
H 1 NMR (DMSO-d 6 ): 8.42(1H, m), 8.18(1H, m), 7.3(1H, m), 6.8, 6.6(1H, dd, d, OH, diastereomer), 6.3, 6.02(1H, d, d, NH, diastereomer), 4.82, 4.5(1H, m,m, diastereomer), 1.8–1.3(2H, m), 1.2, 1.05(9H, s,s, diastereomer), 0.89(3H, m). MS: 306.2(M−1), 308.6(M+1).
Example 3
Synthesis of N-[1-(R)-(1S-benzoxazol-2-ylcarbonylpropylcarbamoyl)-2-cyclopropylmethylsulfonylethyl]morpholine-4-carboxamide
Step 1
L-Cysteine (100 g, 0.825 mol) was suspended in ethanol (850 mL). A solution of sodium hydroxide (1.65 mol) in ethanol (650 mL) was added during 40 min at 20–25° C. To the solution was added bromomethylcyclopropane (0.907 mol) at 25–30° C. The reaction mixture was stirred at ambient temperature overnight, the neutralized with 2N HCl (300 mL). The suspension was concentrated under vacuum to 400 mL, then water (750 mL) was added, and pH was adjusted to 6.5 with 2N HCl. The mixture was stirred for 2 h at 0–5° C., the precipitate was filtered, washed with water and dried under vacuum to give (R)-2-amino-3-cyclopropyl-methylsulfanylpropionic acid as a white crystalline solid (128.2 g; yield=88.6 %). C 7 H 13 NO 2 S; MW=175.3; T melt =2090 C; NMR (DMSO, ppm): 0.20 (m, 2H), 0.50 (m, 2H), 0.94 (m, 1H), 2.50 (m, 2H), 2.78 (dd, J=14.5 and 8.5 Hz, 1 H), 3.08 (dd, J=14.5 and 4 Hz, 1 H) and 7.64 (ls, 1H (mobile)); SM (EI; m/z): 130 (M + —COOH), 89, 74.
Step 2
(R)-2-Amino-3-cyclopropyl-methylsulfanylpropionic acid (100 g; 0.570 mol) and triethylamine (1.25 mol) were suspended in acetonitrile (1500 mL) and water (150 mL). Morpholinecarbonyl chloride (0.656 mol) was added for 4 h at 20–25° C. The solution was stirred at room temperature overnight, then concentrated under vacuum to 400 mL. Water (250 mL) was added to the suspension, and pH was adjusted to 12.5 with 2N sodium hydroxide (ca 1.20 mol). The aqueous phase was washed with dichloromethane, then dichloromethane was added and pH was adjusted to 2.0–2.5 with 2N HCl (ca 0.57 mol). The dichloromethane phase was washed with water and concentrated to ca 400 mL. Dichloromethane was replaced by 2-propanol by distillation under vacuum at constant volume. Water (500 mL), tungstic acid (11.4 mmol) and 30% hydrogen peroxide (1.25 mol) were added at 20–30° C. The reaction mixture was stirred vigorously for 5 h at 30° C., and then at room temperature overnight. Excess peroxide was reduced with aqueous sodium metabisulfite. The product was extracted with a mixture of ethyl acetate and 2-propanol. Concentration under vacuum, trituration in ethyl acetate, filtration and drying overnight under vacuum afforded (R)-3-cyclopropylmethylsulfonyl-2-(morpholine-4-carbonylamino)-propionic acid as a white crystalline solid (145.5 g; yield=80%). C 12 H 20 N 2 O 6 S; MW=320.4; T melt =136° C.; NMR (DMSO, ppm): 0.35 (m, 2H), 0.60 (m, 2H), 1.03 (m, 1H), 3.02 (dd, J=14.5 and 7.5 Hz, 1H), 3.09 (dd, J=14.5 and 7 Hz, 1H), 3.27 (m, 4H), 3.54 (m, 6H), 4.51 (ddd, J 8.5, 8 and 3.5 Hz, 1H), 7.11 (d, J=8 Hz, 1H (mobile)) and 12.79 (ls, 1H (mobile)); SM (ESP; m/z): 321 (MH + ).
Step 3
Triethylamine (144 mmol) was added at room temperature to a suspension of (R)-3-cyclopropylmethanesulfonyl-2-(morpholine-4-carbonylamino)-propionic acid (46.2 g; 144 mmol) and (S)-2-amino-1-benzoxazol-2-yl-propan-1-ol. HCl salt (35 g; 144 mmol) in dichloromethane (350 mL). A fresh solution of EDC.HCl (202 mmol), HOBT (37 mmol) and dichloromethane (350 mL) was added during ca 2 h at 0–5° C. The mixture was neutralized with aqueous 5% sodium hydrogencarbonate (104 mmol). After decantation, the organic phase was washed with aqeous 5% acetic acid, aqueous 5% sodium hydrogencarbonate, then water. TEMPO (1.4 mmol), sodium bromide (144 mmol) and sodium hydrogencarbonate (144 mmol) were added at 0° C. A solution of sodium hypochlorite (187 mmol) in water (400 ml) was added under vigorous stirring during ca 2 h at 0–5° C. The mixture was stirred for 3–4 h at 0–5° C., then quenched with aqueous 10% sodium thiosulfate (130 mmol). After decantation, the organic phase was washed with water and dried over sodium sulfate. The solution was concentrated to ca 800 mL, and dichloromethane was replaced by ethanol by distillation at constant volume at ca 40° C. N-[1-(R)-(1S-benzoxazol-2-yl-carbonylpropyl-carbamoyl)-2-cyclopropylmethylsulfonylethyl]morpholine-4-carboxamide (ethanol solvate) crystallised out and was filtered off, washed with ethanol and dried under vacuum (49.7 g; yield=68%; white crystalline solid). C 23 H 30 N 4 O 7 S; MW=506.6; T melt =89° C.; NMR (DMSO, ppm): 0.34 (m, 2H), 0.57 (m, 2H), 0.97 (t, J=7.5 Hz, 3H), 1.03 (m, 1H), 1.77 (m, 1H), 2.01 (m, 1H), 3.01 (dd, J=14.5 and 7.5 Hz, 1H), 3.12 (dd, J=14.5 and 7 Hz, 1H), 3.29 (m, 4H), 3.47 (m, 2H), 3.53 (m, 4H), 4.69 (dt, J=8.5 and 5 Hz, 1H), 5.20 (ddd, J=8.5, 6.5 and 4.5 Hz, 1H), 6.98 (d, J=8.5 Hz, 1H (mobile)), 7.55 (lt, J=8.5 Hz, 1H), 7.65 (lt, J=8.5 Hz, 1H), 7.90 (ld, J=8.5 Hz, 1H), 8.00 (ld, J=8.5 Hz, 1H) and 8.63 (d, J=6.5 Hz, 1H (mobile)); SM (ESP; m/z): 507 (MH + ), 466, 303.
Proceeding as described above but substituting bromomethylcyclopropane with 1-bromo-2-methylpropane gave N-[1-(R)-(1S-benzoxazol-2-ylcarbonylpropyl-carbamoyl)-2-(2-methylpropylsulfonylethyl]morpholine-4-carboxamide. C 23 H 32 N 4 O 7 S; MW=508.6 ; T melt =111° C. ; NMR (DMSO, ppm): 0.97 (t, J=7 Hz, 3H), 1.01 (2d, J=7 Hz, 6H), 1.76 (m, 1H), 2.02 (m, 1H), 2.18 (m, 1H), 2.99 (dd, J=14 and 7 Hz, 1H), 3.04 (dd, J=14 and 6.5 Hz, 1H), 3.29 (m, 4H), 3.44 (m, 2H), 3.54 (m, 4H), 4.70 (dt, J=8.5 and 4 Hz, 1H), 5.19 (ddd, J=8.5, 6.5 and 4.5 Hz, 1H), 6.96 (d, J=8.5 Hz, 1H (mobile)), 7.55 (lt, J=8.5 Hz, 1H), 7.64 (lt, J=8.5 Hz, 1H), 7.89 (ld, J=8.5 Hz, 1H), 8.00 (ld, J=8.5 Hz, 1H) and 8.69 (d, J=6.5 Hz, 1H (mobile)); SM (ESP; m/z): 509 (MH + ), 305.
In step 2 above, (R)-3-(3-methylpropylsulfonyl)-2-(morpholine-4-carbonylamino]-propionic acid was crystallized from ethyl acetate in 82% yield. C 12 H 22 N 2 O 6 S; MW=322.4; T melt =124° C.; NMR (DMSO, ppm): 1.02 (t, J=6.5 Hz, 6H), 2.18 (m, 1H), 2.98 (dd, J=14.5 and 7 Hz, 1H), 3.04 (dd, J=14.5 and 6.5 Hz, 1H), 3.28 (m, 4H), 3.45 (dd, J=15 and 3.5 Hz, 1H), 3.54 (m, 4H), 3.57 (dd, J=15 and 9.5 Hz, 1H), 4.50 (ddd, J=9.5, 8 and 3.5 Hz, 1H), 7.09 (d, J=8 Hz, 1H (mobile)) and 12.43 (ls, 1H (mobile)); SM (ESP; m/z): 323 (MH + ).
The foregoing invention has been described in some detail by way of illustration and example, for purposes of clarity and understanding. It will be obvious to one of skill in the art that changes and modifications may be practiced within the scope of the appended claims. Therefore, it is to be understood that the above description is intended to be illustrative and not restrictive. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the following appended claims, along with the full scope of equivalents to which such claims are entitled. All patents, patent applications and publications cited in this application are hereby incorporated by reference in their entirety for all purposes to the same extent as if each individual patent, patent application or publication were so individually denoted. | The present invention is directed to a novel process for preparing heteroaryl and unsaturated heterocycloalkylmagnesium reagents that are useful in the synthesis of a variety of pharmaceuticals, in particular certain cysteine protease inhibitors. | 2 |
FIELD OF THE INVENTION
The present invention relates to a configuration system for configuring a chemical separation system, which system enables a user to in real-time obtain a customised configuration of the chemical separation system. The present invention also relates to a method of selling a customised chemical separation system using a configuration system.
BACKGROUND OF THE INVENTION
Computer-based systems for configuring a customised merchandise are known, for example from the car sales market, where a user through a software-based program can chose car parameters, such as colour, decorative elements, equipment packages, engine size, etc, and then place his order. The resulting customisation may also be presented as real-time modifications of the car's appearance. Mutually conflicting selections are not possible. For example, it is not possible to select broad tyres alone as an option to an economy version of the car, since broad tyres is an option associated with certain rim types, wherefore new rims must then be chosen.
P. Conti et al (“Integrating expert systems for high-performance liquid chromatographic method development”. Chemometrics and Intelligent Laboratory Systems, 11, 27-35 (1991)) describes a complex expert system for high-performance liquid chromatographic method development. The expert system is obtained by linking several small stand-alone expert systems (modules), each representing a part of the entire domain. The authors of the article have attempted to solve the problem of how to create expert systems for high-performance liquid chromatography by making stand-alone chemical separation modules cooperate with each other.
The process of selling a customised chemical separation system is a laborious process for both sales persons as well as buyers. The process starts when a customer presents his specific requirements to the sales person. If the customer's needs cannot be met with available products, a project team which includes technicians from the selling and buying companies is formed. For complex cases, a project leader may also have to be involved. The process may, especially for complex systems, require many months, typically 6-12 months, before the system is operational. Customised products, requiring project teams for their creation, often generate very poor profits for the sales company.
Thus, there is a need for making the customisation process more rapid, in order to free sales resources and decrease the development costs associated with customised products, and thereby increase the profits for the sales company, as well as enabling the customer to more quickly obtain an operational, customised chemical separation system, thus shortening delays in production, reducing the customer's costs, and in the end, increasing his profits.
To the present date, no system for configuring a chemical separation system, which gives a customer the possibility to in real-time customise said system, or a method of selling a customised chemical separation system using such a configuration system, has yet been presented.
SUMMARY OF THE INVENTION
The present invention provides a novel and efficient way of enabling a customised chemical separation system to be configured and ordered.
In one aspect, the present invention relates to a system for configuring and optionally ordering a chemical separation system, comprising a configuration tool, a database comprising data relating to chemical separation hardware modules, including how they are linked and controlled, which system enables a user in real-time to obtain a customised configuration of the chemical separation system. The user may be a customer or a sales person helping the customer to configure the system.
In a second aspect, the present invention relates to a method of selling a customised, configured chemical separation system, wherein a user customises a desired chemical separation system using the inventive system for configuring and optionally ordering a chemical separation system. The inventive system may generate personalised configuration data in the form of user-viewable graphical representations, which the user can save as a template for future modifications of the system, download for further consideration, and/or use as the specification of a system in a purchase order.
The fact that data (visual, technical, performance, construction, etc.,) relating to the user's customised chemical separation system is provided in real-time, enables the user to see and understand how the final chemical separation system will look like, what capacity it will have, how to operate it, and to confirm that its constituent hardware modules will be compatible and optimised. This makes it easier for the user to select system components in a structured fashion.
The real-time provision of the extensive information relating to the chemical separation system, gives the user a real-time picture of the system, and optionally includes the sales price, which makes it much easier for the user to decide if to proceed with the purchase, whereby the decision phase is facilitated and shortened.
All the configuration data may be downloaded as user-viewable graphical representation files, and the customised configuration may be identifiable by a user identification number or code, including an order number, a time stamp, etc, in order to simplify identification of the configuration data and to ensure the correct configuration data is used when placing and fulfilling a purchase order for a system. The data files comprising the user-viewable graphical representations may be used as a purchase order and manufacturing specification when ordering the system, whereby the purchase phase is also facilitated and shortened. The data files may be stored for future use, for example for use as a spare parts list.
Since all the constituent hardware modules and associated control software for use in such a separation system have preferably already been made compatible and optimised, the time to construct, test, and assemble the separation system is also decreased.
An advantage of the present invention is the provision of a means and a method of obtaining a customised, fully operational chemical separation system within a total time of typically 8 weeks, i.e. from the start of the configuration to the delivery of the separation system. This means that the time to delivery of the system could be reduced substantially, compared to present processes for customising chemical separation systems.
Some important benefits of the present invention for the sales company are that sales resources are freed and that the development costs associated with customised products are decreased to a level that make them profitable. A customer will swiftly obtain an operational, customised chemical separation system, thus shortening delays in production and reducing the customer's costs, and in the end, increasing his profits.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart of the method of selling a customised, configured chemical separation system according to an embodiment of the present invention
FIG. 2 is a perspective view of a chemical separation system configured using the system for configuring a chemical separation system according to an embodiment of the present invention, showing in this case the dimensions and certain important features of the system.
FIG. 3 is a schematic view of part of the process flow chart and its constituent hardware modules of the configured system shown in FIG. 2 .
FIG. 4 is a sheet of the general specification of the configured system shown in FIG. 2 .
FIG. 5 is a sheet of the bill of material of the configured system shown in FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
According to the invention, one embodiment of the method of selling a customised, configured chemical separation system, wherein a user customises his chemical separation system by choosing hardware modules using a system for configuring a chemical separation system comprising a configuration tool and a database comprising data relating to chemical separation hardware modules, comprises the steps of:
the user selecting hardware modules defining said chemical separation system; the configuration tool (C.T.) generating configuration data based on the user-selected hardware, said configuration data reflecting said chemical separation system and chemical separation system data; the C.T. accepting the user's hardware selection as a compatible selection; the C.T. presenting the user's hardware selection accepted by the C.T. and configuration data as a user-viewable graphical representation; the user accepting the presented hardware selection and configuration data; and optionally the user placing an order for the customised system.
FIG. 1 describes an embodiment of the method according to the present invention illustrated by a process flowchart of the steps involved.
The first step of the method, step 100 , describes when the user configures his desired system by selecting initial hardware modules. The user may start the configuration from scratch, selecting one hardware module after the other, or from a default system configuration where hardware modules have already been chosen.
In step 110 , the C.T. (operatively linked to a data base comprising data relating to hardware modules, software modules, settings, capacity, and the like, as data files) generates configuration data resulting from the user's initial customised hardware selection. Said configuration data may be downloaded by the user.
In step 120 the C.T. evaluates the hardware selections made by the user. Should the hardware be selected in a way that the configuration tool accepts as generating a compatible or optimised configuration, the configuration tool will in step 130 then present graphical representations of the chosen hardware and configuration data related to the hardware.
The configuration data presented in step 130 includes details relating to the customised chemical separation system, such as details relating to the construction, modularised control software, process flow charts, process settings, capacity, and at least one graphical representation of the chemical separation system as assembled. Said configuration data is presented as user-viewable data and may be downloaded by the user.
Should the selected hardware modules selected in step 100 not be compatible with each other or represent a non-optimised hardware selection according to the C.T. in step 120 , the C.T. preferably displays solutions to overcome said incompatibility or changes in the chosen hardware to optimise the performance are suggested by the C.T. in step 125 . Such incompatible or non-optimised hardware selections may be displayed with a different colour, font or in some other way highlighted in order to distinguish them from compatible or optimised selections. Should the user change the configuration according to the suggested solutions, he will return to step 110 where the C.T. generates new configuration data that it will accept in step 120 , and in step 130 presents as graphical representations of the selected hardware and configuration data related to said hardware.
In step 140 the user evaluates his chemical separation system and its configuration data as presented by the C.T.
Should the user not be satisfied with the hardware selection and configuration data presented by the C.T. in step 130 , he may then in step 145 select new hardware from which the C.T. will generate new configuration data, i.e. returning to the step 110 of generating configuration data.
Should the user in the step 140 be satisfied with the presented customised configuration data, and accepts it, the C.T. will then in step 150 generate a unique code identifying the user's customised hardware selection and configuration data.
The order takes place if the user in step 160 orders the system utilising the unique code. The order may be performed by utilising the unique code and/or the generated configuration data. Preferably, at least part of the configuration data is used by a sales company as a manufacturing specification of the user's customised chemical separation system.
If the step of generating the configuration data is generated in a user's stand-alone computer, by the C.T., said configuration data may be transferred as electronic data files to the sales company as a purchase order. If the configuration data for example is generated by the user in the sales company's web-based system for configuring a chemical separation system, then the personal identification number, identifying the data relating to the user's customised configuration, may be used as a purchase order. In both cases, the user-viewable graphical representations with its unique identification number may be used by the sales company as the manufacturing specification of the user's customised chemical separation system.
Preferably, for security reasons, the access to the system for configuring a chemical separation system is obtained through the provision of a user key.
According to the invention, a first embodiment of the system for configuring and ordering of a chemical separation system, comprises:
a configuration tool (C.T.) adapted to generate configuration data and determining if a hardware selection is compatible, said C.T. comprising: a database comprising data relating to chemical separation hardware modules, including how they are linked and controlled, and computer hardware and software for running said C.T. and inputting data to, and outputting data from, said C.T., a user interface adapted to enable a user to select hardware modules, a graphical user interface adapted to receive configuration data from the C.T. and display the configuration data to a user in a user-viewable format, wherein the user interface enables a user to accept a presented configuration of the chemical separation system,
wherein the system is adapted to enable a user to select hardware modules comprised in a chemical separation system, to generate configuration data relating to said chemical separation system, and to display it as a user-viewable graphical representation, such that the user in real-time obtains a customised configuration of the chemical separation system and may order a fully functional chemical separation system.
Said C.T. may be an expert system or configuration tool according to the present invention, or a conventional expert system or configuration tool, or any other computerised system capable of performing the steps in the method according to the present invention. The C.T. calculates if selected hardware modules in the chemical separation system are compatible with each other and what the capacity of the customised chemical separation system will be, based on the information provided by the database. The C.T. may also calculate how non-compatible hardware selections may be made compatible, or how a non-optimised performance of the chemical separation system may be improved. Said C.T. is preferably software-based.
The hardware modules for which information is stored in the database include conventional components of a chemical separation system, such as separation columns, pumps, valves, connectors, tubing, filters, detectors, and the like. Information on software that controls hardware modules may be associated with the respective hardware modules. The database also comprises information on how the different hardware modules can be linked and their respective capacity. The content of the database depends on what type of chemical separation system is to be customised.
The configuration data relating to the customised system are in real-time updated by the C.T. and displayed by the graphical user interface when the user changes a changeable parameter of the customised system. Preferably the graphical user interface in real-time displays graphical representations relating to at least one of: the construction details, modularised control software, process flow charts, process settings, capacity, and at least one graphical representation of the chemical separation system. Optionally the price of the configured system is displayed to the user, in which case the real-time updates may also include an updated price.
Any of the user's hardware selections that the C.T. deems incompatible or leading to non-optimised performance may be displayed by the graphical user interface with a different colour, font or are high-lighted with respect to compatible or optimised choices, and the system may also suggest solutions to overcome said incompatibility or to optimise the performance of the customised chemical separation system.
The configuration system according to the present invention may generate a unique identification code identifying the details relating to the customised configuration of the chemical separation system. Said C.T. may also generate downloadable customised configuration data in the form of computer-readable files and user-viewable files comprising at least one of: unique identification code, information relating to the construction details, modularised control software process, flow charts, process settings, capacity, and graphical representations of the chemical separation system as assembled.
In one embodiment of the system according to the invention, the C.T., or the C.T. and the database, is/are located in a customer's or a sales person's stand-alone computer. In another embodiment, the C.T. and/or database is/are located in the sales company's server or computer network, which are accessible via a web-based (internet) connection.
The present configuration and ordering system is suitable for all kinds of system size—ranging from laboratory scale systems to industrial scale systems. The present invention relates to configuration of chemical separation systems, specifically to chemical separation systems, and more specifically to chromatographic separation systems. However, the present invention is applicable to similar chemical separation systems, such as filter systems or analytical systems. | The present invention relates to a configuration system for configuring and ordering a chemical separation system, which configuration system comprises a configuration tool, a database comprising data relating to chemical separation hardware modules and the linkage of said hardware modules. Said configuration system enables a user in real-time to obtain a customized configuration of the chemical separation system. The present invention also relates to a method of selling a customized chemical separation system using said configuration system. The present invention system and method considerably shorten the time required for customizing a chemical separation system. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of and priority to co-pending U.S. Provisional Patent Application No. 61/039,377, filed Mar. 25, 2008, the entire contents of which are incorporated by reference herein.
GOVERNMENT RIGHTS
[0002] The invention was supported, in whole or in part, by grant 1 R44 ES012699-01 of the National Institute of Environmental Health Sciences. The Government has certain rights in the invention.
FIELD OF THE INVENTION
[0003] The invention relates generally to animal restraining systems for in vivo imaging across multiple tomographic modalities and/or imaging systems. More particularly, in certain embodiments, the invention relates to an animal holder compatible with optical imaging systems in conjunction with magnetic resonance, computed tomography, positron emission tomography, and/or other tomographic imaging systems, to enhance and simplify the registration of reconstructed datasets acquired on different systems.
BACKGROUND OF THE INVENTION
[0004] Tomography is a process that relies upon a selected form of energy being directed toward and passing through an object at more than one angle, and permits the construction of detailed images of internal structures of the object. The energy from the various angles is detected and corresponding data processed to provide a tomographic image. The received signals typically are less intense (for example, are darker) where the object is thicker or more dense, and more intense (for example, brighter) where the object is thinner or less dense.
[0005] A signal received by a single energy sensor (for example, at one angle) does not contain sufficient information to generate either a two-dimensional or a three-dimensional representation of internal structures of the object. Signals received by energy sensors arranged in a plane or volume provide sufficient information to generate a three-dimensional representation of internal structures of the object.
[0006] Tomography can be used in a variety of imaging systems with different types of transmitted and received electromagnetic radiation. In particular, in X-ray Computed Axial Tomography (CAT, or CT), X-ray radiation is projected through an object, typically at a variety of angles, and a variety of X-ray receivers, at a corresponding variety of angles, are used to receive the X-rays transmitted through the object. A computer is used to generate an image of internal structures of the object in three dimensions from signals received by the variety of X-ray receivers.
[0007] X-rays tend to pass through the object in straight lines with relatively little attenuation, allowing non-invasive capture of certain anatomical features at high resolution (for example, distinguishing features as small as 50-100 μm in one or more dimensions). X-ray CAT imaging systems can be used to image bones, organs, blood vessels, and tumors of a particular subject. While X-ray CAT imaging is able to provide high resolution of certain anatomical structures, it is relatively limited in its ability to detect, distinguish, or quantify specific chemical or biological species in the subject. Therefore, existing X-ray CAT systems cannot provide functional (or, “molecular”) information about a subject or disease state at the cellular or molecular level.
[0008] Imaging techniques such as X-ray CAT, magnetic resonance imaging (MRI) and ultrasound (US) primarily rely on physical parameters such as absorption, scattering, proton density, and relaxation rates as the primary source of contrast for imaging. Specific molecular information with these modalities cannot often be obtained or is limited. Optical imaging, for example, optical tomographic imaging, uses specific molecular activity or alterations as the source of image contrast and therefore, can provide much more molecular or functional information about a subject or disease state than imaging techniques such as X-ray CAT that primarily capture anatomical information based on physical parameters.
[0009] Optical tomographic systems use one or more wavelengths of visible or invisible light, rather than X-rays. Unlike X-ray tomography, in which X-rays tend to pass through an object in a straight line with relatively little attenuation, visible and invisible (ultraviolet or infrared) light tends to be absorbed and to scatter when passing though an object. Therefore, light does not travel in straight lines when passing through the object. Light also tends to be absorbed and scattered more when passing through a relatively thick and/or non-homogeneous medium, than when passing through a relatively thin and/or homogeneous medium.
[0010] Most conventional optical tomography systems use near infrared (near-IR, NIR) light, instead of light in the visible spectrum when passing through animal tissues, since NIR tends to be absorbed less and to scatter less than visible light. The use of NIR light generally provides the ability to image deeper tissues, for example, thicker tissues, and/or the ability to image with higher sensitivity than the use of visible light.
[0011] While optical tomography is well suited to providing molecular/functional information about a subject, the achievable resolution is not as high as with X-ray CAT or MRI. Two exemplary optical tomographic techniques are Diffuse Optical Tomography (DOT) and Fluorescence Molecular Tomography (FMT). Both DOT and FMT allow optical tomographic imaging of the internal structure of animal and/or human subjects.
[0012] DOT is an imaging technique capable of providing biological functional information by imaging hemoglobin concentration and tissue oxygenation state. DOT approaches are currently being used to detect certain types of tumors, including breast tumors.
[0013] Unlike most DOT approaches, FMT uses fluorescent molecular probes, which absorb light propagating inside of an object and emit light at a longer wavelength (lower energy) than the absorbed light inside of the object, allowing non-invasive, in vivo investigation of functional and molecular signatures in whole tissues of animals and humans. FMT systems enable molecular imaging, for example, FMT can be used to visually indicate molecular abnormalities that are the basis of a disease, rather than just imaging the anatomical structures in the area of suspected molecular, abnormalities, as with conventional imaging approaches. Specific imaging of molecular targets provides earlier detection and characterization of a disease, as well as earlier and direct molecular assessment of treatment efficacy. An illustrative FMT system is described in U.S. Patent Application Publication No. US2004/0015062, the text of which is incorporated by reference herein, in its entirety.
[0014] Most existing DOT and FMT systems use light sources and light sensors in direct contact with the object to be imaged and/or use optical matching fluid. For both DOT and FMT systems, the use of fiber guides and/or optical matching fluids limits the tomographic capacity of such systems and impedes their practicality in research and/or clinical settings.
[0015] Recent improvements in fluorescence molecular tomography have led to the development of more versatile imaging techniques that do not require either direct contact or optical contact between the light sources/detectors and the object to be imaged. These techniques employ more powerful algorithms that account for heterogeneities of the index of refraction within and surrounding the animal tissue which give rise to photon reflections at the boundaries. See, for example, International (PCT) Application Publication No. WO 03/102558, published 11 Dec. 2003; and R. Schulz, J. Ripoll and V. Ntziachristos, “Experimental Fluorescence Tomography of Tissues with Noncontact Measurements,” IEEE Transactions on Medical Imaging, Vol. 23, No. 4, pp. 492-500 (2004), the texts of which are incorporated herein by reference in their entirety. These techniques are further augmented by the use of so-called free-space transformations, which take into account the presence of a non-turbid medium (air) between the object to be imaged and the detectors. See, for example, International (PCT) Application Publication No. WO 2004/072906, published 26 Aug. 2004; and J. Ripoll, R. Schulz and V. Ntziachristos, “Free-Space Propagation of Diffuse Light: Theory and Experiments,” Physical Review Letters, Vol. 91 No. 10 (2003), the texts of each of which are incorporated herein by reference in their entirety.
[0016] Multi-modality tomographic imaging is emerging as an increasingly important tool in pre-clinical and clinical imaging, as it allows the combination of complementary image datasets, for example, from Fluorescence Molecular Tomography (FMT), Magnetic Resonance Imaging (MRI or MR), Computed Axial Tomography (CAT or CT), Positron Emission Tomography (PET), and others, to indicate, highlight and correlate specific biological processes with morphological or functional information.
[0017] Co-registering image datasets for a given subject that are obtained from different modalities may be quite difficult because it is normally necessary to move the subject from one imaging system to another, and movement of the subject often causes complex misalignment of the datasets because the subject is not a rigid body. One approach to solving this problem is a hardware-based approach that involves a complex architecture of sources and detectors from two or more modalities within a single rotating gantry. A second approach is a software approach that involves mathematically advanced image transformation algorithms to allow the fusion of image datasets from the different imaging modalities into a single integrated dataset. The primary limitation of the hardware approach is the complexity and cost associated with multi-modality gantries. The primary limitation of the software approach resides in the relatively inferior image fusion results due to the softness or non-rigidity of biological tissue as it is transported from one imaging modality to another. Thus, there exists a need for new technologies and methods to enable the simple and accurate registration of data sets across optical, X-ray, magnetic resonance, nuclear or other tomographic modalities that overcome the limitations of existing solutions.
SUMMARY OF THE INVENTION
[0018] The invention provides a portable animal holder for use with in vivo imaging systems that features adjustable, substantially parallel (planar) frames to secure an animal within the holder. The invention enables the transport of an anesthetized, rigid or pseudo-rigid, small animal from one imaging workstation to another, or from one location to another within a single imaging workstation, without loss of subject positional information, allowing accurate co-registration of image data obtained using multiple imaging modalities. Throughout the application the terms “animal holder” and “animal cassette” are used interchangeably.
[0019] The animal holder has two substantially parallel frames that can be adjusted to accommodate a small animal (for example, a mouse or other mammal) between the frames. Each of the frames includes a window through which the electromagnetic radiation can be transmitted, as needed for the various imaging modalities used. The animal is secured between the frames, for example, by gentle compression, such that a portion of its body that is to be imaged is flush against both windows. In preferred embodiments, no harness is used, because it is not necessary to secure the animal.
[0020] In addition to maintaining subject positional information, the animal holder provides two deterministic, planar boundary conditions that are useful for quantitative tissue modeling in tomographic image reconstruction. Tomographic image reconstruction is performed, for example, in imaging systems that feature an FMT imaging modality. The planar boundary conditions offer a substantial simplification of the computations necessary for image reconstruction, thereby saving computation time and cost and improving accuracy. The flat surfaces of the animal holder have the additional advantages of being compatible with an MRI surface coil.
[0021] Thus, the animal holder enables simplified tomographic reconstruction, as well as enabling the transport of an animal subject from one workstation to another. The workstations can include single-modality and/or multiple-modality imaging workstations. The modalities may include, for example, Fluorescence Molecular Tomography (FMT), Magnetic Resonance Imaging (MRI or MR), Computed Axial Tomography (CAT or CT), Positron Emission Tomography (PET), Diffuse Optical Tomography (DOT), and/or single photon emission computed tomography (SPECT).
[0022] The animal holder is compatible with the fields of view of preclinical animal imaging stations such as micro-CT, micro-MR, micro-PET, micro-SPECT, and FMT systems (the prefix “micro-” is used to indicate a system configured for small animal imaging/analysis). The animal holder is configured to fit into an aperture (for example, as a cassette) in each of the individual imaging chambers, and the animal holder is made of materials that are compliant with all of the above modalities. Particular attention has been paid to ensuring parallelism of imaging surfaces while avoiding metal-based or other incompatible materials in the is mechanisms of the animal holder. In certain embodiments, the animal holder is fabricated from non-metallic materials.
[0023] In certain embodiments, the animal holder includes an integrated set of fiducial marker wells which accommodate fiducial markers that are detected by a plurality of imaging modalities (either simultaneously or at different times) in one or more planes. These fiducial markers then are aligned in standard image processing or image analysis software with image translation and rotation operations, without the need for more advanced scaling, distortion or other operations.
[0024] The animal holder also integrates elements for providing the animal with inhalation anesthesia, for example, isoflurane, and is designed to fit into identical receptacles inside and/or outside the imaging workstation(s) that provide heating to prevent animal hypothermia.
[0025] In one aspect, the invention provides a portable animal holder configured for use in one or more in vivo imaging systems. The animal holder including two adjustable, substantially parallel frames and a mechanism operable to secure the animal within the animal holder, thereby preventing substantial movement of the animal during imaging of the animal in the one or more in vivo imaging systems. In certain embodiments, the mechanism is operable to gently compress the animal between the substantially parallel frames. Each of the frames includes an imaging window that transmits electromagnetic radiation therethrough, for example, X-rays, gamma rays, positron rays, visible light, near-infrared light, radio waves, micro-waves, tetra-hertz radiation, infrared light, and/or ultraviolet light, for example, as required for imaging by the one or more in vivo imaging systems.
[0026] In certain embodiments, the imaging windows can be made of glass, aerogel, or plastic such as acrylic resin, Polyarylethersulfone (Radel® R PAES), polycarbonate, polyethersulfone, polypropylene, polysulfone, polyurethane resin, ALON™ and SPINEL™ Optical Ceramic or any combination thereof. The imaging windows preferably are substantially transparent to the electromagnetic radiation used to produce the image data in a given system, that is, the imaging windows allow most of the electromagnetic radiation used by a given imaging device to produce an image to pass through the window unattenuated—for example, from about 85% to about 100% of the electromagnetic radiation is not attenuated. Each of the imaging windows may have a thickness, for example, from about 0.1 mm to about 3 cm, although thicknesses greater than or less than these limits are possible. The imaging windows may have an antireflective coating. The parallel frames may be made with polyoxymethylene (e.g., Delrin®, manufactured by E.I. duPont de Nemours & Co. of Wilmington, Del.), acrylonitrile butadiene styrene (ABS), PolyEtherEther-Ketone [PEEK (30% Carbon Filled)], Self-Reinforcing Polyphenylene (TECAMAX™ SRP), Polyamide (30% Glass-Reinforced Extruded Nylon 6/6), or other plastic, for example. In preferred embodiments, particularly those using MR imaging, the animal holder is composed of non-metal, MR-compatible materials.
[0027] In preferred embodiments in which one of the imaging modalities is a tomographic imaging modality (for example, FMT), the imaging windows are substantially parallel, thereby providing two substantially planar boundary conditions for three-dimensional image reconstruction of at least a portion of the animal upon gentle compression of the animal between the substantially parallel imaging windows such that the portion of the animal of interest is flush against both windows.
[0028] In certain embodiments, the portable animal holder further includes a plurality of fiducial markers and/or wells that accommodate fiducial markers. In certain embodiments, the animal holder is configured to permit transport of the animal within the animal holder as a rigid body or pseudo-rigid body from a first imaging location to a second, different, imaging location, the fiducial markers allow co-registration of data sets obtained at the first and second imaging locations. Preferably, at least a subset of the fiducial markers are detectable by both a first imaging modality and a second imaging modality which can occur in the same or different in vivo imaging systems. For example, the fiducial markers are detectable by the first imaging modality performed with the animal at the first imaging location, and the fiducial markers are detectable by the second imaging modality performed with the animal at the second imaging location (for example, such that the animal is moved between the first and second imaging locations as a rigid or pseudo-rigid body). The first and second imaging modalities can each be chosen, for example, from among the following: magnetic resonance, X-ray, X-ray computed tomography, nuclear, positron emission tomography (PET), single photon emission computed tomography (SPECT), ultrasound, fluorescence, fluorescence tomography, and/or bioluminescence imaging. In particular embodiments, the first and second imaging modalities are selected from fluorescence molecular tomography (FMT), magnetic resonance (MR), and X-ray computed tomography (CT). In a further particular embodiment, one of the two imaging modalities is FMT and the other is MR or CT.
[0029] In certain embodiments, the fiducial markers include a fluorescent compound, a gamma emitting compound, a positron emitting compound, a silicon polymer, and/or a metal. In other embodiments, the fiducial markers are non-metal (for example, MR-compatible). In certain embodiments, the animal holder has a plurality of wells for insertion of a solid or liquid marker substance therein to provide the fiducial markers for imaging.
[0030] In certain embodiments, the fiducial markers include an organic fluorophore, an inorganic fluorophore, an indocyanine dye, quantum dots, a visible-wavelength fluorophore, an infra-red fluorophore, a superparamagnetic agent, luminous acrylic, tritium beads, deionized water, and/or a radioactive agent.
[0031] In certain embodiments, the animal holder includes an inlet for delivery of anesthesia to the animal. In certain embodiments, the animal holder includes a heater for maintaining the animal within a given temperature range before and/or during imaging. In other embodiments, the animal holder is configured to fit within a docking station in which anesthesia can be delivered and/or a heater can be used to maintain the animal within a given temperature range before, during, and/or after imaging.
[0032] In certain embodiments, the frames of the animal holder have contoured edges for reduced stray light reflection. The imaging windows optionally can include an anti-reflective coating.
[0033] The description of elements of the embodiments of other aspects of the invention can be applied to this aspect of the invention as well.
[0034] In another aspect, the invention provides a method of imaging a region within an animal, the method including: (a) administering to an animal a probe (for example, a fluorophore); (b) positioning the animal within a portable animal holder including two adjustable, substantially parallel frames, wherein each of the frames includes an imaging window that transmits electromagnetic radiation therethrough; (c) securing the animal between the frames, thereby preventing substantial movement of the animal during imaging, and thereby providing two substantially planar boundary conditions; (d) optionally, administering anesthesia and/or heat to the animal while the animal is within the animal holder; (e) positioning the animal holder within a FMT imaging device configured to accept the animal holder; (f) directing excitation light, for example, through an imaging window of the animal holder, into the animal at multiple locations to transilluminate at least a portion of the animal; (g) optionally, detecting excitation light transmitted through the animal (and, for example, transmitted through the opposite imaging window of the animal holder); (h) detecting fluorescent light emitted from the probe within the animal (and, for example, transmitted through the opposite imaging window of the imaging holder); and (i) processing data corresponding to the detected emitted fluorescent light (and, optionally, processing data corresponding to the detected transmitted excitation light) to provide a tomographic representation of the region within the animal, wherein the two substantially planar boundary conditions are used in providing the tomographic representation.
[0035] In certain embodiments, the portable animal holder comprises a plurality of fiducial markers and the method further includes: (j) detecting locations of the plurality of fiducial markers in relation to the animal while the animal holder is within the FMT imaging device; (k) positioning the animal holder within a non-FMT imaging device configured to accept the animal holder; (l) obtaining image data from at least a portion of the animal with the non-FMT imaging device and detecting locations of the plurality of fiducial markers in relation to the animal while the animal holder is within the non-FMT imaging device; and (m) co-registering the tomographic representation obtained using the FMT imaging device with image data obtained using the non-FMT imaging device to produce a composite image of the region within the animal.
[0036] In certain embodiments, the non-FMT imaging device is a MR imaging device or a CT device. In certain embodiments, step (m) includes co-registering the FMT tomographic representation with the non-FMT image data using one or more affine transformations.
[0037] In certain embodiments, the non-FMT imaging device may employ one or more of the following imaging modalities: magnetic resonance, X-ray, X-ray computed tomography, nuclear, positron emission tomography (PET), single photon emission computed tomography (SPECT), ultrasound, and/or bioluminescence imaging.
[0038] In certain embodiments, the fiducial markers include a fluorescent compound, a gamma emitting compound, a positron emitting compound, a silicon polymer, and/or a metal. In other embodiments, the fiducial markers are non-metal (for example, MR-compatible). In certain embodiments, the animal holder has a plurality of wells for insertion of a solid or liquid marker substance therein to provide the fiducial markers for imaging.
[0039] In certain embodiments, the fiducial markers include an organic fluorophore, an inorganic fluorophore, an indocyanine dye, quantum dots, a visible-wavelength fluorophore, an infra-red fluorophore, a superparamagnetic agent, and/or a radioactive agent. In certain embodiments, the animal is a mammal, for example, a rodent, for example, a mouse.
[0040] The description of elements of the embodiments of other aspects of the invention can be applied to this aspect of the invention as well. For example, elements of the embodiments of the animal holder described above may be used in the imaging methods described herein.
[0041] In yet another aspect, the invention provides a method of imaging a region within an animal. The method comprises the steps of: (a) positioning an animal within a portable animal holder including two adjustable, substantially parallel frames, wherein each of the frames includes an imaging window that transmits electromagnetic radiation therethrough; (b) securing the animal between the frames, thereby preventing substantial movement of the animal during imaging and thereby permitting transport of the animal within the animal holder as a rigid body or pseudo-rigid body; (c) positioning the animal holder within a first imaging device configured to accept the animal holder; (d) obtaining image data using the first imaging device; (e) removing the animal holder from the first imaging device and positioning the animal holder within a second imaging device configured to accept the animal holder; (f) obtaining image data using the second imaging device; and (g) co-registering image data obtained from the first imaging device and the second imaging device to produce a composite image of a region within the animal. In certain embodiments, step (g) includes co-registering the image data using one or more affine transformations. In certain embodiments, the animal holder comprises a plurality of fiducial markers and the method comprises the step of detecting a position of each of one or more of the fiducial markers, and wherein step (g) comprises co-registering the image data using the one or more detected positions.
[0042] In certain embodiments, the first imaging device employs one or more of the following imaging modalities: magnetic resonance, X-ray. X-ray computed tomography, nuclear, positron emission tomography (PET), single photon emission computed tomography (SPECT), ultrasound, fluorescence, fluorescence (molecular) tomography (FMT), and/or bioluminescence imaging. In certain embodiments, the second imaging device employs one or more of the following imaging modalities: magnetic resonance, X-ray, X-ray computed tomography, nuclear, positron emission tomography (PET), single photon emission computed tomography (SPECT), ultrasound, fluorescence, fluorescence (molecular) tomography (FMT), and/or bioluminescence imaging. In certain embodiments, either the first or the second imaging device employs FMT, and the other employs a non-FMT imaging modality.
[0043] In certain embodiments, the fiducial markers include a fluorescent compound, a gamma emitting compound, a positron emitting compound, a silicon polymer, and/or a metal. In other embodiments, the fiducial markers are non-metal (for example, MR-compatible). In certain embodiments, the animal holder has a plurality of wells for insertion of a solid or liquid marker substance therein to provide the fiducial markers for imaging.
[0044] In certain embodiments, the fiducial markers include an organic fluorophore, an inorganic fluorophore, an indocyanine dye, quantum dots, a visible-wavelength fluorophore, an infra-red fluorophore, a superparamagnetic agent, and/or a radioactive agent.
[0045] In certain embodiments, the animal is a mammal, for example, a rodent, for example, a mouse.
[0046] The description of elements of the embodiments of other aspects of the invention can be applied to this aspect of the invention as well. For example, elements of the embodiments of the animal holder described above may be used in the imaging methods described herein.
[0047] Where FMT is one of the modalities, it is appreciated that one or more fluorophores can be detected. The one or more fluorophores can include an endogenous fluorophore and/or an exogenous (delivered) probe. The one or more fluorophores can include one or more examples of one or more of the following: a fluorescent molecular probe, an activatable fluorescent probe, an enzyme-activatable fluorescent probe, a quantum dot-based imaging probe, a fluorescent nanoparticle-based imaging probe, and/or a fluorescent probe targeted to a biomolecule. These materials can also (or alternatively) be used and detected as a fiducial marking substance. Other materials that can be detected by one or more modalities of a multiple-modality system of the present invention (detected as an endogenous substance in the animal, a substance administered to the animal, and/or a fiducial marking substance) include, for example: a wavelength shifting beacon, a multicolor fluorescent probe, a probe with high binding affinity to a target, a non-specific imaging probe, labeled cells, X-ray contrast agent, magnetic resonance contrast agent, a dual modality agent, an optical/CT dual modality agent (for example, an optical agent physically or chemically bound to a CT agent), an optical/MR dual modality agent (for example, an optical agent physically or chemically bound to an MR agent), a fluorescent lanthanide metal-ligand probe, a probe targeted to a biomarker, a molecular structure, a mineral (for example, hydroxyapatite), a biomolecule, and/or any combination of these. Where the probe is targeted to a biomolecule, the biomolecule can include, for example, one or more examples of one or more of the following: an antibody, a protein, a glycoprotein, a cell receptor, a neurotransmitter, an integrin, a growth factor, a cytokine, a lymphokine, a lectin, a selectin, a toxin, a carbohydrate, an internalizing receptor, an enzyme, a protease, a virus, a bacteria, a microorganism, and/or any combination thereof.
[0048] When an FMT modality is used, the light detected by the imaging system preferably includes excitation light from the light source that has been transmitted through the object and fluorescent light emitted from one or more fluorophores within the object. Data corresponding to the excitation light transmitted through the object, or intrinsic light, can be used to correct/calibrate captured fluorescent measurements, thereby providing more accurate tomographic images. The one or more fluorophores emit fluorescent light as a result of excitation by the excitation light. Background fluorescence can be accounted for by obtaining background measurements and processing data corresponding to the captured fluorescent light accordingly. For example, a background signal can be detected and used to generate a corrected measurement of the detected fluorescent light and/or a corrected measurement of the detected excitation light; the corrected measurement(s) can be used in the optical tomographic reconstruction. Image processing can include (i) generating a corrected measurement of the detected fluorescent light and a corrected measurement of the detected excitation light using data corresponding to the detected background light, (ii) generating a calibrated fluorescent measurement from the corrected fluorescent measurement and the corrected excitation light measurement, and (iii) using the calibrated fluorescent measurement in the optical tomographic reconstruction.
[0049] In FMT systems, processing includes simulating photon propagation at the excitation wavelength and simulating photon propagation at the emission wavelength in an optical tomographic reconstruction.
[0050] Methods of the invention can further include the step of using the tomographic image to perform one or more of the following: identifying an area of disease; distinguishing between diseased and normal tissue; localizing diseased tissue; detecting a boundary of a lesion; detecting a tumor; locating a boundary of a tumor; localizing a cell type; and/or characterizing a disease. Where the method includes the step of using the tomographic image to identify an area of disease, the disease may include at least one or more examples of one or more of the following: inflammation, cancer, cardiovascular disease, dermatologic disease, ophthalmic disease, infectious disease, immunologic disease, central nervous system disease, inherited disease, metabolic disease, environmental disease, and/or bone-related disease.
[0051] In certain embodiments, the steps of the method are repeated to obtain a plurality of tomographic images. The method permits the collection of a plurality of images because radiopharmaceuticals do not need to be used and radiotoxicity is not a concern, unlike in nuclear tomographic systems.
[0052] For example, in certain embodiments, the plurality of tomographic images are obtained as a function of time following administration of one or more probes including at least one of the one or more fluorophores. The plurality of tomographic images can be used, for example, to monitor localization of a cell type, monitor expression of a gene, monitor progression of a disease, and/or monitor a therapeutic response, for example, in drug development.
[0053] The step of monitoring localization of a cell type may include one or more examples of one or more of the following cell types: T-cells, tumor cells, immune cells, stem cells, and/or any combination thereof. The method may include the step of monitoring expression of a gene, where the gene encodes a fluorescent protein detected as one of the one or more fluorophores within the object. The step of monitoring therapeutic response can include performing one or more of the following using the plurality of tomographic images: (i) determining efficacy of an administered pharmacological substance; (ii) customizing dosage of a pharmacological substance; (iii) formulating a pharmacological substance; (iv) customizing a formulation of a pharmacological substance; (v) determining pharmacokinetic parameters of a pharmacological substance; and/or (vi) customizing a combination of pharmacological substances for the treatment of a disease.
BRIEF DESCRIPTION OF THE DRAWINGS
[0054] The objects and features of the invention can be better understood with reference to the drawings described below, and the claims. The drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the drawings, like numerals are used to indicate the same or similar parts throughout the various views.
[0055] FIG. 1 is an isometric view of the animal cassette, for example, a small animal cassette, for multimodality imaging in accordance with an embodiment of the present invention.
[0056] FIG. 2 is a side view of the animal cassette shown in FIG. 1 , according to an illustrative embodiment of the invention.
[0057] FIG. 3 is a top plan view of the animal cassette shown in FIG. 1 , according to an illustrative embodiment of the invention.
[0058] FIG. 4 is an end view of the animal cassette shown in FIG. 1 , according to an illustrative embodiment of the invention.
[0059] FIG. 5 is an exploded assembly of the animal cassette shown in FIG. 1 , according to an illustrative embodiment of the invention.
[0060] FIG. 6 is a cross-sectional view of the animal cassette shown in FIG. 1 , taken at the center of the height adjustment knob along the longitudinal axis, according to an illustrative embodiment of the invention.
[0061] FIG. 7 is an isometric view of the adjustment knob, according to an illustrative embodiment of the invention.
[0062] FIG. 8 is a partial trimetric view of a dial-readout gauge embedded within the animal cassette shown in FIG. 1 , according to an illustrative embodiment of the invention.
[0063] FIG. 9 is an isometric view of the dial-readout gauge, according to an illustrative embodiment of the invention.
[0064] FIG. 10 is a partial isometric view of the animal cassette showing fiducial wells in the Top tray, according to an illustrative embodiment of the invention.
[0065] FIG. 11 is an end view of the animal cassette shown in FIG. 1 , highlighting contoured edges of the Bottom and Top trays to reduce stray light reflections during imaging, according to an illustrative embodiment of the invention.
[0066] FIG. 12 is an isometric view of a calibration phantom (both top and bottom components shown separately and combined), according to an illustrative embodiment of the invention.
[0067] FIG. 13 is an isometric view of the calibration phantom and calibration phantom holder disposed within an exemplary animal holder (exploded and non exploded views), according to an illustrative embodiment of the invention.
[0068] FIG. 14 is a side-by-side comparison between animal cassettes of different sizes, according to an illustrative embodiment of the invention.
[0069] FIG. 15 is an isometric view of an external animal cassette docking station, according to an illustrative embodiment of the invention.
[0070] FIG. 16 is an isometric view of an external animal cassette docking station containing an animal cassette disposed therein, according to an illustrative embodiment of the invention.
[0071] FIG. 17 is a top view of an external animal cassette docking station containing an animal holder disposed therein, according to an illustrative embodiment of the invention.
[0072] FIG. 18 is an isometric view of two external animal cassette docking stations with gas connections connected in series, according to an illustrative embodiment of the invention.
[0073] FIG. 19 is a bottom view of an external animal cassette docking station, according to an illustrative embodiment of the invention.
[0074] FIG. 20 is an isometric view of an internal animal cassette docking station designed for imaging animals within the FMT system, according to an illustrative embodiment of the invention.
[0075] FIG. 21 is a top view of an internal animal cassette docking station designed for imaging animals within the FMT system, according to an illustrative embodiment of the invention.
[0076] FIG. 22 is a bottom view of an internal animal cassette docking station designed for imaging animals within the FMT system, according to an illustrative embodiment of the invention.
[0077] FIG. 23 is an end view of an internal animal cassette docking station designed for imaging animals within the FMT system, according to an illustrative embodiment of the invention.
[0078] FIG. 24 is an isometric view of an animal cassette, for example, a large animal cassette, for multimodality imaging in accordance with an embodiment of the present invention.
[0079] FIG. 25 is a side plan view of the animal cassette shown in FIG. 24 , according to an illustrative embodiment of the invention.
[0080] FIG. 26 is a cross-sectional view of the animal cassette shown in FIG. 24 , taken at the center of the height adjustment knob along the longitudinal axis, according to an illustrative embodiment of the invention.
[0081] FIG. 27 is a cross-sectional view of the animal cassette shown in FIG. 24 , taken at the center of the animal cassette along the transverse axis, according to an illustrative embodiment of the invention.
[0082] FIG. 28 is a partial isometric view of a large animal cassette embodiment allowing for direct connection of gas anesthesia administered through the gas pathway to the animal nose cone, according to an illustrative embodiment of the invention.
[0083] FIG. 29 is an isometric view of an internal animal cassette docking station designed for imaging animals within the FMT system, according to an illustrative embodiment of the invention.
[0084] FIG. 30 is a top view of an internal animal cassette docking station designed for imaging animals within the FMT system, according to an illustrative embodiment of the invention.
[0085] FIG. 31 is a bottom view of an internal animal cassette docking station designed for imaging animals within the FMT system, according to an illustrative embodiment of the invention.
[0086] FIG. 32 is an end view of an internal animal cassette docking station designed for imaging animals within the FMT system, according to an illustrative embodiment of the invention.
[0087] FIG. 33 is a partial cross-sectional view of an internal large animal cassette docking station gas pathway taken along the longitudinal axis, according to an illustrative embodiment of the invention.
[0088] FIG. 34 is an isometric view of an internal animal cassette docking station designed for imaging animals within an MR system, according to an illustrative embodiment of the invention.
[0089] FIG. 35 is a partial side view of an internal animal cassette docking station designed for imaging animals within an MR system detailing the gas anesthesia connections and MR depth adjustment, according to an illustrative embodiment of the invention.
[0090] FIG. 36 is an isometric view of an internal animal cassette docking station designed for imaging animals within a CT system, according to an illustrative embodiment of the invention.
[0091] FIG. 37 is a partial side view of an internal animal cassette docking station designed for imaging animals within a CT system detailing the gas anesthesia connections, according to an illustrative embodiment of the invention.
[0092] FIG. 38 is an isometric view of an internal animal cassette docking station designed for imaging animals within a different CT system, according to an illustrative embodiment of the invention.
[0093] FIG. 39 is a partial side view of an internal animal cassette docking station designed for imaging animals within a different CT system detailing the gas anesthesia connections, according to an illustrative embodiment of the invention.
[0094] FIG. 40 is a series of side views of an internal animal cassette docking station designed for imaging animals within a different CT system detailing three positions of the sliding rail, according to an illustrative embodiment of the invention.
[0095] FIG. 41 is an isometric view of an internal animal cassette docking station designed for imaging animals within a different CT system, according to an illustrative embodiment of the invention.
[0096] FIG. 42 is a partial side view of an internal animal cassette docking station designed for imaging animals within a different CT system detailing the gas anesthesia connections, according to an illustrative embodiment of the invention.
[0097] FIG. 43 shows excitation and fluorescence images of a mouse being imaged within the animal cassette, according to an illustrative embodiment of the invention.
[0098] FIG. 44 shows an isometric view of an FMT dataset overlaid upon an excitation image of a mouse with a fluorescence phantom disposed within the abdomen imaged within an animal holder, according to an illustrative embodiment of the invention.
[0099] FIG. 45 shows an isometric view of an FMT dataset overlaid upon a fluorescence image of a mouse with a fluorescence phantom disposed within the abdomen imaged within an animal holder, according to an illustrative embodiment of the invention.
[0100] FIG. 46 shows an isometric view of an MR dataset overlaid upon an fluorescence image of a mouse with a fluorescence phantom disposed within the abdomen imaged within an animal holder, according to an illustrative embodiment of the invention.
[0101] FIG. 47 shows an isometric view of a fusion of a FMT dataset and a MR dataset overlaid upon an excitation/fluorescence overlay image of a mouse with a fluorescence phantom disposed within the abdomen imaged within an animal holder, according to an illustrative embodiment of the invention.
[0102] FIG. 48 shows an isometric view of a fusion of a FMT dataset and a MR dataset of a mouse with a fluorescence phantom disposed within the abdomen imaged within an animal holder, according to an illustrative embodiment of the invention.
[0103] FIG. 49 is a flow chart showing steps in a process to fuse MR, CT and FMT imaging modalities of a small animal imaged in the animal holder according to an illustrative embodiment of the invention.
[0104] FIG. 50 is a flow chart showing steps in a process to align imaged fiducial markers from MR, CT and FMT imaging modalities of a small animal imaged in the animal holder according to an illustrative embodiment of the invention. FIG. 50 provides, by way of example, a sample procedure for co-registering (for example, fusing) data sets by minimizing the error between centers of mass of the fiducials.
[0105] FIG. 51 illustrates the contoured edges of the top and bottom trays (frames) of the portable animal cassettes to reduce stray light reflections into the numerical aperture (NA) of the imaging device during reflectance and tomographic imaging, according to an illustrative embodiment of the invention.
DETAILED DESCRIPTION
[0106] It is contemplated that methods, systems, and processes described herein encompass variations and adaptations developed using information from the embodiments described herein.
[0107] Throughout the description, where systems and compositions are described as having, including, or comprising specific components, or where processes and methods are described as having, including, or comprising specific steps, it is contemplated that, additionally, there are systems and compositions of the present invention that consist essentially of, or consist of, the recited components, and that there are processes and methods of the present invention that consist essentially of, or consist of, the recited processing steps.
[0108] The mention herein of any publication, for example, in the Background section, should not be construed as an admission that the publication serves as prior art with respect to any of the claims presented herein.
[0109] As used herein, the term “image” is understood to mean a visual display or any data representation that may be interpreted for visual display. For example, a three-dimensional image may include a dataset of values of a given quantity that varies in three spatial dimensions. A three-dimensional image (for example, a three-dimensional data representation) may be displayed in two-dimensions (for example, on a two-dimensional screen, or on a two-dimensional printout).
[0110] As used herein, the term “map” is understood to mean a visual display, or any data representation that may be interpreted for visual display, which contains spatially-correlated information. For example, a three-dimensional map of a given volume may include a dataset of values of a given quantity that varies in three spatial dimensions throughout the volume, and the three-dimensional map may be displayed in two-dimensions.
[0111] FIGS. 1-14 illustrate one embodiment of the present invention where an animal holder I for multimodality tomographic imaging includes an adjustment mechanism 1 , fiducial wells 2 and two imaging windows 3 , one disposed in the bottom tray 4 and one in the top tray 5 . The adjustment mechanism 1 repeatably and deterministically set the separation distance and parallelism of the two imaging windows.
[0112] The adjustment mechanism 1 in a preferred embodiment includes height adjustment knobs 7 , knob bearings 8 , retaining rings 10 , height readout dials 11 , wave springs 12 , ball spring plungers 13 , height adjustment nuts 6 , screws 19 , top tray 5 and bottom tray 4 (see FIG. 5 ). In general, all of the components with the possible exception of the ball spring plungers 13 and wave springs 12 may be molded, cast, or machined out of plastics, resins, or non-ferrous metals such as stainless steel, aluminum, titanium or beryllium copper. The height adjustment knobs 7 , knob bearings 8 , height adjustment nuts 6 , and top tray 5 and bottom tray 4 may also be rapid prototyped out of plastics, resins, etc. The imaging windows 3 should be translucent for optical FMT imaging, MR imaging, and CT imaging. Although translucent glass is preferred, plastics, resins, and other similar materials can be used.
[0113] The height adjustment knobs 7 allow the user to deterministically and repeatably set the distance between top tray 5 and bottom tray 4 to discrete distances and maintain parallelism. Gentle compression of the specimen between the top tray 5 and bottom tray 4 ensures that the animal does not move during imaging, during transport to the different imaging modalities, and also gives two deterministic boundary conditions for modeling the mouse tissue for quantitative FMT reconstruction. Height readouts 9 show the relative heights of the adjustment knobs 7 . As shown in FIG. 5-7 , ball spring plungers 13 ride into the detents 14 in the side of the height adjustment knobs 7 forcing the height adjustment knobs 7 into repeatable and deterministic angular orientations. The height adjustment knob rotations are converted to linear motion via threads between the height adjustment knobs 7 and height adjustment nuts 6 ; thus setting the distance between the top tray 5 and bottom tray 4 . The height adjustment knob 7 is secured to the knob bearing 8 by way of a wave spring 12 and a retaining ring 10 (see FIG. 6 ). The knob bearing 8 is secured to the top tray 5 via the T slot cutout 17 , height adjustment knobs 7 , and screw 19 (see FIGS. 6 and 17 ). The height adjustment knob 7 contains a male thread 15 that corresponds to female thread 16 defined by height adjustment nut 6 (see FIG. 6 ). Height adjustment knob 7 also defines a dial alignment keyway 18 (see FIG. 7 ), that interfits with height readout dial adjustment key 20 defined by height readout dial 11 (see FIG. 9 ). The height readout dial alignment key 20 engages with height readout dial alignment keyway 18 (see FIGS. 7-9 ). When assembled, screw 19 and screw cutout 21 (see FIGS. 8 and 9 ) provide a positive stop for the height adjustment knob 7 at the low position “13” and top position “Off,” when height adjustment knob 7 is rotated.
[0114] In one embodiment, height readout dial 11 allows the user to determine the distance between top tray 5 and bottom tray 4 (see FIG. 5 , 6 , 8 ). The height readout dial 11 is keyed to the height adjustment knob 7 and the current height setting can be viewed through apertures defined by the top of top tray 5 (see FIGS. 3 , 8 , 9 ). Setting both adjustment knobs to the same height ensures that the imaging windows 3 are parallel and separated by a known distance and are held to strict tolerances.
[0115] The height adjustment nut 6 is secured to the bottom tray 4 via T-slot cutout 17 and screws 19 (see FIG. 5 , 11 ). Imaging windows 3 made of glass or translucent plastic allow tomographic imaging of the specimen within the animal cassette. The windows may be epoxy glued or cast into top tray 5 and bottom tray 4 during the manufacturing and assembling process to secure the window within the cassette and increase the stiffness of the animal holder (see FIG. 5 ).
[0116] Fiducial wells 2 along the top and bottom of both top tray 5 and bottom tray 4 easily allow data fusion between the tomographic imaging modalities (see FIGS. 10 , 11 ). Droplets of fluorescent dye or water can be injected into the fiducial wells 2 for FMT and MR imaging respectively. Similarly, other materials can be used as fiducial markers, including but not limited to organic fluorophores, inorganic fluorophores, indocyanine dyes, quantum dots, visible-wavelength fluorophores, infra-red fluorophores, super-paramagnetic agents, radioactive agents, and others. These materials can be provided in liquid form as droplets within the fiducial wells directly, or as solutions encapsulated in sealed containers inserted into the fiducial wells, for single-use imaging or multi-use imaging. These materials can also be provided in solid form as inserts into the fiducial wells directly, or encapsulated within sealed containers such as radioactive-sealing compartments. CT imaging does not require fluid injections as the fiducial wells can easily be detected due to the differences in density of the tray and fiducial well. A more detailed description of multimodality imaging and data fusion will be described later below. The animal holder can be imaged with the top tray up or with the cassette rotated 180 degrees about the longitudinal axis such that the bottom tray is up. This allows the user to load the animal in any orientation (dorsal or ventral) into the cassette. The animal can be imaged in the cassette dorsally or ventrally as the cassette is can be imaged in any orientation.
[0117] FIG. 11 illustrates the contoured edges 22 of top tray 5 and bottom tray 4 , which are configured to reduce stray light reflections. As discussed in more detail in connection with FIG. 51 , scattered light emanating from the animal preferably is reflected away from the detector to improve imaging. Stray light emanating from the animal or around the animal hit the contoured edges of the animal holder, which are shaped in such a manner as to re-direct the scattered light outside the numerical aperture of the detector. As a result, contoured edges 22 reduce the amount of scattered light that can hit the detector, which as a result, increases the signal-to-noise ratio of the detection technique.
[0118] FIGS. 12 and 13 illustrate a calibration phantom comprising a calibration phantom top 23 that interfits with a calibration phantom bottom 24 defining calibration phantom cavity 25 . The calibration phantom containing the top 23 and bottom 24 can be inserted into a calibration phantom holder 26 that can then be placed within an animal holder I of the invention (see FIG. 13 ).
[0119] FIG. 14 illustrates two different exemplary animal cassettes for small animals of differing sizes. For example, the small animal cassette denoted as IA can be used for smaller rodents, for example, mice, whereas the larger animal cassette denoted as IB can be used to image larger animals, for example, rats, bats and squirrel monkeys.
[0120] FIGS. 15-23 and 30 - 42 illustrate different animal holder mounts that can be inserted into FMT, MR and CT imaging systems. The external docking station denoted as II (as shown in FIGS. 15-19 ) is used primarily as a holding station for the animal while another animal is being imaged in the tomographic system. The external docking station, for example, as shown in FIG. 15 , comprises an external, docking station base 29 , an external docking station window 28 . Base 29 defines an animal alignment guide 27 . Base 29 and window 28 contains magnets 31 affixed thereto that interact with one another to hold the base 29 and window 28 in place, and a gasket 32 provides an air seal (see FIG. 16 ). The base 29 further comprises female quick connects 30 , power switch 40 , an anesthesia label 42 , and an exhaust label 43 . Window 28 further comprises a handle 41 for moving the window 28 relative to base 29 . As shown in FIG. 17 , the base further comprises an anesthesia valve 34 for introducing anesthesia into the holder via anesthesia part 35 . Exhaust port 36 exhausts gas out of the holder.
[0121] When in use, the user, for example, places the animal into the holder ( FIG. 16 ), by removing the top tray and places the animal into the holder using the animal alignment guide 27 ( FIG. 15 , 17 ) to position the animal within the desired scan region. The user then places the top tray 5 back onto the holder and sets the height adjustment knobs 7 to a known height. Then, the user closes the external docking station window 28 and gas anesthesia is dispensed to keep the animal sedated. FIG. 18 illustrates the serial connection the anesthesia of two or more external docking stations II via quick connects 30 and 33 .
[0122] Also, as detailed in FIG. 19 , the external docking station is equipped with one or more heaters 38 which can be used to regulate, via thermostats 39 , the body temperature of the animal. This can protect the animal from hypothermia, which is possible when the animals are anesthetized. The heaters 38 provided in the docking station can be made of electric resistive heating sheets, such as sheets manufactured by Omega Engineering (Stamford, Conn.) coupled to one or several thermostats regulating the set temperature of the assembly, such as thermostats manufactured by Thermtrol Corporation (North Canton, Ohio). The thermostats can be set to animal body temperature, or 37° C. in the case of most mammals. As shown from underneath, the external docking station contains a power connector 44 and fuse 45 . The base also contains a lid stop block 46 for stopping the movement of external docking station window 28 . The base also contains wire tie down 47 for securing the wiring and anesthesia tubes (not shown). The associated wiring connects heaters 38 and thermostats 39 to the terminal block 48 and electrical connector 56 . The associated tubing connects the anesthesia port 35 and exhaust port 36 to the anesthesia quick connect 62 and exhaust quick connect 63 . The conduits contain T connection 49 to route anesthesia gas to anesthesia port 35 and route waste gas from the exhaust port 36 via tubing which is not shown.
[0123] FIG. 20-23 illustrate an animal holder internal docking station denoted III for imaging an animal in the FMT system. The internal docking station III comprises an internal docking station top 50 that interfits with an internal docking station bottom 51 . The top 50 defines fiducial pass-throughs 52 . The docking station further comprises an internal docking station door 53 . From top view (see FIG. 21 ), the base docking station comprises a trans-illumination window 54 , through which the animal can be exposed to the source of the imaging system for collecting tomographic data. The bottom 51 is connected to a left mounting leg 59 and a right mounting leg 60 . Disposed within left mounting leg 59 is threaded ball 55 for adjusting the position of the docking station for alignment and thumbscrew 64 for fixing the docking station into place inside an FMT system. Attached to right mounting leg 60 is connecting bracket 61 , anesthesia quick connect 62 , exhaust guide connect 63 and electrical connector 56 . As shown in FIG. 23 , the internal docking station comprises sealing gasket 67 for sealing the small animal holder IA within the internal docking station and anesthesia can be introduced into the small animal holder IA via anesthesia plenum 57 . The animal holder IA is placed into the internal docking station III (see FIG. 23 ) and door 53 is closed. Upon closing the door, gas anesthesia is dispensed into the plenum 57 and vacuum connected to the exhaust port 36 draws the anesthesia across the mouse body ( FIG. 23 ). As shown in FIGS. 20 and 21 , fiducial pass-through holes 52 allow reflectance imaging of the fiducial wells 2 defined by the animal holder.
[0124] FIG. 24-28 illustrate a large animal holder IB for multimodality tomographic imaging. The animal holder, as shown in FIG. 24 , comprises a top tray 68 that interfits with bottom tray 69 , two imaging windows 70 , a plurality of fiducial wells 71 , an adjustment mechanism 114 that contains among other things height adjustment knobs 72 , and a nose cone 73 for dispensing anesthetic to the animal disposed within the holder. As shown in FIG. 25 , top tray 68 defines window retainer top 76 and bottom tray 69 defines a window retained bottom 77 . The bottom tray 69 further defines detents 74 that provide a positive stop at three present positions. In an exemplary FMT system, a camera visualizes an area of about 80 mm×80 mm. Detents 74 allow a user to scan the full body of an animal by providing stops that allow the scanned areas to be slightly overlapped.
[0125] Adjustment mechanism 114 repeatably and deterministically sets the separation distance and parallelism of the two imaging windows. The adjustment mechanism 114 in one embodiment, and as shown in FIG. 26 , includes height adjustment knobs 72 , wave springs 12 , retaining rings 10 , male thread 80 , ball spring plungers 78 , female thread 81 , screws 82 , top window retainer 76 , bottom window retainer 77 , atop tray 68 and a bottom tray 69 . In general, the components with the possible exception of the ball spring plungers 78 , male thread 80 , and wave springs 12 may be molded, cast, or machined out of plastics, resins, or non-ferrous metals such as Stainless Steel, Aluminum, Titanium or Beryllium Copper. The height adjustment knobs 72 , top window retainer 76 , bottom window retainer 77 , top tray 68 and bottom tray 69 may also be rapid prototyped out of plastics, resins, etc. The imaging windows 70 preferably are translucent for optical FMT imaging, MR imaging, and CT imaging. Although translucent glass is preferred, plastics, resins, and other similar translucent materials can be used to fabricate imaging windows 70 .
[0126] The height adjustment knobs 72 and male thread 80 allow the user to deterministically and repeatably set the distance between top tray 68 and bottom tray 69 to discrete distances and maintain parallelism. Gentle compression of the specimen between the top tray 68 and bottom tray 69 ensures that the animal does not move during imaging, during transport to the different imaging modalities, and also gives two deterministic boundary conditions for modeling the mouse tissue for quantitative FMT reconstruction. As shown in FIG. 26 , ball spring plungers 78 ride into the detents 79 in the side of the height adjustment knobs 72 forcing the height adjustment knobs 72 into repeatable and deterministic angular orientations. The height adjustment knob rotations are converted to linear motion via threads between the male thread 80 and female thread 81 ; thus setting the distance between top tray 68 and bottom tray 69 . The height adjustment knob 72 is secured to top tray 68 by way of a wave spring 12 and a retaining ring 10 (see FIG. 26 ).
[0127] In one embodiment, as shown in FIG. 25 , a height scale 75 allows the user to determine the distance between top tray 68 and bottom tray 69 . Setting both adjustment knobs to the same height ensures that the imaging windows 70 are parallel and separated by a known distance and are held to strict tolerances.
[0128] The female thread 81 is secured to the bottom tray 69 via screws 82 (see FIG. 26 ). Imaging windows 70 made of, for example, glass or translucent plastic, allow tomographic imaging of the specimen within the animal holder. The windows are secured to top tray 68 and bottom tray 69 with top window retainer 76 and bottom window retainer 77 .
[0129] Fiducial wells 71 along the top of top tray 68 allow data fusion between the tomographic imaging modalities (see FIGS. 24 and 27 ). Droplets of fluorescent dye or water can be injected into the fiducial wells 71 for FMT and MR imaging, respectively. Similarly, other materials can be used as fiducial markers, including but not limited to organic fluorophores, inorganic fluorophores, indocyanine dyes, quantum dots, visible-wavelength fluorophores, infra-red fluorophores, super-paramagnetic agents, radioactive agents, and others. These materials can be provided in liquid form as droplets within the fiducial wells directly, or as solutions encapsulated in sealed containers inserted into the fiducial wells, for single-use imaging or multi-use imaging. These materials can also be provided in solid form as inserts into the fiducial wells directly, or encapsulated within sealed containers such as radioactive-sealing compartments. CT imaging does not require fluid injections as the fiducial wells can easily be detected due to the differences in density of the tray and fiducial well. A more detailed description of multimodality imaging and data fusion is described below. The animal holder can be imaged with the top tray up or with the cassette rotated 180 degrees about the longitudinal axis such that the bottom tray is up. This allows the user to load the animal in any orientation (dorsal or ventral) into the cassette. The animal can be imaged in the cassette dorsally or ventrally as the cassette is can be imaged in any orientation.
[0130] FIG. 27 illustrates contoured edges 113 of the top tray 68 , bottom tray 69 , top window retainer 76 , and bottom window retainer 77 to reduce stray light reflections into the numerical aperture (NA) of the imaging device during reflectance and tomographic imaging. The contoured edges are shaped to re-direct the reflected light outside the numerical aperture of the objective lens or other optical device placed in front of the detector. As the reflected and re-directed stray light falls outside the numerical aperture or acceptance cone of the detector optics, such stray light will have no (or very limited) disruptive impact on the detection of useful signal, which enhances the signal-to-noise ratio of the detection technique. FIG. 27 also shows gas pathway 86 through which anesthesia can be introduced into the holder.
[0131] FIG. 28 illustrates one approach for sedating a large animal via direct connection of gas anesthesia and vacuum to the animal holder. The gas anesthesia is passed through the holder via gas pathway 86 and into flexible tubing (not shown) attached at one end to barbed fitting 83 and attached at the other end to the animal nose cone 73 . The barbed fitting 83 is immobilized in bottom tray 64 by means of set screw 84 and O-ring 85 . The nose cone 73 is placed adjacent the animal's head and allows gas anesthesia scavenging through the vacuum line connection. Inhalation or gas anesthesia, such as isoflurane- or halothane-based anesthesia is a common and sometimes preferred anesthesia technique in animal-handling environments. An inhalation anesthesia delivery system, such as products offered by LEI Medical (Boring, Oreg.), administers a mixture of the anesthetic gas (for example, isoflurane) with pure oxygen. The animal usually is sedated in a sealed induction-chamber. When ready to be imaged, the anesthetized animal is retrieved from the sealed induction-chamber and placed in the imaging instrument, for example, in the animal holder described herein.
[0132] As illustrated in FIG. 28 , inhalation anesthesia can be delivered in order to maintain the animal in its sedated state during imaging. In certain embodiments, such as in the case of small animal imaging, a nose cone may not be necessary for gas anesthesia delivery and the animal may receive anesthesia directly within a gas-flooded chamber. In certain embodiments, an animal respiration monitor is used to coordinate optimal image recording conditions with the animal's physical state. For example, a pressure transducer can allow respiratory gating whereby the imaging device is triggered to take images only during a particular phase of the respiratory cycle, minimizing motion artifacts.
[0133] FIGS. 29-33 illustrate an animal holder internal docking station for imaging an animal in the FMT system. As shown in FIGS. 29-31 , the animal holder docking station comprises an internal docking station top 87 that interfits with docking station bottom 88 . The docking station bottom 88 is coupled to left mounting leg 91 and right mounting leg 92 . Ball spring plungers 115 (see FIG. 29 ) engage detents 74 of the animal holder (see FIG. 25 ). The plungers connect to the detents to hold the animal holder in position. The whole bodies of large animals such as rats can be scanned by changing the position of the holder within the docking station. The detents mark an animals position for consistent imaging. Wire tie downs 58 (see FIGS. 20 , 29 and 30 ) serve to secure the wiring and anesthesia tubing (not shown), which are part of the internal docking stations. The associated wiring connects heaters 38 and thermostats 39 to the terminal block 48 and electrical connector 56 . The associated tubing connects the anesthesia port 35 and exhaust port 36 to the anesthesia quick connect 62 and exhaust quick connect 63 , respectively.
[0134] Docking station top 87 defines a plurality of fiducial well pass through holes 90 , to allow reflectance imaging of the fiducial wells 71 defined by the animal holder. The anesthesia can be controlled by anesthesia valve 89 . The docking station comprises a trans-illumination window 93 , which permits imaging of the animal. FIG. 32 shows that the docking station comprises gas pathway 94 for introducing gas, for example, anesthesia, into and out of the animal holder IB. The animal holder is placed into the internal docking station ( FIG. 32 ). Upon insertion, gas anesthesia is dispensed into the animal holder and vacuum connected to the exhaust port 36 draws the anesthesia across the mouse body ( FIG. 32 ).
[0135] FIGS. 34-35 illustrate an animal holder docking station for imaging an animal in an MR system. The animal holder IA is placed into a slot defined by the docking station (see FIG. 34 ). The docking station comprises an MR animal holder mount 96 which defines a cavity for receiving the animal holder and counter weight 95 . The MR docking station then is placed concentrically into the MR coil to be imaged. The user can adjust the depth to which the animal cassette is placed into the MR coil by sliding the MR depth adjustment 98 and the depth is noted by MR depth readout 97 . There can be provisions to pass heated air over the animal body in order to prevent hypothermia from long imaging sessions, along with a gas anesthesia inlet 99 to keep the animal sedated. Gas block 109 permits the delivery of anesthesia to the holder when the holder is placed in the adapter. Anesthesia is routed through tubing (not shown) which is connected to anesthesia inlet 99 . The anesthesia passes through the inlet 99 and gas block 109 to the cavity of the adapter that houses the animal holder (denoted as IA in FIG. 35 ).
[0136] FIGS. 36-42 depict three different CT mounts (Gamma Medica, Siemens Inveon, and GE CT) that allow the small animal holder to mount into three different CT systems. FIG. 36 shows small animal holder IA disposed within a CT mount containing an adapter tube 100 connected to adapter mount 101 via adapter block 102 that further defines anesthesia inlet 99 . The anesthesia system is shown more specifically in FIG. 37 where anesthesia is introduced through anesthesia inlet 99 and passes through gas pass through 103 . FIGS. 38 and 39 show the small animal holder IA disposed in adapter tube 100 , which is connected to adapter block 105 . The animal holder can be moved via sliding rail assembly 107 that translates relative to the adapter mount 106 . Anesthesia can be introduced via gas pass through 108 . As shown in FIG. 40 , the animal holder can translate through a plurality of positions referred to as position 1 , position 2 , and position 3 .
[0137] FIGS. 41 and 42 show another CT mount, where animal holder IA is placed within adapter tube 100 , which is connected to adapter block 110 that contains adapter mount 111 .
[0138] FIG. 43-48 depict images of a mouse imaged in an animal holder of the invention. FIG. 43 show an excitation image ( FIG. 43A ), a fluorescence image ( FIG. 43B ), and overlayed excitation and fluorescence images ( FIGS. 43C ). The mouse is shown in animal holder IA, where the fiducial wells are visible in both the excitation image ( FIG. 43A ) and the fluorescence image ( FIG. 43B ). The fluorescence images also show the fluorescent phantom (see FIGS. 43B and 43C ).
[0139] FIGS. 44-48 illustrate fused MR and FMT images of a mouse with a phantom filled with Alexa Fluor 680 (Invitrogen, Carlsbad, Calif.) inserted into the mouse's abdomen. The excitation and fluorescence images ( FIG. 44 and FIG. 45 , respectively), both of which are overlayed with the FMT dataset, clearly show the location of the fluorescence phantom within the mouse and the fiducial wells. The fluorescence image was registered with the MR dataset using the fiducial wells in each dataset to determine the relative locations of the two datasets, as shown in FIG. 46 . Fused images of the FMT and MR datasets are shown in FIGS. 47-48 , which clearly show the correlation between the FMT and MR data, as indicated by the co-localization of the phantom in the FMT reconstruction and the MR scan. The images demonstrate that the animal holder can be used to facilitate imaging across multiple modalities and to facilitate co-registration of the resulting images.
[0140] FIG. 49 is a flow chart illustrating the process of fusing two or more datasets from the tomographic imaging systems. Instructions for an exemplary multimodality imaging session include: (1) placing the animal into the animal holder, (2) imaging the animal in a tomographic system once fiducial wells have been filled with appropriate marker (if needed), (3) exporting the reconstructed tomographic image using relevant software, and (4) repeating steps 2 and 3 for each modality the user is interested in. Once all the datasets have been collected, the user then can fuse the datasets via software such as Amira (Visage Imaging, Carlsbad, Calif.) (see FIG. 50 ). If the dataset is an FMT dataset, the user can compute the center of mass of at least two fiducial wells from the reflectance images, giving the x and y locations of each fiducial. The z location of the fiducial can be computed from the adjustment knob height and knowing the fiducial well offsets within the animal holder. If the dataset is from an MR or CT system, the center of mass of at least three fiducial wells can be found in the tomographic data, giving their x,y,z coordinates. To fuse the datasets, an affine transformation (scale and rotate) is applied to all but one dataset such that the x,y,z locations match. In one embodiment, the user can apply a least squares error fitting scheme to compute the appropriate affine transformation. Once the datasets have been scaled and aligned properly then they can be displayed, for example, as shown in FIGS. 47 and 48 .
[0141] As depicted in FIG. 50 , when registering an FMT dataset with that from another modality, a first step in the co-registration process is the extraction of centers of mass (COM) of a plurality of fiducial markers. As these fiducial markers are imaged in reflectance, the location of the centers of mass can be computed based on an optical reflectance image, as part of the FMT acquisition. The optical reflectance image, FMT tomographic dataset, and other modality tomographic dataset can then be co-registered. It is also possible to import this same fiducial information into the FMT tomographic reconstructed dataset directly and integrate the fiducial marker information within the voxel mesh. One of the benefits of such an approach includes eliminating one step in the general process of fusing FMT and other modality datasets together, so that only two datasets (FMT and other modality) need to be co-registered instead of three.
[0142] FIG. 51 shows an exemplary animal holder I having contoured edges 22 of the top tray and the bottom tray to reduce stray light reflections into the numerical aperture (NA) 116 of the imaging device, which as shown includes lens 117 and camera 118 , during reflectance and tomographic imaging. During trans-illumination imaging, the incoming light 119 passes through the animal and diffuses through the animal tissue. The diffusion process scatters the light in random directions resulting in the scattered light 120 emanating from the mouse tissue in all directions. The stray light emanating from the animal preferably is reflected away from the camera in order to reduce their effects upon the automatic camera exposure settings. As shown in FIG. 51 , the stray light emanating from the animal or from around the animal hits the contoured edges of the animal holder, which re-direct the reflected light outside the numerical aperture of the objective lens or other optical device placed in front of the detector. As the reflected and re-directed stray light falls outside the numerical aperture or acceptance cone of the detector optics, such stray light will have little or no disruptive impact on the detection of useful signal, which enhances the signal to noise ratio of the detection technique.
Example 1
Multi-Modality Imaging using the Animal Holder
[0143] An example of multi-modality imaging is depicted in FIGS. 46-48 . Alexa Fluor 680 (AF 680) dye (Invitrogen, Carlsbad, Calif.) was dissolved in water and injected into a plastic imaging phantom. The imaging phantom was surgically inserted subcutaneously into the thoracic cavity of an adult NU/NU mouse (Charles River Laboratories, Wilmington, Mass.). The mouse then was placed into an animal holder of the invention and secured for imaging before the entire cassette was placed inside an FMT2500 imaging system (VisEn Medical, Inc., Bedford, Mass.). Free dye dissolved in water (AF 680) was injected into the fiducial wells of the animal holder. An FMT imaging dataset was collected and subsequent reconstruction was performed using software included in the FMT2500. The animal holder containing the same mouse then was placed inside a 7 Tesla Bruker MR system (Bruker BioSpin, Billerica, Mass.) and an MR dataset was collected using Paravision 4 acquisition software. Fusion of the FMT and MR datasets was performed using Amira software (Visage Imaging, Carlsbad, Calif.). This demonstrates the use of an animal holder of the invention for performing multi-modality experiments on the same animal and co-registering the resulting imaging data to produce an accurate composite image.
INCORPORATION BY REFERENCE
[0144] The teachings of all the references, patents and patent applications cited herein are expressly incorporated by reference herein in their entirety for all purposes.
[0145] The text of the following documents is incorporated herein by reference and this subject matter may be applied in the embodiments described herein: U.S. Pat. No. 6,615,063; U.S. Patent Application Publication No. US2004/0015062; International (PCT) Patent Application Publication No. WO03/102558; International (PCT) Patent Application Publication No. WO2004/072906; and International (PCT) Patent Application Publication No. WO2007/111669.
Equivalents
[0146] While the invention has been particularly shown and described with reference to specific preferred embodiments, it should be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. | The invention facilitates transport of an immobilized, anesthetized small animal across multiple single-modality or multiple-modality imaging workstations at the same or different physical locations without loss of subject positional information. The animal holder is compatible with preclinical animal imaging stations such as micro-CT, micro-MR, micro-PET, micro-SPECT, and FMT. The animal holder is configured to be accommodated by (for example, fit within) individual imaging chambers of such instruments and is fabricated from materials that are compliant with all of the imaging modalities used. In certain embodiments, an integrated set of fiducial marker wells accommodates the dispensing of markers that are picked up by several modalities simultaneously in multiple planes. The fiducial markers then are aligned in standard image processing or image analysis software with simple image translation and rotation operations, without the need for more advanced scaling, distortion or other operations. The animal holder optionally also includes a system for providing the animal with inhalation anesthesia, for example, isoflurane, and is designed to fit into identical receptacles inside or outside the imaging workstation(s) that provide heating to minimize or prevent animal hypothermia. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and the benefit of Korean Patent Application No. 10-2009-0071276, filed on Aug. 3, 2009, in the Korean Intellectual Property Office, the entire content of which is incorporated herein by reference.
BACKGROUND
[0002] 1. Field
[0003] One or more embodiments of the present invention relate to an organic light emitting display and a method of driving the same.
[0004] 2. Description of the Related Art
[0005] Various flat panel displays (FPD) that are lighter in weight and smaller in volume than comparable cathode ray tube (CRT) displays are being developed. Non-limiting examples of the FPDs include a liquid crystal display (LCD), a field emission display (FED), a plasma display panel (PDP), and an organic light emitting display.
[0006] Among the FPDs, the organic light emitting display displays an image using organic light emitting diodes (OLED) that generate light by re-combination of electrons and holes generated to correspond to the flow of current.
[0007] The organic light emitting display is widely utilized in a personal digital assistant (PDA), an MP3 player, and/or a mobile telephone due to its excellent color reproducibility and small thickness.
[0008] FIG. 1 is a block diagram illustrating the structure of an organic light emitting display according to an embodiment of the present invention. Referring to FIG. 1 , the organic light emitting display includes a pixel unit (a display region) 10 , a data driver 20 , a scan driver 30 , and a controller 40 .
[0009] A plurality of pixels 11 are arranged in the pixel unit 10 and each of the pixels 11 includes an organic light emitting diode (OLED) that emits light to correspond to the flow of current therein. The pixel unit 10 includes n scan lines S 1 , S 2 , . . . , Sn−1, and Sn formed to extend in a first direction (a row direction) and to transmit scan signals, and m data lines D 1 , D 2 , . . . , Dm−1, and Dm formed to extend in a second direction (a column direction) crossing the first direction and to transmit data signals.
[0010] In addition, the pixel unit 10 receives a first power of a first power source and a second power of a second power source having a lower voltage level than that of the first power source to be driven. Therefore, in the pixel unit 10 , current flows to the OLED by utilizing the scan signals, the data signals, the first power source, and the second power source to emit light and to display an image.
[0011] The data driver 20 receives data driver control signals DCS and image signals R, G, B data from the controller 40 to generate the data signals. The data driver 20 is coupled to the data lines D 1 , D 2 , . . . , Dm−1, and Dm of the pixel unit 10 to apply the generated data signals to the pixel unit 10 .
[0012] The scan driver 30 receives scan driver control signals SCS from the controller 40 to generate the scan signals. The scan driver 30 is coupled to the scan lines S 1 , S 2 , . . . , Sn−1, and Sn to transmit the scan signals to specific rows of the pixel unit 10 . The data signal output from the data driver 20 is transmitted to the pixel 11 where the scan signal is transmitted so that the voltage corresponding to the data signal is transmitted to the pixel 11 .
[0013] The controller 40 controls the data driver 20 and the scan driver 30 so that the pixel unit 10 can display an image.
[0014] When the above structured organic light emitting display is used for a mobile telephone, in a standby mode, an image representing date and hour is displayed only on a partial region of the pixel unit and the image is not displayed on the remaining region, that is, the remaining region is displayed black (displays no emitting light).
[0015] The image is displayed only on the partial region (a partial screen) in order to reduce power consumption and to increase the use time of a battery of the organic light emitting display.
[0016] However, in the standby mode where there are many regions displayed black, the data driver 20 is driven in the same way. Therefore, the power consumptions of the data driver 20 do not change in the standby mode. Therefore, in order to reduce power consumption, an improved method of reducing power consumption in the data driver 20 in the standby mode is needed.
SUMMARY OF THE INVENTION
[0017] Aspects of embodiments of the present invention are directed toward an organic light emitting display with a relatively small power consumption and a method of using the same.
[0018] Aspects of embodiments of the present invention are directed toward an organic light emitting display capable of reducing power consumption in a standby mode and a method of using the same.
[0019] An embodiment of the present invention provides an organic light emitting display, including a pixel unit having a first emission region and a second emission region, wherein the pixel unit is configured to generate a driving current in accordance with data signals and scan signals to emit light so that light is emitted by the pixel unit only in the first emission region in a standby mode; a data driver for transmitting the data signals only to the first emission region in the standby mode; a scan driver for outputting the scan signals; and a power source supplier for generating and outputting voltages of an initialization power source and for blocking the driving current from flowing to the second emission region by utilizing a voltage of the initialization power source in the standby mode.
[0020] In one embodiment, the pixel unit includes a plurality of pixels, and each of the pixels includes: an organic light emitting diode (OLED); a first transistor including a first electrode coupled to a first node, a second electrode coupled to a second node, and a gate coupled to a third node so that driving current flows from the first node to the second node in accordance with a voltage of the gate; a second transistor including a first electrode coupled to a data line, a second electrode coupled to the first node, and a gate coupled to a first scan line; a third transistor including a first electrode coupled to the second node, a second electrode coupled to the third node, and a gate coupled to the first scan line; a fourth transistor including a first electrode coupled to the initialization power source, a second electrode coupled to the third node, and a gate coupled to a second scan line; a fifth transistor including a first electrode coupled to a first power source, a second electrode coupled to the first node, and a gate coupled to an emission control line; a sixth transistor including a first electrode coupled to the second node, a second electrode coupled to the organic light emitting diode (OLED), and a gate coupled to the emission control line; and a capacitor including a first electrode coupled to the first power source and a second electrode coupled to the third node.
[0021] In one embodiment, the data driver is configured to be driven only in a period where data signals are transmitted to the first emission region in the standby mode.
[0022] In one embodiment, the power source supplier is configured to output a first voltage when the initialization power source is set to have the first voltage and a second voltage differing form the first voltage and when the data driver stops driving in the standby mode, and is configured to output the second voltage when the data driver is driven.
[0023] In one embodiment, the first voltage is a voltage, at which the driving current is not generated by the first transistor.
[0024] Another embodiment of the present invention provides a method of driving an organic light emitting display having a pixel unit having a first emission region and a second emission region, wherein the pixel unit is configured to generate a driving current in accordance with data signals and scan signals to emit light. The method includes: transmitting a voltage of an initialization power source set to have a first voltage or a second voltage differing from the first voltage to the pixel unit and setting the transmitted voltage of the initialization power source as the first voltage in a standby mode to output the first voltage; and converting the transmitted voltage of the initialization power source from the first voltage into the second voltage when data signals are transmitted to the first emission region in the standby mode.
[0025] In one embodiment, the pixel unit includes a plurality of pixels, and each of the pixels includes: an organic light emitting diode (OLED); a first transistor including a first electrode coupled to a first node, a second electrode coupled to a second node, and a gate coupled to a third node so that driving current flows from the first node to the second node in accordance with a voltage of the gate; a second transistor including a first electrode coupled to a data line, a second electrode coupled to the first node, and a gate coupled to a first scan line; a third transistor including a first electrode coupled to the second node, a second electrode coupled to the third node, and a gate coupled to the first scan line; a fourth transistor including a first electrode coupled to the initialization power source, a second electrode coupled to the third node, and a gate coupled to a second scan line; a fifth transistor including a first electrode coupled to a first power source, a second electrode coupled to the first node, and a gate coupled to an emission control line; a sixth transistor including a first electrode coupled to the second node, a second electrode coupled to the organic light emitting diode (OLED), and a gate coupled to the emission control line; and a capacitor including a first electrode coupled to the first power source and a second electrode coupled to the third node.
[0026] In one embodiment, when the initialization power source has the first voltage, the pixel unit display is displayed black.
[0027] In one embodiment, when the initialization power source has the first voltage, an operation of a data driver for transmitting the data signals is stopped.
[0028] In the organic light emitting display and the method of driving the same according to embodiments of the present invention, the driving time of the data driver is reduced so that the power consumption of the data driver is reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The accompanying drawings, together with the specification, illustrate exemplary embodiments of the present invention, and, together with the description, serve to explain the principles of the present invention.
[0030] FIG. 1 is a block diagram illustrating the structure of an organic light emitting display;
[0031] FIG. 2 is a block diagram illustrating the structure of an organic light emitting display according to an embodiment of the present invention;
[0032] FIG. 3 is a view illustrating an image displayed on the pixel unit of the organic light emitting display of FIG. 2 in a standby mode;
[0033] FIG. 4 is a circuit diagram illustrating a pixel adopted by the organic light emitting display of FIG. 2 ; and
[0034] FIG. 5 is a timing diagram illustrating a voltage change in the scan signals, the emission control signals, and the initialization power source input to the organic light emitting display of FIG. 2 in the standby mode.
DETAILED DESCRIPTION
[0035] Hereinafter, certain exemplary embodiments according to the present invention will be described with reference to the accompanying drawings. Here, when a first element is described as being coupled to a second element, the first element may be not only directly coupled to the second element but may also be indirectly coupled to the second element via one or more third elements. Further, some of the elements that are not essential to the complete understanding of the invention are omitted for clarity. Also, like reference numerals refer to like elements throughout.
[0036] Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings.
[0037] FIG. 2 is a block diagram illustrating the structure of an organic light emitting display according to the present invention. Referring to FIG. 2 , the organic light emitting display includes a pixel unit (display region) 100 , a data driver 200 , a scan driver 300 , a controller 400 , and a power source supplier 500 .
[0038] A plurality of pixels 101 are arranged in the pixel unit 100 , and each of the pixels 101 includes an organic light emitting diode (OLED) that emits light to correspond to the flow of current. The pixel unit 100 includes a plurality of scan lines S 1 , S 2 , . . . , Sn−1, and Sn formed to extend in a first direction (a row direction) and to transmit scan signals, a plurality of emission control lines E 1 , . . . , and En−1 formed to extend in the first direction (the row direction) and to transmit emission control signals, and a plurality of data lines D 1 , D 2 , . . . , Dm−1, and Dm formed to extend in a second direction (a column direction) crossing the first direction and to transmit data signals.
[0039] In addition, the pixel unit 100 receives a first power of a first power source ELVDD and a second power of a second power source ELVSS having a lower voltage level than the first power source ELVDD to be driven. Also, the pixel unit 100 receives an initialization power source Vinit for initializing a voltage stored in the pixel 101 . Therefore, in the pixel unit 100 , current flows to the OLED by utilizing the scan signals, the data signals, the first power source ELVDD, and the second power source ELVSS to emit light and to display an image. The voltage stored in the pixel 101 is initialized by the initialization power source Vinit.
[0040] Here, the pixel unit 100 can be operated to display an image in a standby mode and an image in a display mode. In the standby mode, an image is displayed only in a part of the pixel unit 100 and the remaining part is displayed black (displays no emitting light). Current does not flow to the part displayed black so that the amount of power consumed by the pixel unit 100 is reduced. The shape of the pixel unit 100 in the standby mode will be described in more detail in FIG. 3 .
[0041] The data driver 200 receives data driver control signals DCS and image signals R, G, B data from the controller 400 to generate the data signals. The data driver 200 is continuously driven in the display mode, however, a period where operation is stopped is generated in a period in one frame in the standby mode. Therefore, the operation of the data driver 200 is stopped so that the amount of power consumed by the data driver 200 is reduced.
[0042] The scan driver 300 receives scan driver control signals SCS from the controller 400 to generate the scan signals and the emission control signals. The scan driver 300 is coupled to the plurality of scan lines S 1 , S 2 , . . . , Sn−1, and Sn and the plurality of emission control lines E 1 , . . . , and En−1 to transmit the scan signals to specific rows of the pixel unit 100 . The data signal output from the data driver 200 is transmitted to the pixel 101 where the scan signal is transmitted so that the voltage corresponding to the data signal is transmitted to the pixel 101 .
[0043] The controller 400 transmits the image signals R, G, B data and the data driver control signals DSC to the data driver 200 and transmits the scan driver control signals SCS to the scan driver 300 to control the operations of the data driver 200 and the scan driver 300 .
[0044] The power source supplier 500 generates the first power of the first power source ELVDD, the second power of the second power source ELVSS, and the initialization power of the initialization power source Vinit to transmit the generated first power of the power source ELVDD, the second power of the second power source ELVSS, and the initialization power of the initialization power source Vinit to the pixel unit 100 . Here, the initialization power source Vinit has a first voltage, a second voltage, a third voltage between the first voltage and the second voltage to correspond to the driving of the data driver 200 .
[0045] FIG. 3 is a view illustrating an image displayed on the pixel unit of the organic light emitting display of FIG. 2 in a standby mode. Referring to FIG. 3 , the organic light emitting display is driven in a display mode where images such as a moving picture and a photograph are displayed and in a standby mode where only date and hour are displayed. The pixel unit is divided into a first emission region 120 and a second emission region 110 . The first emission region 120 emits light in the standby mode and the display mode. The second emission region 110 emits light only in the display mode.
[0046] The second emission region 110 emits light only in the display mode in order to reduce power consumption in the standby mode. In the standby mode, the icons such as date and hour are displayed on the first emission region 120 and the second emission region 110 does not emit light but is displayed black.
[0047] Since the organic light emitting display displays an image to correspond to the current that flows to each pixel, current flows to the pixel positioned in the first emission region 120 in the standby mode and current does not flow to the pixel positioned in the second emission region 110 . That is, since the area where light is emitted in the pixel unit 100 in the standby mode is smaller than in the display mode, the amount of the current that flows to the pixel unit 100 in the standby mode is smaller than the amount of the current that flows to the pixel unit 100 in the display mode. Therefore, the power consumption of the pixel unit 100 is reduced.
[0048] However, when the data driver 200 performs the same operation as when the data driver 200 operates in the display mode in the case where an image is displayed only in the first emission region 120 that is not the entire region of the pixel unit 100 but is only a part of the pixel unit 100 in the standby mode, in this standby mode, the data driver 200 has the same power consumption as in the display mode. Therefore, in order to effectively reduce power consumption and in one embodiment of the present invention, the data driver 200 stops operating at the point of time where the pixel positioned in the second emission region 110 is selected by the scan signal in the standby mode and the data driver 200 operates at the point of time where the pixel positioned in the first emission region 120 is selected. That is, in order to effectively reduce power consumption, it is necessary that the data signals input to the pixel unit 100 are differently transmitted in the display mode and in the standby mode.
[0049] FIG. 4 is a circuit diagram illustrating a pixel adopted by the organic light emitting display of FIG. 2 . Referring to FIG. 4 , the pixel 101 includes a first transistor M 1 , a second transistor M 2 , a third transistor M 3 , a fourth transistor M 4 , a fifth transistor M 5 , a sixth transistor M 6 , a capacitor Cst, and an organic light emitting diode (OLED).
[0050] The source of the first transistor M 1 is coupled to a first node N 1 . The drain of the first transistor M 1 is coupled to a second node N 2 . The gate of the first transistor M 1 is coupled to a third node N 3 . Therefore, the amount of the driving current that flows from the source to the drain of the first transistor corresponds to the voltage of the third node N 3 .
[0051] The source of the second transistor M 2 is coupled to the data line Dm. The drain of the second transistor M 2 is coupled to the first node N 1 . The gate of the second transistor M 2 is coupled to the scan line Sn. Therefore, the data signal transmitted through the data line Dm can be selectively transmitted with the second transistor M 2 to the first node N 1 in accordance with the scan signal transmitted through the scan line Sn.
[0052] The source of the third transistor M 3 is coupled to the second node N 2 . The drain of the third transistor M 3 is transmitted to the third node N 3 . The gate of the third transistor M 3 is coupled to the first scan line Sn. Therefore, the second node N 2 and the third node N 3 are electrically coupled to each other to correspond to the scan signal transmitted through the first scan line Sn so that the voltage of the second node N 2 is equal to the voltage of the third node N 3 and that the first transistor M 1 is diode coupled (connected as a diode by the transistor M 3 ).
[0053] The source of the fourth transistor M 4 is coupled to the initialization power source Vinit. The drain of the fourth transistor M 4 is coupled to the third node N 3 . The gate of the fourth transistor M 4 is coupled to the second scan line Sn−1. Therefore, the initialization power source Vinit is transmitted to the third node N 3 to correspond to the scan signal transmitted through the second scan line Sn−1.
[0054] The source of the fifth transistor M 5 is coupled to the first power source ELVDD. The drain of the fifth transistor M 5 is coupled to the first node. The gate of the fifth transistor M 5 is coupled to the emission control line En−1. Therefore, the first power of the power source ELVDD can be selectively transmitted with the fifth transistor M 5 to the first node N 1 in accordance with the emission control signal transmitted through the emission control line En−1.
[0055] The source of the sixth transistor M 6 is coupled to the second node N 2 . The drain of the sixth transistor M 6 is coupled to the OLED. The gate of the sixth transistor M 6 is coupled to the emission control line En−1. Therefore, the transmission of the driving current generated by the first transistor M 1 to the OLED is controlled (with the sixth transistor M 6 ) in accordance with the emission control signal transmitted through the emission control line En−1.
[0056] The first electrode of the capacitor Cst is coupled to the first power source ELVDD. The second electrode of the capacitor Cst is coupled to the third node N 3 . Therefore, the voltage of the third node N 3 is maintained.
[0057] The anode electrode of the OLED is coupled to the first power source ELVDD. The cathode electrode of the OLED is coupled to the second power source ELVSS. A light emitting layer is formed between the anode electrode and the cathode electrode. Light is emitted to correspond to the current that flows from the anode electrode to the cathode electrode. Therefore, light is emitted to correspond to the amount of current that flows through the source of the first transistor M 1 and the drain of the first transistor M 1 .
[0058] FIG. 5 is a timing diagram illustrating a voltage change in the scan signals, the emission control signals, and the initialization power source input to the organic light emitting display of FIG. 2 in a standby mode. For convenience sake, in the standby mode, it is assumed that the row of pixels, to which a data signal is transmitted by utilizing an (a+1)th scan signal SSa+1, to the row of pixels, to which a data signal is transmitted by utilizing an (a+4)th scan signal SSa+4, are the pixels positioned in the first emission region 120 , in which an image is displayed in the standby mode. Referring to FIG. 5 , in the operation of the pixel, initially, the fourth transistor M 4 is turned on to correspond to the scan signal transmitted through the second scan line Sn−1. When the fourth transistor M 4 is turned on, the initialization power source is transmitted to the third node N 3 so that the third node N 3 has the voltage of the initialization power source Vinit. The scan signal transmitted through the first scan line Sn is transmitted. The fourth transistor M 4 is turned off. The second transistor M 2 and the third transistor M 3 are turned on. When the second transistor M 2 and the third transistor M 3 are turned on, the data signal that flows to the data line Dm is transmitted to the first node N 1 . Then, the second node N 2 and the third node N 3 are electrically coupled to each other by the third transistor M 3 so that the second node N 2 and the third node N 3 have equal potential. Therefore, the first transistor M 1 is diode coupled. At this time, since the fifth transistor M 5 and the sixth transistor M 6 are turned off by the emission control signal transmitted through the emission control line En−1, current does not flow to the OLED. Here, the third node N 3 stores the voltage corresponding to the data signal. Then, when the fifth transistor M 5 and the sixth transistor M 6 are turned on by the emission control signal transmitted through the emission control line En−1, the third node N 3 still stores the voltage corresponding to the data signal. Therefore, since driving current flows from the first node N 1 to the second node N 2 by the first transistor M 1 and the driving current is transmitted to the OLED, the OLED emits light.
[0059] In the pixels that operate as described above, in the pixels that receive the data signals by utilizing the first scan signal to the ath scan signal SSa, the initialization power source Vinit has the first voltage. At this time, the first voltage has the same voltage (for example, 4.2V) as the first power of the first power source ELVDD. Therefore, since the initialization power source Vinit having the first voltage is transmitted to the third node N 3 , the voltage of the third node N 3 has the first voltage. When the data signal is transmitted to the first node N 1 and the first transistor M 1 is diode coupled by the third transistor M 3 in the state where the third node N 3 has the first voltage, since the third node N 3 has a high voltage, the voltage of the third node N 3 maintains the first voltage. That is, the voltage of the third node N 3 maintains the first voltage regardless of the voltage of the data signal. When the third node N 3 has the first voltage, current does not flow from the source of the first transistor M 1 to the drain of the first transistor M 1 so that the OLED does not emit light. Therefore, the OLED is displayed black. Due to the above, although the data driver 200 does not output the data signal, the OLED is displayed black by the initialization power source.
[0060] The pixels that received the data signals by utilizing the (a+1)th scan signal SSa+1 to the (a+4)th scan signal SSa+4 receive the second voltage as the voltage of the initialization power source Vinit. At this time, the second voltage is in a low level (for example, −2V).
[0061] Then, when the fourth transistor M 4 is turned on, the second voltage is transmitted to the third node N 3 by the initialization power source Vinit and the second voltage is maintained in the third node N 3 by the capacitor Cst. When the first transistor M 1 is diode coupled in a state where the third node N 3 has the second voltage, current flows to the third node N 3 and the third node N 3 has the voltage corresponding to the voltage of the data signal. Then, when the fifth transistor M 5 and the sixth transistor M 6 are turned on by the emission control signal, since the driving current flows from the source of the first transistor M 1 to the drain of the first transistor M 1 by the voltage of the third node N 3 , the driving current corresponding to the data signal flows to the OLED so that the OLED emits light.
[0062] Therefore, the data driver 200 can be stopped from being driven for a period of time excluding the period of time where the data signals are received by the pixels positioned in the first emission region 120 by utilizing the (a+1)th scan signal SSa+1 to the (a+4)th scan signal SSa+4. As such, the amount of power consumed by the data driver 200 can be reduced.
[0063] While the present invention has been described in connection with certain exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, and equivalents thereof. | An organic light emitting display capable of reducing power consumption in a standby mode and a method of driving the same. The organic light emitting display includes a pixel unit having a first emission region and a second emission region, wherein the pixel unit is configured to generate a driving current in accordance with data signals and scan signals to emit light so that light is emitted by the pixel unit only in the first emission region in a standby mode, a data driver for transmitting the data signals only to the first emission region in the standby mode, a scan driver for outputting the scan signals, and a power source supplier for generating and outputting voltages of an initialization power source and for blocking the driving current from flowing to the second emission region by utilizing a voltage of the initialization power source in the standby mode. | 6 |
BACKGROUND OF THE INVENTION
For years outdoor decking has been a desirable feature for use either freestanding or joined to a housing structure such as a conventional dwelling of brick, lumber, siding, or other exterior surface material, or with mobile homes and the like. Various lumber yards and home supply stores have made available pre-cut flooring material, stair treads, and banisters for assembly on site by a carpenter or other craftsman, however, these pre-cut boards solved only a part of the problem of erecting a deck and left a great deal of the detail work to be done on site by a skilled carpenter.
Even with the pre-cut pieces available heretofore, substantial cutting and fitting was necessary to make a finished deck and as a result of field versus shop cuts, the pieces were often not of uniform size and squareness required to produce a first-class finished deck when done by workman of less than consummate skill and carefulness.
An object of the present invention is to provide a modular deck having all components pre-cut and some pre-assembled and also having the necessary holes for lag bolts or screws pre-drilled to facilitate correct assembly of the various components with the prefabricated floor section without the critical measuring and placement of the connecting holes left to the assembler. This way, a person with less than craftsman skills can produce a deck which is symmetrical and which, when finished, has the appearance of being constructed by professionals. A further object of this invention is to provide a modular deck with floor sections which may be joined together to provide a deck of any number of several sizes. It is also an object of this invention to provide a connecting member for joining adjacent interior corners of the various floor sections to quickly and easily secure them together in proper alignment and to provide a means for securing a vertical support member beneath the interior corners of the deck.
SUMMARY
The present invention includes a modular deck system which includes a central substantially horizontal floor section positioned above a grade by a plurality of legs which extend above the floor level to provide supports for a railing around the perimeter of the floor and a stairway and banister assembly providing access to and from the floor from ground level. Various components and parts are pre-cut and pre-drilled to facilitate erection and means are provided to connect adjacent interior corners of the floor together when a deck having at least four floor panels with abutting corners is erected.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially exploded view of a side rail with support legs for supporting the deck above grade;
FIG. 2 is an isometric view of a floor section with a cutaway view of a stair banister;
FIG. 3 is an isometric view partially cut away of a pair of sides abutting one another;
FIG. 4 is a partially cut away isometric view of the deck and a stair;
FIG. 5 is a cross sectional view taken on line 5--5 of FIG. 1;
FIG. 6 is a partial isometric view of the means for connection adjacent floor section corners together; and
FIG. 7 is an isometric exploded view of the deck assembly including side rails and stairs and banisters.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Shown in FIG. 7 of the drawings are the basic components of the deck structure of the present invention which include the floor designated generally F, the side railings, designated generally R, and the stair designated generally S. The floor section F is generally rectangular and includes perimeter beam members 11 and 12 which are shown as well as corresponding perimeter members which are not shown but which are on the opposite end and opposite side of the rectangle from the members 11 and 12.
The floorboards 14 are secured to the perimeter members by nails or other securing means and the four corners formed by the perimeter members are also secured together by nails or screws to form a rigid floor section which is preferably of a standard size such as four feet by eight feet. Any number of these basic floor sections may be joined together to form a deck of any desired size or configuration in which the four by eight abutting sections may be arranged.
The perimeter members 11 and 12 are provided with pre-drilled holes 11a, 11b, and 11c, which are formed near the outer ends of the perimeter member 11 and its opposite counterpart at the other end of the floor section F. The single hole 11a on the left is spaced laterally apart from the vertically spaced pair of holes 11b and 11c a standard width to receive either the stair assembly S or a railing assembly R, as desired, which allows interchangeability of the stair and railing sections to provide a free choice of the location of a stair or railing at either end of the floor section F.
The side perimeter member 12 and its opposite counterpart also are provided with sets of pre-drilled holes comprising a single hole 12a and a pair of vertically spaced holes 12b and 12c. The single hole 12a is positioned on the left and is spaced laterally the standard distance from the vertically spaced pre-drilled holes 12b and 12c on the right extreme of the same standard spacing distance as the holes 11a are spaced from the pair of holes 11b and 11c and thus are arranged for receiving either a standard stair section S or a section of railing R. Similarly, the stair S has a left-hand banister support 20 which is provided with a single pre-drilled bolt hole 20a and a right vertical support member 21 which is provided with a vertically spaced pair of bolt holes 21b and 21c, which are located so as to be aligned with the holes 11b and 11c or, alternatively, the holes 12b and 12c. Thus the stair may be positioned on the side of the rectangular floor section F or at either end by aligning the single left banister support 20 with its support hole 20a over either single hole 12A and the perimeter side member 12 or with respect to the single hole 11a and the end member 11. Also, the right vertical banister support may have its spaced pair of holes 21b and 21c registered with the spaced pair of holes 12b and 12c respectively or the spaced pair of holes 11b and 11c.
Thus, it will be appreciated that the stair section S may be positioned at either end of the rectangular floor section F or at either of the two positions on each of the two longitudinal sides of such a rectangle.
Together with the vertical banister supports 20 and 21, are provided side runners 23 and 24 which have recessed slots 25 and their facing sides for receiving the ends of the stair treads 27. Spaced pairs of bolt holes 25a are provided in the recessed slots 25 and corresponding spaced holes 27a are provided in the ends of the stair treads 27 for receiving lag bolts 28 for securing the stair treads 27 in the slots 25 and the runners 23 and 24. The stairs are provided with a pair of hand rails or banisters 29 and 30. As shown in FIG. 7 of the drawings, the left banister is supported at its upper end by vertical support 20 and at its lower end by vertical support 32. A plurality of vertical rods or bars 33 are also provided which bars are substantially parallel to the vertical supports 20 and 32 and which extend downwardly from banister 29 to an intermediate support 29a which is generally parallel to the banister 29. Also, as shown in the drawings, the right banister 30 is supported at its upper end by vertical support 21 and at its lower end by vertical support 35. A plurality of vertical rods 36 extend downwardly from banister 30 to the intermediate support 30a. The lower ends of the vertical banister supports 32 and 35 are provided with pre-drilled bolt or lag screw holes 32a and 35a, respectively for receiving lag screws of bolt 38 which are received in pre-drilled holes such as 24a near the lower ends of the stair runners to 23 and 24.
In addition to the stair assembly S which may be located in any one of several positions provided by the pre-drilled holes in the floor section perimeter members, there are also provided a plurality of railing sections R that may be positioned in registry with the pre-drilled holes in the floor perimeter members to provide a continuous railing or banister structure around the full perimeter of the floor section, except for the stairway. The railing sections R comprise a pair of spaced vertical supports 40 and 41 with a generally horizontal upper member or handrail 43 and a pair of spaced horizontal members 44 and 45 there below. The lower horizontal member 45 is preferably spaced slightly above the upper level of the floor section F. Also there are included in the railing sections R and plurality of vertical bars 47 that extend between the intermediate an lower horizontal members 44 and 45, respectively. Also, a lattice work or diagonal members 49 may be provided between the upper handrail 43 and the intermediate horizontal member 44, if desired.
As shown in the drawings the left vertical support 40 of the railing section is provided with a single pre-drilled hole 40a adapted to be positioned in registry with one of the single holes 11a or 12a depending on where the railing section is positioned. Similarly, the other or right vertical support 41 is provided with a spaced pair of vertical holes 41b and 41c adapted to be registered relative to the vertical spaced holes 11b and 11c or 12b and 12c, as the case may be, depending upon the location of the railing section R relative to the floor section F. Each of the vertical supports 40 and 41 is provided with a knee piece 40d. This knee is bolted or otherwise secured to the vertical support 40 or 41 in its position with its upper end at an elevation such as to engage the lower edge of the floor perimeter members 12 and provide support for the floor section.
Further, at each outside corner of the assembled deck section there is provided a vertical link 50 which is positioned abutting the inside corner of the two adjacent rail sections or a rail section and a stair section as the case may be. As shown in FIG. 5, when two vertical supports such as 40 and 41 shown in FIG. 1 are positioned adjacent to each other in a corner configuration the knee 40d is secured to both of the vertical supports with its upper end at an elevation such as to engage the lower edge of the floor perimeter member 12 and provide support for the floor section.
Further, at each outside corner of the assembled deck section, such as illustrated in FIG. 5 and FIG. 1, there is provided a vertical link member 50 which is positioned abutting the inside corner formed by the two adjacent rail sections or a rail section and a stair section as the case may be. This link is secured to the two adjacent vertical supports by screws, bolts, or the like. It will be appreciated that with this type of structure in the corners, the modular deck section of the present invention is substantially strengthened and a relatively large cross sectional area of the combined assembled components of the two vertical supports 40 and 41 together with the knee 40d and the link 50.
Also as shown in the drawings, FIG. 5, and FIGS. 1 and 3, the interior surfaces of the vertical legs 40 and 41, respectively are provided with longitudinal extending grooves 55 for receiving a projecting center end projection 56 of the horizontal lower and intermediate members 44 and 45 which provides a type of tongue in groove construction which substantially strengthens the assembled rail section R.
As shown in FIG. 6 of the drawings, there is provided a cross-shaped connection member designated generally C which consists of four U-shaped troughs or channel members 60 disposed at 90° relative to one another and having a common bottom member 61. Each of the channels 60 is provided with a pair of upstanding sides 62 and 63 which extend at approximately 90° upwardly relatively to the bottom 61 and which terminate at their upper ends with downwardly and inwardly disposed connecting flanges or teeth which are provided for penetrating into the adjacent surfaces of the perimeter members 11 or 12 or to at least impose a strong compressive force thereon to rigidly hold such members together. As shown in the drawings, the bottom of each channel 60 is substantially the same width as the thickness of two adjacent perimeter members 12 or when the two are pressed tightly together in a side-by-side relationship. This is also true with respect to two of the end members 11 which are pressed closely together in a side-by-side relationship. When the floor panel sections are positioned in the channel connector C with the lower edges of such perimeter members 11 and 12 engaging the upper surface of the bottom 61 the flanges 62a and 63a are stressed by being bent downwardly by such floor section members and, depending upon the hardness of the wood forming the perimeter members 11 and 12, may penetrate the outer surface of such wood to hold such members firmly against relative movement. As shown, the channel connector C is positioned on a vertical support member 65 which may be either a four-by-four or other suitable size vertical support member that is preferably supported at grade level either on a concrete block (not shown) or may be positioned in a hole or depression in the ground surrounded by concrete or other suitable supporting material.
It will be appreciated that the modular deck construction of the present invention may be assembled by unskilled or semiskilled workers who can simply assemble the various parts in the desired arrangement and connect them together and to the deck or flooring by means of screws or lag bolts or the like put into position in the appropriate openings such as 11a, b, or c, and 12a, b, or c, and such other suitable openings as may be provided in the vertical support members such as 40a or 41b and c. Also, the vertical supports for the stair banisters may be positioned in the appropriate desired position relative to the floor simply by aligning or registering the predrilled holes 20a and 21b and c in the appropriate predrilled holes formed in the perimeter members 11 or 12, respectively. Also, it will be appreciated that any number of the rectangular floor sections F may be joined together to provide a deck of a desired configuration and, that the channel connector C may be provided in an alternative design in which a T shaped connector is provided for certain applications where for example two corners may abut a longitudinal perimeter member 12. | A modular deck construction characterized by having one or more prefabricated floor panels with prefabricated stair parts, i.e., treads and side runners, together with prefabricated banisters and side railing members. The deck frame and other parts are pre-drilled as necessary to provide a fail-safe arrangement for mounting the stairs, banisters, and side rails with the floor panel such that the stair may be positioned on either side or either end of the floor deck. The modular system facilitates assembling a deck of any number of the prefabricated floor panels. The invention also includes connecting means for joining interior corners of adjacent floor panels and supporting them in an elevated position above ground level. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 60/920,907 entitled “HIGH EFFICIENCY BIOCONVERSION SURFACE MATERIALS,” filed on Mar. 30, 2007, which is hereby incorporated herein by reference in its entirety for all purposes.
BACKGROUND OF INVENTION
[0002] 1. Field of the Invention
[0003] At least one embodiment of the present invention relates generally to water treatment and, more particularly, to high efficiency bioconversion surface materials for use in biofiltration operations.
[0004] 2. Discussion of Related Art
[0005] The treatment of wastewater is complex, generally categorized as being a combination of chemical and biological treatments. The pH level and heavy metal concentration are generally controlled by various chemical treatments. Live bacteria that often exist in wastewater are usually destroyed by chemical oxidation treatments, such as by chlorine or ozone addition to the wastewater. Some other known methods of removing various undesirable constituents from water utilize activated charcoal, foam fractionation, zeolites, activated sludge and fluidized sand bed filters.
[0006] In most wastewaters, such as those generated during closed system aquaculture operations, toxic ammonia is formed as the result of decay of organic, especially proteinaceous material. Ammonia toxicity is somewhat dependent on temperature and pH, and is of greater concern the more heavily loaded the system.
[0007] The most common process for ammonia removal is nitrification. The process of nitrification is carried out by aerobic bacteria, such as nitrosomas and nitrobacter. Nitrosomas oxidizes ammonia to nitrite and nitrobacter oxidizes nitrite to nitrate. Nitrate is much less toxic but still can be harmful at high levels, thus even in recirculating systems a 5 to 10% water change daily is the usual practice. The nitrifying bacteria are sensitive to sudden changes in water ammonia levels, temperature, chemicals such as chlorine and hydrogen peroxide oxidizing agents and some drugs.
[0008] The conversion of the ammonia to less toxic forms of nitrogen such as nitrate ions is generally done by biochemical treatments. This treatment is referred to in practice as biofiltration although more accurately should be called bioconversion. Biofiltration is a common method of treating wastewater, such as from municipal, industrial or aquaculture origin. For the most part, the process involves bioconverting the toxic ammonia in the wastewater first to nitrite [No 2 − ] ions then to nontoxic (in moderate concentrations) nitrate [NO 3 − ] ions. The nitrifying bacteria, nitrosomas and nitrobacter , are usually grown on a substrate and the water flows over, under or through this substrate.
[0009] Two standard methods used to accomplish biofiltration of polluted water are trickling filters and rotary biological contactors (RBC's). Trickling filters are submerged and water flows either upward or downward through the substrate which may be sand or another media. These filters must be backwashed periodically and are prone to clogging depending on the type of filtration media utilized. RBC's are drum shaped with an inside substrate for attachment of bacteria. The drum is placed horizontally, approximately half (depending on bacterial load) submerged in water and slowly rotated. This system exposes the water to the bacteria and also self cleans. A disadvantage of RBC's as used currently is their relatively low available surface area and large space requirement.
[0010] In biofiltration systems, biological support media is employed to promote bacterial growth for facilitating bioconversion. In RBC's, the primary support media is typically a corrugated plastic sheet, such as a polyvinylchloride (PVC) sheet. Trickling filters may use media from rock, ceramic aggregate, and shaped plastic among other materials. Water treatment by bioconversion is a rapidly growing industry that presently does not involve many textile products.
[0011] The effect of textile flocking on the anti-biofouling of surfaces in the marine environment have been studied in which samples of flocked surfaces including flocked nylon netting were exposed in the near shore marine environment. In all cases it was found that the flocked surfaces were able to repel “hard fouling” such as barnacles and the like. (See Alms (U.S. Pat. No. 5,618,588).) The observation made in these earlier studies was the fact that flocked surfaces were found to greatly enhance marine plant and algae growth. Discussed herein, flocked nylon netting and fabrics in general serve as an unexpectedly excellent media for various biofiltration media applications. In some embodiments, for example, bioconversion of ammonia by nitrosomas and nitrobacter bacteria may be mediated. In other embodiments, the reduction of hydrogen sulfide pollutants to non-toxic byproducts may be mediated.
SUMMARY OF INVENTION
[0012] In accordance with one or more embodiments, the invention relates generally to high efficiency bioconversion surface materials for use in biofiltration operations. In accordance with one or more embodiments, the invention relates to a biological growth support media, comprising a textile biofiltration media substrate, and an array of fibers disposed on a surface of the textile biofiltration media substrate.
[0013] Other advantages, novel features and objects of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0014] The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures is represented by like numeral. For purposes of clarity, not every component may be labeled in every drawing. Preferred, non-limiting embodiments of the present invention will be described with reference to the accompanying drawings, in which:
[0015] FIG. 1 illustrates Unflocked and Flocked Water Flow Resistance Test Chambers (Top # 1 —plain [not flocked] surface, Bottom # 2 —flocked surface);
[0016] FIG. 2 is a schematic representation of a Water Flow Resistance Testing Device;
[0017] FIG. 3 illustrates Ammonia Bioconversion Capabilities of “Bare” and Adhesive Coated Flat Panels;
[0018] FIG. 4 illustrates Ammonia Bioconversion Capabilities of Flocked Panels;
[0019] FIG. 5 illustrates Bioconversion of Ammonia to Nitrite/Nitrate Ions by Flocked ½″ Hole Size Nylon (nylon flock) and ⅜″ Hole Size PET Netting;
[0020] FIG. 6 illustrates Bioconversion of Nitrite Ions to Nitrate Ions by Nylon Flocked ½″ Nylon and ⅜″ PET Netting Materials;
[0021] FIG. 7 illustrates Bioconversion of Ammonia by Flocked ½″ Nylon Netting Rolled and Placed in an Open Grid PVC Plastic Tube;
[0022] FIG. 8 illustrates Bioconversion of Nitrite Ions to Nitrate Ions by Flocked ½″ Nylon Netting Rolled and Placed in An Open Grid PVC Plastic Tube;
[0023] FIG. 9 illustrates Re-circulating Trickling Biofilter [RTB] Media Testing Module (BMTM) and Operational Diagram;
[0024] FIG. 10 presents photographs of commercially available Bio-Ball® and Bio-Fill® biofilter Media Material;
[0025] FIG. 10A presents a microphotograph of a flocked netting in accordance with one or more embodiments of the present invention
[0026] FIG. 10B presents a close-up microphotograph of the flocked netting of FIG. 10A in accordance with one or more embodiments of the present invention;
[0027] FIG. 10C presents a microphotograph of a flocked planar fabric surface in accordance with one or more embodiments of the present invention;
[0028] FIG. 10D presents a microphotograph of a double-sided flocked planar fabric surface in accordance with one or more embodiments of the present invention;
[0029] FIG. 11 illustrates Bio-Conversion Reaction Rate vs. Water Flow Rate for Bio-Ball® Standard Bio-Filter Media Compared to Flocked Fabric using the RTB method;
[0030] FIG. 12 illustrates Effect of Surface Area of Flocked Media on Bio-conversion Rate (Based on 1 cubic meter volume of media material) using the RTB method;
[0031] FIG. 13 illustrates Effect of Presence of Nutrient on Re-circulating Trickling Bio-Filtration Efficiency; and
[0032] FIG. 14 illustrates Dynamic Response of Flocked Media in Re-circulating Trickling Bio-Filtration Systems.
DETAILED DESCRIPTION
[0033] This invention is not limited in its application to the details of construction and the arrangement of components as set forth in the following description or illustrated in the drawings. The invention is capable of embodiments and of being practiced or carried out in various ways beyond those exemplarily presented herein.
[0034] In accordance with one or more embodiments, the present invention relates generally to new configurations of bioconversion surface materials for use as media in the fabrication of compact-size, biofilter water and air remediation systems. High surface area to flow resistance ratios coupled with small occupied volume is desirable.
[0035] This invention pertains to the experimental observation that fiber flocked surfaces have an unexpectedly favorable ability to support bio-growth. In accordance with one or more embodiments, flocked media may facilitate various biofiltration media applications. This serves to make flocked media an effective surface for the rapid bioconversion (using nitrosomas and nitrobacter cultures as an example) of ammonia to nitrate in closed system aquaculture as well as other wastewater treatment bioconversion operations. In other embodiments, flocked media may facilitate reduction of hydrogen sulfide pollutants to non-toxic byproducts. In other embodiments, flocked media may facilitate converting syn gas from waste cellulose or plastics to ethanol without taxing food grade corn fermentation. This bioconversion is a sustainable, environmentally sound approach. As used herein, the term “flocked” refers to the process of electrostatically coating short/cut (say 0.250″ to 0.002″ in length) textile fibers onto substrate surfaces. Flocking is the textile process whereby short textile fibers such as nylon or polyester are electrically charged in a D.C. field, then align themselves in this electrostatic field and accelerated such that they perpendicularly impinge into a substrate surface coated with an uncured (fluid) adhesive. In this manner, the short fibers are oriented perpendicular to and are assembled onto the adhesive coated surface. The adhesive is subsequently cured fixing the perpendicularly oriented array of fibers in place. While flocking is the preferred process, there are other perpendicularly oriented textile surface types are also applicable in this biofilter media invention. Any textile surface quality characterized as textured, napped, patterned, veloured, velveted or otherwise modified such as by a brushing or raising process.
[0036] In accordance with at least one embodiment, a biological growth support media is disclosed comprising a biofiltration media substrate onto which exists an array of substantially perpendicularly oriented fibers disposed on a surface of the biofiltration media substrate. For example, a plastic media support sheet of an RBC may be coated with flock fibers. While plastic, such as PVC, polyacrylic or polycarbonate, is one potential primary support media, the invention is not so limited and is equally applicable to various other primary support media compositions. In some embodiments, the substrate may be a textile material comprised of nylon, polyester, acrylic, cellulose acetate, cotton, nitrile fiber, or a combination thereof. The substrate may be of any configuration, generally planar, knitted, netting, flexible woven or non-woven fabric, screen or panel.
[0037] The fibers may be made of any material compatible with the media substrate and other constituents with which it may come into contact. In some embodiments, the flock fibers are made of a textile material. For example, the flock fibers may be nylon, polyester, acrylic, cellulose acetate, any common fibrous material, or a combination thereof. In one embodiment, the fibers may be composed of nylon (nylon6, nylon 66), polyester (PET, PTT, PBT, PLA), acrylics, polyolefin (PP, PE).
[0038] In some embodiments, the array of fibers may substantially cover the surface of the media substrate. In at least one embodiment, the density of the fiber array on the textile substrate is at least about 20 fibers per square millimeter. The fibers in the array may be of any dimension. In one embodiment, for example, the fibers may be from about 2 micrometers to about 50 micrometers in diameter. In some embodiments, the fibers may comprise filaments from about 0.25 millimeter to about 10 millimeters in length. In some embodiments, the filaments may be from about 0.25 millimeter to about 8 millimeters in length. In at least one embodiment, the filaments may be from about 0.25 millimeter to about 6 millimeters in length.
[0039] The fibers may be oriented at any desirable angle relative to a surface of the media substrate. In some embodiments, the fibers may be oriented at an angle of about 40, 50, 60 or 70 degrees relative to a plane of the flocked surface. In other embodiments, the fibers may be oriented at an angle of about 80 degrees relative to a plane of the flocked surface. In still other embodiments, the fibers may be oriented at an angle of about 85 degrees relative to a plane of the flocked surface. In at least one embodiment, the fibers may be oriented substantially perpendicular relative to a surface of the media substrate. For example, FIGS. 10A and 10B present microphotographs of flocked netting. The flocked netting contains about 8 holes per square inch and the holes are approximately 9.5 mm in nominal diameter. The flock fibers are oriented predominantly perpendicular to the netting web substrate. Likewise, FIGS. 10C and 10D present microphotographs of a flocked planar fabric surface and a double-sided flocked planar fabric surface, respectively, in accordance with one or more embodiments of the present invention. The flock fibers illustrated are 18 denier nylon 4.6 mm long fibers. The orientation of the flock fibers may be described as substantially perpendicular relative to the substrate surface.
[0040] The fibers may be attached to the biofiltration media substrate in accordance with various known techniques. For example, a binder, such as an adhesive, glue or resin, may be used to adhere the flock fibers to the primary support media. The fibers may alternatively be attached to the substrate by a flocking method.
[0041] In accordance with at least one embodiment, flocking surfaces, such as plastic sheets and textiles, have been found to greatly enhance the biological growth and bioconversion capabilities of the media substrate. This allows the bioconversion treatment of larger volumes of wastewater in the same sized RBC unit or other treatment system. Alternatively, this allows for the construction of smaller sized RBC units to perform the same level of bioconversion activity. It is expected that an order of magnitude reduction in volume/floor space is achievable when flock fiber based high specific surface area biofilter materials are used as the bioconversion media.
[0042] The present invention goes beyond the observation that flocked surfaces form excellent biosurfaces for various biofiltration media applications, for example, the reduction of hydrogen sulfide pollutants or the action of nitrosomas and nitrobacter (ammonia converting) bacteria. In accordance with one or more embodiments, flock fibers are placed on an open (knitted) net fabric structure, further enhancing the excellent bioconversion effect observed for (planar) flocked surfaces. For example, the substrate may comprise a knitted netting fabric, a perforated woven fabric, or a woven fabric screen, such as a woven fabric metal wire screen. The surface of the substrate may therefore define a plurality of apertures. The apertures may be in the range of about 0.25 millimeter to 12.7 millimeters in circular diameter or polygonal dimension. Alternatively, the apertures may be square or open rectangular in shape. In a preferred embodiment, flocked netting with a ⅛ inch to ½ inch or larger mesh size is utilized.
[0043] The openings in the net structure allows for an efficient flow of treatment water through the structure. Intimate contact of the wastewater, uniform “slime” growth on the netting surfaces and interstices is assured. Also with this open web-like structure the wastewater can more easily “slough” through the netting making it more easily accessible to the bio-reacting species. All these factors make flocked (open) netting surfaces more effective in their bioconversion function.
[0044] The flocked netting configurations disclosed have many other advantages over materials commonly used for bioconversion media. Beneficially, it can be used as a continuous web or a porous sheet. Sheets can be stacked or rolled onto each other. Significantly, the netting material can be easily cleaned by rinsing off the netting with water. This washing enables debris, alien biofouling species and/or excessive “slough” build-up on the netting to be flushed off very easily. Also, flocked fiber/yarn netting offers the opportunity of creating new forms of biofilters. For example, continuous, self-cleaning designs that can be adapted to computer control operation of wastewater treatment and aquaculture systems are possible.
[0045] In accordance with one or more embodiments, the substrate may comprise layers constructed and arranged to facilitate fluid bypass through a plane of the substrate. In some embodiments, the substrate may be rolled to define an open conduit constructed and arranged to channel fluid flow. The substrate may be constructed and arranged such that a fluid stream flows substantially parallel to the surface of the substrate, across ends of the perpendicularly oriented fibers for treatment. These and other embodiments may facilitate integrating the flocked media substrate into, for example, a biofilter.
[0046] In addition to the uses of flocked netting for RBC-like applications, many types of biosupport media used in trickling biofilter configurations could be enhanced by the application of fiber flock to the material surfaces. Adaptation of the subject invention of flocked netting materials to trickling filter configurations and new, more efficient biofilter designs are now possible.
[0047] In some embodiments, the disclosed biofilter media material can have a surface area packing density of 1000 to 5000 m 2 /m 3 with low hydrodynamic impediment. It is conceivable that velvet, velour, raised or pile fabrics will also have a relatively high surface area packing density. However, to produce fiber based biofiltration media in massive volume at a competitive price on various forms of substrates (linear, 2-D and 3-D geometries), fiber electro-coating (flocking) appears to be the most enabling technology.
[0048] Developing a compact, cost-effective and low maintenance, continuous process bioconversion reactor substrate material/device system for application in re-circulating closed aquaculture and circulating wastewater treatment systems results in a critical economic benefit by a reduction in aquaculture process/operational floor space requirements. Primary beneficiaries may include aqua-farming operations of land based reuse-water aquaculture systems. Furthermore, the proposed bioreactor design could also be utilized in treating industrial and municipal liquid waste streams using selected micro-organisms as well as for the bio-industrial production of useful micro-organisms.
[0049] The total surface area available for bacterial growth is a good predictor of the capacity of a bioconversion media for the remediation of ammonia polluted water. The bulk surface area is an important variable that influences the cost of the biofilter vessel and support mechanisms. From an economic, including efficient floor space usage standpoint, it makes sense to use the smallest vessel possible to accomplish a given task. Provided there are no other overriding factors, using a biomedia packing with the most surface area per unit volume will allow for the minimal size vessel and unit operations costs. Vapor and liquid phase biological scrubbing technology has been growing and adapting to new applications. Emphasis is now on reducing system size while increasing throughput. Overall, the proper application of textile materials to a geometrically designed surface structure offers the potential of increasing surface contact area within a small volume. There appears to be many high quality and cost-effective benefits from the fiber-based technology herein disclosed.
[0050] It is important to distinguish between total claimed surface area and surface area that is available as a substrate for biological growth and bioconversion. As a biofilter device matures, the biomass (“slime layer”) of bacteria steadily grows and the layer of bacteria that covers all available media surfaces (biomass) becomes thicker. Since the organisms inside the layer can only receive food and oxygen by diffusion, they receive less and less food and oxygen as the biomass layer grows thicker. Generally speaking, only the outermost layer of bacteria will be operating at peak efficiency in conventional biofilter media materials. Flock fabric packing geometry is an important factor in the search for an effective bioconversion media material.
[0051] Flocked fabric media can be used to design more compact biofilter and bioconversion ammonia-water remediation systems. The surface area and fabric geometry are important factors to optimize flock fiber-coated polymer and textile fabric surfaces for bioconversion activity. Modeling and understanding the hydrodynamic flow characteristics of water across fiber coated (e.g. flocked) surfaces and, bioconversion efficiency of the fiber surface are also important.
[0052] Establishing the chemical and mechano-physical conditions that will enable the fiber coated bioconversion surfaces to be easily regenerated, should they become contaminated or coated with excessive biomass is also a consideration. In at least one embodiment, the flocked fabric biofilter media materials may be recycled by being removed from the media chamber, such as from an RBC, washed and re-conditioned with de-ionized water before being brought back online.
[0053] It is envisioned that flocked media surfaces such as those described herein may be equally applicable to bioconversion reactions in air biofilter applications.
[0054] The function and advantages of these and other embodiments of the invention can be further understood from the examples below, which illustrate the benefits and/or advantages of the system and method of the invention but do not exemplify the full scope of the invention.
EXAMPLES
[0055] In Examples 1-4, the hydrodynamic, adhesion and biocompatibility behavior of flock materials and fiber flocked surfaces were examined as a preview to applying these flocked surfaces to functional prototype biofilters.
Example 1
Water Flow Against Flocked Surfaces
[0056] Water flow (hydrodynamics) past flocked fiber surfaces was studied. In this context, flock fiber type, denier (fiber diameter) and length were tested. To study the hydrodynamics of biofilter systems, an apparatus for measuring the flow resistance of water through slot shaped channels was constructed. In designing this apparatus consideration was given to its ultimate versatility. First, the apparatus can be used for measuring flow rates of water through several types and designs of biofilter test chambers. Furthermore, this apparatus formed the basis for possible future biochemical and biofiltration property studies. Its primary purpose however, was to study the hydrodynamic resistance of flocked surfaces. Referring to FIG. 1 , the main chamber of the test device consists of 4¾″×9⅜″ stacked layers of 3/16″ thick polycarbonate (PC) sheet. The configuration of each sheet of PC alternated between: (1) sheets with a 2¾″×⅜″ slot on one end of the panel and (2) sheets with a 2¾″ wide×7″long×⅜″ deep cavity or channel which allows the water to flow across the surface of the end slotted panel.
[0057] With this arrangement, the water is made to “zig-zag” through the test chamber. By stacking these panels alternately in a number of layers, a compact assembly with low overall geometric volume and a long linear water flow distance is achieved. If the surfaces of the slotted PC (# 1 ) are flocked, the water passing through the channel in PC sheet # 2 will be subjected to a flow resistance caused by the flock material (see FIG. 1 ). Water pressure through this apparatus was supplied by a constant level water tank held above the test chamber. Water was fed into the water channels by a connecting hose. The water is driven through the test chamber by gravity forces. In these initial studies, the flow rate of water through the test chamber was measured using a graduated cylinder (or beaker) and a stopwatch (see FIG. 2 ).
[0058] In some preliminary studies, an elution time of 20 seconds through the non-flocked test cell apparatus was chosen for comparative evaluations. Here, two flocked test chambers were surfaced with (1) 1.8 denier/0.05 inch long nylon flock fibers, and (2) 25 denier/0.06 inch long polyester flock fibers. The comparative non-flocked test chamber had a water flow-contact surface area of 74 m 2 /m 3 . The results of these tests are presented in Table 1. The comparable test chamber flocked with 1.8 denier nylon had a water flow-contact surface area of approximately 1364 m 2 /m 3 . With this configuration, only a 9.6% reduction in flow rate was observed when one compares flow rates in the 1.8 denier nylon flocked and unflocked polymer surface chambers under the same testing conditions. These initial tests show that the flocked chamber has significant surface area increment, but minimal drag of water flow. Note, however, that this flocked (experimental) test chamber was not optimized. Yet it was close to a 7 times higher specific water contact surface area compared to typical trickling biofilters (150-200 m 2 /m 3 typical) and 12 times that of commercial RBC type biofilters (115 m 2 /m 3 typical).
[0059] In additional studies, the effect of flocking mechanically stiffer fibers on the test cell flow rate was tried. When 25 denier PET (polyester) fiber was flocked onto the PC panel surface, a flock density of only 12 fibers per square micrometer was achieved. This resulted in a surface area in this cell of only 328 m 2 /m 3 . The flow rate in this 25 denier PET flocked cell was 150 ml/sec. These stiffer flock fibers were found to increase the hydrodynamic drag in the test cell with only a modest increase in surface area. This test provided some useful design information, namely, stiff flock fibers on surfaces of biofilters are capable of interfering with water flow. The next studies focused on flock fibers that are more flexible. Here it was hypothesized that surfaces with finer denier, less stiff flock fibers should be able to bend down in the direction of flow. This should cause less flow resistance.
[0060] Overall, the goal of these experiments was to determine the flock fiber surface configuration that will give the test cell the highest surface area (SA) to flow time (FT) ratio, i.e. a maximum SA/FT. These data will enable one to select a somewhat optimized flock fiber configuration for larger scale biofilter experiments. In these studies, flow time, FT, is taken as the reciprocal of the flow rate in seconds per liter. Data were obtained on a surface flocked with a lower denier PET flock fiber. Results are presented in Table 1 as well as results on the previous samples. As hypothesized, the PET 3 denier flock restricted hydrodynamic flow less than the stiffer PET 25 denier flock. The data in Table 1 are also presented in terms of the important SA/FT (Surface Area to Flow Time) ratio. Note the very high SA/FT ratio for the nylon fiber flocked sample. This result reflects the fact that nylon fibers were flocked onto the substrate at a much higher density than any of the PET flocked samples. Also, nylon fibers are inherently more flexible that PET fibers, especially in aqueous media. From a hydrodynamic viewpoint, it appears that nylon flocked surfaces is a good surface choice for prototype biofilter design/configurations.
[0000]
TABLE 1
Flow Rate (FR) of Water Through Flocked Slotted Channels (all
data are an average of at least 10 replicate runs).
Flock Density
SA
(fibers/mm 2 )
(m 2 /m 3 )
FR (ml/s)
FT (s/ml)
SA/FT
Not Flocked
Not applicable
74
304
3.3
22
Nylon 1.8D,
393
1364
253
4.0
345
0.05″ long
PET 3.0D,
27
218
243
4.1
53
0.05″ long
PET 25D,
12
289
132
7.6
38
0.06″ long
[0061] In some supporting work, techniques on improving the flock density of polyester (PET) fiber flocked surfaces were sought. This work was performed in order to establish the efficacy of using PET flock fibers in future biofilter designs. A formulation (Floctan) for a tannic acid D.C. flock finish was applied to the surface of 3 denier PET flock fiber. This so-treated flock fiber was first conditioned at 45 and 60% RH. These samples were then tested for (1) electrical resistivity and (2) flock activity. The flock density of this treated PET flock fiber was determined by first flocking the fiber onto a polycarbonate (PC) plastic substrate using the LUBRIZOL® FL 1059B adhesive and then measuring the flock density by a photographic/optical counting method. The results of these experiments are presented in Table 2. As shown, the FlocTan treated PET fibers conditioned at 45 or 60% RH are much more flockable than the untreated PET flock fibers. As indicated, the important flock density value doubles by applying the FlockTan DC finish to the fiber before flocking.
[0000]
TABLE 2
Behavior and Flock Properties of Tannic Acid [FlockTan] (DC)
Finished PET Flock Fiber.
FloctTan -
FlocTan -
No Treatment
45% RH
60% RH
Electrical Resistivity
>10 9
5 × 10 7
1 × 10 7
(ohms) (a)
Flock Activity (b)
no movement
6.6 seconds
6.2 seconds
Flock Density
43
82
89
(fibers/mm 2 )
(a) Measured using a Mahlo Texo Conductivity Meter.
(b) Maag Flockmaschinen SPG 1000 flock activity meter used. {The flock activity test involves placing 2 grams of flock fiber on a metal (lower) electrode “pan” (3.75″ dia.) of the flock activity tester. Above is an upper metal electrode (2.5″ dia.). These electrodes are mounted in a chamber and positioned 4″ apart. A DC electric field of 40 KV is then applied and the electrostatic activity of mass of flock fiber is visually observed. The amount of flock fiber electrostatically removed from the lower pan is measured. The measurement involves recording either: (1) the time (in seconds) for all of the (2 grams) of flock fibers to be removed from the lower pan electrode, or (2) the amount of flock fiber left on this lower pan after 2 minutes in the electric field (whichever comes first).}
Example 2
Adhesion Strength of Flock Fibers to Surfaces
[0062] Various flock adhesives were examined for adhesion strength, durability in water and exposure to biological media. In other supporting work, the flock-to-PC (polycarbonate) substrate adhesion strength was evaluated for the flocked test configurations presented above. The adhesion strengths were measured as prepared and also after a six-day water immersion (at RT). These results are shown in Table 3. The adhesion strength tests were performed using a Maag-Flockmachinen—MECMESIN AFG 250N tensile flock adhesion tester. The test involves placing a machined, circular, aluminum fitting having a 1 cm diameter hole at its base onto the surface of a flocked solid PC plastic (or fabric) substrate. A hot-melt adhesive is then injected into the top of this aluminum fitting so the hot-melt adhesive is absorbed by and wetted into the flock fibers. When the hot-melt adhesive solidifies (by cooling to room temperature), the aluminum fitting is now attached to a 0.785 cm area of the flocked fiber surface. This assembly is then configured into a tensile force measuring apparatus so that the force necessary to pull/tear the flock fibers away for the substrate is measured and recorded. The failure surfaces are then visually examined (optical microscope) to establish the type of failure i.e. (a) tearing of the fibers out of the adhesive, (b) failure of the flock adhesive at the substrate surface, or (c) breakage within the flock fibers themselves.
[0000]
TABLE 3
Adhesion Strength of Nylon Flock Bonded to Polycarbonate
Surfaces (all pull-out strength numbers in Newtons of force).
Pull-out
Adhesive
Pull-out Strength
Type of Failure
Strength*
Type of Failure*
Epoxy Coat -
120 +/− 22
Adhesion to PC
114 +/− 57
Adhesion to PC
Solvent Based
excellent, mixed
excellent, smooth
failure at the
failure at
fiber/adhesive
flock/coating
interface
interface
BFG Acrylic
107 +/− 5
Mixed - some
118 +/− 50
Mixed failure -
Emulsion
adhesive pulled
Patchy, some
off the PC
coating pulled
substrate
away from PC
surface
LUBRIZOL ®
136 +/− 7
Some nylon
135 +/− 12
Smooth fracture
Water Based
fibers remain on
surface at
Acrylic
the coated PC
flock/coating
surface
interface
*immersed in water for 6 days, dried at room temperature and tensile adhesion tested.
[0063] Interpreting the nature of the failure was enhanced by treating the fracture surfaces in a fiber identification dye (DuPont #4) solution. Furthermore, the results show that water immersion does not affect adhesion strength. Also, the most consistent and highest adhesion strengths were observed with the LUBRIZOL® FL 1059B adhesive. The data indicate that the LUBRIZOL® FL 1059B adhesive performs best in the described adhesion test. If the LUBRIZOL® FL 1059B adhesive performs well in biological compatibility test (discussed in subsequent examples), it will be a good choice for use in the preparation of nylon flocked bio-surfaces. LUBRIZOL® FL 1059B adhesive is an acrylic polymer-water based flock adhesive and was used throughout this study. The use of other adhesive types such as epoxy resin and polyurethane are not excluded from use in the creation of the patented flocked structure. Flock adhesives are chosen as being able to adhere to the flock fiber as well as the substrate onto which the fibers are flocked. The added qualification in this present application is that the adhesive must also be resistant to continuous water immersion. The LUBRIZOL® FL 1059B adhesive that was used was found to satisfy all of these requirements.
[0064] For self-cleaning and continuous biofilter system designs, some (nylon) flocked yarn is under consideration as a substrate for the bio-functioning of nitrosomas and nitrobacter bacteria. Flocked yarn can be configured into strands, as an open web or else a woven or knitted fabric. Flocked yarn offers some innovative biofilter design possibilities. To this end, a supply of (nylon) flocked yarn was obtained from Filova International SA, Guillaume, Luxembourg. A flock adhesion strength test was devised to test the adherence of the (nylon) flock fiber to the (nylon) yarn “core”. The test involved clamping the tip of the flocked yarn in the grips of a conventional (electrical) wire stripper. The hole in the wire stripper is chosen so that the flock is stripped from the yarn core when the tip of the yarn is pulled through (as in stripping the insulating cover from an electrical wire). Tests were carried out where different (“tail”) lengths of the flocked yarn were stripped away from the core yarn. Tests were carried out on (1) “as received” flocked yarns, (2) “cured” yarns and (3) flocked yarns soaked in water for 7 days. The cured yarns were dried or “post cured” at 83° C. for 30 minutes.
[0065] The data obtained followed a liner relationship between the force to strip (lbs.) and the length of yarn being stripped (“tail length”), up to 1.5 cm. Also, these data could be extrapolated to a hypothetical zero length to give a value of the “intrinsic adhesion strength” of the flock fiber to the yarn core. It was found that the “post cured” samples have a slightly lower flock adhesion strength than the “as received” samples. Furthermore, water immersion does not have any drastic affect on lowering the adhesion or the flock to the core yarn. Overall, from the extrapolated-to-zero stripping length value, “intrinsic adhesion strength” of the flock fiber to the yarn ranges from 1.98 to 1.86 pounds of stripping force. Apparently, these water and heat treatments did not alter the flock yarn too drastically. From these studies, it was concluded that the (nylon) flocked yarn as received from Filova International, SA will be structurally suitable for use in prototype biofilter design configurations. The important property of biocompatibility of this flocked yarn material was determined in subsequent biocompatibility studies as discussed below.
Example 3
Tests for Biocompatibility of Flocked Surfaces
[0066] Data in Tables 4 and 5 and FIGS. 3 and 4 compare the results of several experiments that were conducted to evaluate the effectiveness of several media surfaces that are commonly used in RBC and trickling biofilter type devices. The invented nylon flocked materials are found to be much more effective bioconverting surfaces for toxic ammonia than presently used biofilter media such as glass, PVC plastic, and polycarbonate (PC) flat surfaces. Additionally, from Table 6 and 7 and FIGS. 5 and 6 , it shows that flocked nylon netting is more effective in bioconversion than the flocked flat panel materials described in Tables 4 and 5 and FIGS. 3 and 4 . The flocked netting material has the ability to bioconvert the ammonia at a faster rate than the flocked flat surfaces. For flocked netting, the bioconversion reaction starts during the first days of exposure time. With the flocked flat plates, however, there seems to be an “induction period” of up to about 3 days before the bioconversion reaction starts. Therefore flocked netting materials can be considered to be the preferred embodiment in this subject invention.
[0067] The biocompatibility of flocked and material surfaces was tested with the goal of choosing a suitable combination of flock type, flock adhesive and base material for the construction of prototype, operational biofilter designs and configurations. Laboratory scale nitrosomas and nitrobacter culture survival tests were conducted to determine how well the ammonia converting bacteria grow on flocked and support media surfaces. These tests enabled a determination of the efficacy of flocked fibers in biofilter applications. These in-lab biological adaptability tests were performed in UMD's Biology Department. The data obtained in these experiments will aid in determining what types of fiber flock and adhesive material will be best to use in future biofilter structures. Two types of flock and two types of adhesive were evaluated in these biocompatibility tests. All test support media were 10 cm by 20 cm samples of (1) 0.375″ thick polycarbonate [PC], (2) 0.375″ thick Polyvinylchloride [PVC] or (3) 10 cm by 20 cm rectangles of fiber based netting materials. A 45 gallon water conditioning tank and a 35 gallon back-up tank were set up for the study. Aquarium supply and culture tank chemical test kit materials were used to monitor the ammonia and nitrite content of the test chambers. In these tests, large-mouth, one gallon (volume) glass jars for the nitrosomas and nitrobacter culture survival tests were used. A recipe was determined for the preparation of the nitrosomas and nitrobacter culture media by UMD Biology Department personnel. Provisions were made for the conditioning tanks to be regulated at a pH of 7.2. Also the total ammonia nitrogen (TAN) in these conditioning tanks was maintained between 4 and 6 mg/L.
[0068] First, the flat test plates and netting materials were “extracted” in a constant water wash for about 1 week before attempts are made to grow biological cultures on them. This was done to leach out possible chemical and toxic substances from the plastic plate, fibrous netting, glass, adhesive and flock materials that were used to prepare the bioconversion test samples. This type of water conditioning is always performed when preparing various biofilter devices in commercial aquaculture operations.
Details of Biocompatability Tests
[0069] Biocompatibility testing of flocked surfaces for biofilter effectiveness involved preparing eighteen, 10 cm×20 cm test panels of flocked, adhesive coated and bare PC plastic test panels. The samples included three replicates of each of the following: (1) “bare” Polycarbonate, PC, (2) Epoxy adhesive coated PC, (3) nylon flocked/epoxy adhesive, (4) LUBRIZOL® FL 1059B water based adhesive coated, (5) nylon flocked/LUBRIZOL® FL 1059B adhesive, (6) nylon flocked/BFG acrylic emulsion adhesive. These samples were first leached in water for one week before starting a three week bacteria exposure test. Eighteen (18) wide mouth one gallon glass jars were set up for these studies. Test panels, inoculated with nitrosomas and nitrobacter bacteria, were first immersed in a dilute (buffered) ammonia solution in water. Provisions were made for the conditioning jars to be regulated at a pH of 7.2. Also the total ammonia nitrogen (TAN) in these tanks was maintained between 4 and 6 mg/L. The concentration of ammonia was monitored as a function of time for three weeks. For the present experiments, only nylon flock fiber was tested for biocompatibility. Nylon flocked surfaces were shown to have a much lower hydrodynamic flow resistance, at the much higher surface area than PET (polyester) flocked PC surfaces.
Results of Biocompatibility Tests
[0070] The compatibility testing of flocked surfaces for biofilter effectiveness indicated that surfaces flocked with nylon fiber are excellent substrates for the ammonia converting nitrosomas and nitrobacter bacteria. During the test, all the flocked samples showed a decrease in ammonia concentration accompanied by a decrease in nitrite ion concentration. This confirms the proper bio-functioning of the nitrosomas and nitrobacter bacteria. All the flocked panels showed (visibly) a thick growth of bacteria on their surfaces compared to the bare polycarbonate (PC) and the adhesive coated PC panels. Overall, the flocked samples using the two water based adhesives (BFG—acrylic emulsion and LUBRIZOL® FL 1059B adhesive) were found to be the most effective in converting ammonia into nitrate. The data were scattered however.
[0071] An analysis of these data and the adhesion test results reported in the previous section indicates that the nylon fiber flock (1.8 denier, 0.05″ long)/LUBRIZOL® FL 1059B adhesive flock system was the overall best system to use in future studies. Specific bioconversion data are presented in Table 4 and FIG. 3 for the comparison of “Bare” glass plate, PC, corrugated RBC/PVC (PVC as used in RBC's) and PVC plate.
[0072] From these data it is concluded that solid, flat material (not flocked) panels show little or no bioconversion effectiveness. Table 5 and FIG. 4 present bioconversion data for some of the same flat panel materials (PC, PVC and RBC/PVC) presented in Table 4 and FIG. 3 . They are compared to the nylon fiber flocked panels. As shown, the nylon flocked flat panel surfaces are very effective ammonia bioconversion media for nitrosomas and nitrobacter bacteria. It was concluded that the nylon flocked PC and PVC surfaces flock-bonded using the LUBRIZOL® FL 1059B water based acrylic adhesive material is an excellent materials configuration for effectively and durably bio-converting (A) ammonia to nitrite and (B) nitrite to nitrite in various pollution control and aquaculture bioconversion devices. Note that the bioconversion effectiveness of these panels seems to be independent of the substrate material. This behavior is to be expected since the substrate is first coated with adhesive and then flocked. The base substrate material is not directly exposed to the bioactive media. The substrate is essentially encapsulated by the adhesive coating.
[0000]
TABLE 4
Biochemical Conversion Effectiveness of Flat Panel Support
Materials (NH 3 and NO 2 Data in ppm).
Glass
RBC/PVC
Exposure
Plate
PC
PVC
Adhesive
Time
“Bare”
“Bare”
“Bare”
Coated
(days)
NH 3
NO 2
NH 3
NO 2
NH 3
NO 2
NH 3
NO 2
0
4.5
—
5
1
4.5
1
5
1
1
4.5
—
5
1
4.5
1
5
1
3
4.5
—
5
1
4.5
1
5
1
4
4.5
—
4.2
1
4.5
1
4.2
1
5
4.5
—
4
1
4.5
1
4
1
6
4.5
—
4
1
4.5
1
4
1
7
4.5
—
4
1
4
1
4
1
10
4.5
—
4
1
4
1
4
1
11
4.5
—
4
1
4
1
4
1
[0000]
TABLE 5
Ammonia Bioconversion Capabilities of Flocked Panels
(flat panels flocked with 1.5 denier, 0.05″ long nylon flock using
LUBRIZOL ® FL 1059B adhesive).
“Bare” PC and
Exposure Time
RBC/PVC nylon
Adhesive Coated
(days)
PC nylon flocked
flocked
RBC/PVC*
0
5
5
1
5
5
5
3
5
5
5
4
4.7
4.3
5
5
3.3
3.2
4.2
6
1.7
2.5
4
7
1.6
1.5
4
10
0
0.25
4
11
0
0
4
*These data are added for comparison. The “bare” PC and the adhesive coated RBC/PVC showed the same low bioconversion effectiveness (see Table 4).
Example 4
Additional Biocompatibility Tests
[0073] To expand overall knowledge of bioconverting/biofilter materials, additional biocompatibility studies were conducted. This second study focused on the use of open-weave netting materials as the base onto which flock fibers were applied. It was considered that open net fibrous structures would allow a more uniform and easy circulation of the ammonia containing fluid water waste stream through the bioconverting media. The flocked netting configuration may also present the opportunity for creating some “self-cleaning” biofilter designs.
[0074] The biocompatibility test was carried out the same as what was described for the flat PC and PVC (see previous results). All samples were similarly conditioned and then placed into gallon jars containing the ammoniacal water solution. The study involved ½″ nylon and ⅜″ PET based knotless netting material. The LUBRIZOL® FL 1059B water based acrylic adhesive was used as the flocking adhesive. As before, the concentration of ammonia and nitrite ion was followed during the planned exposure time. The results of these bioconversion tests are presented in Table 6. As shown, the bioconversion of ammonia and nitrite ion (to nitrite/nitrate ions) shows a dramatic increase (a decrease in ammonia concentration) in the presence of the flocked netting surfaces compared to the “bare” adhesive coated netting (no flock). In additional experiments, the bioconversion capabilities of other netting configurations were determined. These test samples consisted of flocked ½″ nylon netting loosely rolled into a 6 cm diameter, 20 cm long PVC (plastic) net tube. This represents a unique biofilter configuration that is designed as a “cartridge” that can be adapted into a wastewater bioconversion device that can be easily cleaned. The ammonia/nitrite bioconversion test results of these configurations are presented in Table 7.
[0000]
TABLE 6
Bioconversion Effectiveness of Flocked Netting Support Materials
(ammonia and nitrite ion concentrations in ppm).
½″ Nylon
½″ Nylon
⅜″ PET
⅜″ PET
Net
Net
Net
Net
Exposure
(adhesive
Nylon
(adhesive
Nylon
Time
coat)
Flocked
coat)
Flocked
(days)
NH 3
NO 2 −
NH 3
NO 2 −
NH 3
NO 2 −
NH 3
NO 2 −
0
5.00
0.75
5.00
1.00
5.00
1.00
5.00
1.00
1
4.50
0.50
4.00
0.88
5.00
1.00
3.44
0.50
2
4.00
0.50
2.88
0.50
5.00
1.00
1.62
0.50
5
4.00
0.50
1.75
0.50
4.75
1.00
0.88
0.50
6
4.00
0.50
1.38
0.44
4.50
1.00
0.75
0.19
7
4.00
0.50
0.62
0.19
4.50
1.00
0.25
0.06
8
4.00
0.50
0.12
0.01
4.50
1.00
0.01
0.01
[0000]
TABLE 7
Bioconversion of Rolled in PVC Plastic Tube Sections Containing
½″ Netting Materials and Flocked with Nylon Fibers
(ammonia and nitrite ion concentrations in ppm).
Double
Rolled
Rolled
Rolls
Flat Flocked
Exposure
Netting
Netting
Flocked
Netting
Time
(no flock)
(flocked)
Netting
(Table 2)
(days)
NH 3
NO 2 −
NH 3
NO 2 −
NH 3
NO 2 −
NH 3
NO 2 −
0
5.00
1.00
5.00
1.00
4.50
1.00
5.00
1.00
1
5.00
1.00
3.88
0.75
2.75
0.62
4.00
0.88
2
5.00
1.00
2.38
0.50
2.62
0.19
2.88
0.50
5
5.00
1.00
1.12
0.44
1.38
0.06
1.75
0.50
6
5.00
1.00
0.62
0.38
0.62
0.01
1.38
0.44
7
5.00
1.00
0.38
0.13
0.25
0.01
0.62
0.19
8
5.00
1.00
0.01
0.00
0.00
0.00
0.12
0.01
[0075] For additional comparison purposes, the data in Tables 6 and 7 were plotted in FIGS. 5 , 6 , 7 and 8 . The bioconversion ability of flocked versus un-flocked surfaces is clearly shown. In these comparisons, both the ammonia and the nitrite bioconversion abilities must be considered. In FIGS. 5 and 6 the ⅜″ PET (adhesive coated) netting was the overall best base material. Note that the PET is the base fiber making up the netting material and is not expected to influence the bioconversion activity of the adhesive coated or the nylon flocked (using the same adhesive) substrates. FIGS. 7 and 8 also show the bioconversion effectiveness of flocked netting surfaces. With the exception of the ability of the “double roll” flocked netting to very effectively bioconvert nitrite ions ( FIG. 8 ), the bioconversion effectiveness of the “rolled” and un-rolled (planar) flocked netting are similar. This is observed feature would help in the design of any future biofilter devices.
[0076] Recent biocompatibility test results indicate that polyvinyl chloride (PVC) surfaces enhance the growth of the ammonia-reducing bacteria. Bacterial growth on the bare PVC was much better than on the bare polycarbonate (PC) or glass surfaces. A most important observation was that the nylon flocked PVC plates and especially the (nylon flocked) corrugated PVC sheet material that is used in the Aquatic Eco-Systems RBC, exhibited superior visual growth of the bacterial cultures. Also, the rate of ammonia conversion on these flocked RBC and PVC panels was the highest among all the surfaces in the test. It appears that the choice of flocking nylon fibers onto PVC surfaces using the LUBRIZOL® FL 1059B water based acrylic adhesive is an excellent system for biofilter/bioconversion applications.
[0077] Other bioconversion test data are available showing that polyester (PET) fiber flock can also function to produce bioconversion flock surfaces. However, PET flock surfaces were not quite as effective as the nylon flock fiber material as described herein. Data are also available showing that ¾ inch nylon netting (very open mesh) netting exhibited very little bioconversion capability. It was poor. This suggests that there is an optimal range to the netting mesh opening size that is effective in the inducement of flocked netting bioconversion action. This “net opening size” range appears to be from below ¾ inch to a virtual zero open size which would be that for a flocked flat panel of fabric substrate. Flocked netting materials are the preferred embodiment of the invention.
Example 5
Bioconversion Efficiency of Flock Fiber Coated Surfaces
[0078] To determine the effect of flock fiber material type (nylon, polyester, cellulose acetate), flock density, fiber length on the bioconversion efficiency of flocked surfaces, an instrument controlled, laboratory scale bioconversion/biofilter tank system was constructed to carry out these experiments. Using the bioconversion of ammonia to nitrite and to nitrate using nitrobacter and nitrosomonas bacteria as the “model” biochemical conversion reaction was continued. While past RBC experiments demonstrated the enhanced bioconversion effects of flocked surfaces, work was now turned to using a Recirculating Trickling Biofilter (RTB) as the experimental bioconversion media materials testing methodology. A schematic of the trickling biofilter structure, referred to as a Biofilter Media Testing Module {BMTM} that was constructed is presented in FIG. 9 . Two, identical BMTMs were constructed for this study. Here the biofilter media under test is placed in a chamber where water “contaminated” with ammonia is “trickled” through ammonia converting bacteria ( nitrosomonas and nitrobacter ) inoculated media.
[0079] The operating conditions for these two BMTM's are presented in Table 8. These conditions were kept constant during each ammonia bioconversion experiment described herein. In this study, two commercially available bio-media materials were evaluated for trickling biofilter effectiveness. These were chosen to be the “standard biofilter media” against which the experimental flocked fabric media will be compared. One of these media is a high surface area convoluted (open structure) “spiked” plastic balls known as Bio-Balls® [Aquatic Eco-Systems, Apopka, Fla.]. A picture of this media is presented in FIG. 10 . Bio-Balls® have a surface area of 525 square meters per cubic meter of volume (160 ft2/ft3). Its packing density is 14.1 lbs/sq. foot. Of importance is that in practice, these Bio Balls® are virtually non-compressible. This medium fills the media holding chamber of the BMTM as 1″ diameter solid spheres. Bio-Ball® media is commonly used in the closed-system aquaculture industry. A second commercially available bio-media material, called Bio Fill® [Aquatic Eco-Systems, Apopka, Fla.] was selected as a comparative baseline media in this study. Bio-Fill® media (see FIG. 10 ) is a high surface area PVC straw-like mesh in the form of an approximately 2 mm wide ribbon mesh. It has a surface area of approximately 551 square meters per cubic meter (165 ft2/ft3) with a packing density of approximately 2.7 lbs per cubic foot.
[0080] Bio-Ball® and Bio-Fill® media were both evaluated in terms of the rate and overall ability of each media material to lower the ammonia concentration in the water reservoir under identical processing conditions. The side-by-side (identical) BMTM systems were employed to assure uniformity of the test conditions. Baseline experiments were started using nitrosomas and nitrobacter microorganisms as the bio-species in the ammonia-in-water biochemical remediation process. A typical “run” consists of starting the concentration of ammonia in both the biofilter tanks at approximately 9 to 10 ppm by the addition of ammonium hydroxide to a fixed volume of de-ionized water (300 liters) in the recirculating tank. The systems are then allowed to stabilize for two days by circulating the ammonia containing water through the biofilter media without inoculating the media. Then the biomedia is inoculated with nitrosomonas and nitrobacter bacteria once the pH and ammonia concentration in the tank have stabilized. The inoculation cycle is carried out over an eight-day period. The flow rate of water in both systems is kept constant; typically chosen to be from 0.5 to 2.5 gallons per minute. During this time, the ammonia concentration, pH, temperature are routinely measured and recorded. The drop in ammonia concentration from its original 9 to 10 ppm value signals the successful inoculation of the media.
[0081] The ammonia concentration is then continually followed until it reaches a low value of 1 to 3 ppm. Very low ammonia concentrations were avoided so the micro-bacteria would not be likely to “starve to death” thus destroying the bio-culture on the media. The attainment of this lower 1 to 3 ppm of ammonia concentration signifies the end of a “first” cycle. For a “second” cycle, another portion of ammonia (as NH 4 OH) is added so that the reservoir tank ammonia concentration is again at the 9 to 10 ppm level. This starts the second cycle. This experiment is then continued for several ammonia cycles until several ammonia depletion rate “cycles” are obtained. Note that after the first “run”, a second and beyond “cycle” experiments can be carried out at different water flow rates without performing the inoculation step. This general procedure is used to evaluate the standard as well as experimental media.
[0082] A summary of results on the standard “commercial” media is presented in Table 9. These data show that overall, the Bio-Ball® media is a slightly better biofilter media than the Bio-Fill®. Therefore, the Bio-Ball® media was chosen as the “standard” media material for use in continued studies. In view of this decision, a plot of ammonia depletion versus the flow rate in presented in FIG. 11 . This represents the “standard” bio-conversion effectiveness plot against which experimental media data will be compared. In follow up to this, the ammonia bioconversion behavior of a flocked fabric experimental media material is also plotted in FIG. 11 . These comparative data clearly show the superior bio-reactive effect of the flocked surfaced fabric media.
[0000]
TABLE 8
List of Trickling Biofilter (BMTM) Operating Conditions.
Volume of Water in Reservoir
300 +/− 5 liters
Tank
Volume of Media Test Chamber
0.0297 cubic meters
Temperature of water
25 +/− 1° C.
pH of water
7 to 8
Dissolved oxygen in water
9 to 11 mg/liter
Approximate (induced) starting
9 to 12 ppm (mg/liter)
ammonia nitrogen concentration
for each ammonia depletion
rate experiment.
Water flow rates through Media
Must be set for each individual test.
test chamber
Generally 0.5 to 2.6 gallons per
(adjusted for each experimental
minute (GPM) is the range that has
run).
been used in this study. These flow
rates apply to the flow of water
through the 0.0297 m3 media test
chamber of the BMTM
[0000]
TABLE 9
Comparison of Ammonia Depletion (bioconversion) Rates Between
Flocked Fabric Experimental Media Material and Commercial
“Standard” Media (Bio Ball ® and BioFill ®)(a)
(d) Flocked
(d) Flocked
(d) Flocked
( b ) Bio-
Fabric
Fabric
Fabric (e)
Flow
Balls ®
(36.2 m 2 per
(50.1 m 2 per
(84.2 m 2 per
Rate
(15.4 m 2
( b ) Bio-Fill ®
0.0297 m 3 )(c)
0.0297 m 3 )(c)
0.0297 m 3 )(c)
(gallons/
per
(24.4 m 2 per
63-layers
85-layers
63-layers
minute)
0.0297 m 3 )(c)
0.0297 m 3 )(c)
fabric
fabric
fabric
2.5
0.12 [4.04]
NA
0.45 [15.2]
NA
NA
1.5
1.14 [38.4]
0.98 [33.0]
1.92 [64.6]
2.00 [67.3]
3.1 [104.5]
0.55
1.59 [53.5]
1.24 [41.8]
2.15 [72.4]
2.25 [75.8]
3.7 [124.6]
(a)All the data represent depletion of ammonia in ppm (part per million)/day or [mg/liter-day] and are based on the actual 0.0297 m 3 volume of media in the BMTM test chamber. To convert data to 1 cubic meter volume, divide these numbers by 0.0297. Data in brackets [ ] are surface areas normalized to a one cubic meter volume.
( b ) Bio-Balls ® are “shaped” PE (1″ diameter) “spiked” open spheres; Bio-Fill ® is an assembly of (4.8 mm wide) PVC ribbon (straw-like) members (see FIG. 10). These are commercially available from Aquatic Eco-Systems, Apopka, FL
(c)Total overall surface area of media material in biofilter test chamber of 0.0297 m3 volume.
(d) Flocked fabric prepared by flocking 15 to 18 denier, 3.8 mm long, nylon fibers onto a 20 holes per sq. inch PET netting fabric substrate using a water based acrylic flocking adhesive (LUBRIZOL ® FL1059B adhesive).
(e) This is an 8 hole per sq. inch PET netting fabric flocked with 18 D, 3.8 mm long nylon fiber configuration. Each of the 63 panels has a higher flock density than the 20 hole per sq. inch netting panel shown above.
Example 6
Flocked Biofiltration Media Surfaces
[0083] Studies of various experimental flocked fabric biofilter media configurations were carried out showing the superior bioconversion effectiveness of flocked fabric media. For example, in one particular test, at a 1.5 gallon per minute ammonia-water flow rate, a special flocked fabric configuration had a bioconversion rate of 3.1 ppm (ammonia)/day compared to a rate of 1.1 ppm (ammonia)/day for the Bio-Balls®. This special configuration was made by flocking the nylon flock fibers onto an 8 hole per sq. inch netting fabric at a high flock density. This configuration had the highest surface area of media packed into the bio-reaction chamber of the BMTM. This suggests the importance of the surface area (volume) packing of media in the bio-reaction chamber as a good criterion for high bioconversion rates. Overall, the data in Table 9 clearly show the superiority of flocked surfaces as biomedia compared to the Bio-Ball® and Bio-Fill® commercial media.
[0084] Performance data on some additional representative biofiltration media materials are presented in Table 9. Data on the commercial media and three configurations of flocked fabric media material are shown. The three experimental flocked media samples are the same except in the degree of packing in the media material in the BMTM test chamber. For all media tested, an increase in bio-conversion reaction rate occurs as the water flow rate decreases. Also, compared to the “standard” media, the higher bio-conversion rates for the flocked fabric surfaces are well demonstrated.
[0085] The data in Table 9 represent the bio-reaction rate based on the total volume of media that is enclosed in the BMTM's test chamber. For the commercial media and the 63 layer flocked fabric samples, the media is packed in a way to “comfortably” fill the test chamber. No extra force or packing pressure is used. For the 85 layered flocked fabric sample, the sample an additional 22 fabric layers were “squeezed” into the BMTM test chamber (in addition to the original, already present 63 layers). In another “run”, 63 layers of a “special configuration” flocked fabric were placed into the test chamber. Overall, this study was done in order to determine what affect a higher flocked fabric packing density and surface area effects would have on the bio-reaction rate.
[0086] As shown, the media volume based bio-reaction rate increases as the packing density and the surface area of the flocked fabric increases. As indicated based on a “normalized” 1 cubic meter volume, the surface area of the 63 layer flocked media increases from 1220 m 2 /m 3 to 1687 m 2 /m 3 for the 85 layered flocked, higher packing density media sample. Note that the specially flocked fabric sample had a surface area of 2835 m 2 /m 3 .
Example 7
Compact Trickling Biofilter Media Chamber—Design Calculation
[0087] Some model design calculations are presented showing that by using this specialty flock fabric media material in the bio-reactor media chamber, a Re-circulating Trickling Biofilter (RTB) device can be constructed having about ⅓ the (volume) media chamber size compared to the chamber size that would be needed if Bio-Balls® media were used in the same RTB bioconversion device. The media volume bio-conversion rate data of Table 9 enable one to design more compact (smaller volume) trickling biofilter installations. Here, the Bio-Ball's® bio-reaction rate performance can be taken as the “standard” reaction rate to be attained in a desired re-circulating trickling bio-reactor system. The “Volume Performance” of the flocked fabric media can now be compared on this basis.
[0088] For example: Choosing a flow rate of 1.5 GPM, it can be established from Table 9 that Bio-Balls® media has a bio-reaction performance rate of 38.4 ppm/m 3 -day. This can be set as the performance condition for a smaller, more compact RTB system. If flocked fabric media materials have a better bio-reaction performance at this same flow rate, it can be assumed that one would need a geometrically smaller (volume) bio-reactor to accomplish the same bio-reaction rate as the Bio-Balls®. Following this approach, the best bio-conversion rate results for a flocked fabric at 1.5 GPM flow rate (Table 9) is the special flocked fabric configuration which has a bio-conversion rate of 104.5 ppm/m 3 -day. To achieve or match the same bio-reaction rate as the Bio-Ball® containing media chamber, the volume of the flocked fabric media tank must be 38.4 divided by 104.5 or 37% fractionally smaller in volume than a comparably performing Bio-Ball® media containing tank. This means that if the original Bio-Ball® media containing tank was 1 cubic meter in volume, a comparably performing special flocked fabric material containing tank would have to be only 0.37 cubic meters in volume. A volume-of-tank reduction of 63% is achieved.
[0089] The final calculation in this exercise is to determine the “residence time” the ammonia-water must have in this smaller, flocked fabric media containing trickling biofilter tank. Therefore the ammonia-water flow rate through the media chamber must be adjusted in this smaller tank volume to give a residence time of 5.2 minutes. This is the residence time of the ammonia-water has in the experimental 0.0297 m 3 BMTM tank at a 1.5 gallons per minute flow rate. This is the time it takes a 0.0297 m 3 volume of the reservoir water to empty the media containing tank; this value can be taken as the time the ammonia water has in contact with the media. Since there are 12.46 increments of this 0.0297 m 3 volume in this newly “sized” 0.37 m 3 volume tank, this means that a flow rate of 18.7 GPM will be needed to pass through this smaller tank. This is an achievable flow rate level. Based on these calculations a suitable, much smaller, RTB device can be constructed. This example illustrates how data such as is given in Table 9 can be used to design and construct smaller, more compact re-circulating trickling biofilter devices for ammonia-water bio-remediation. Flocked fabric media materials having much higher bioconversion effectiveness than the example cited above can be developed.
[0090] Based on experiments using three different biofiltration techniques: (1) Laboratory Screening Tests, (2) Rotational Biological Compactor (RBC) a commonly used commercial biofiltration process and (3) Re-circulating Trickling Biofilter (RTB) technique, flocked fabric surfaces are more effective than “control” and commercially available media materials in the bio-remediation of ammonia-in-water applications. From trickling biofilter experiments, it is demonstrated that on a volume of media basis, flocked fabric experimental media are superior to Bio-Ball® and Bio-Fill® commercially available biofilter media for the bio-conversion of ammonia in water. An example calculation, using data existing to date, show that a volume reduction of a trickling biofilter media/chamber apparatus of almost two thirds (⅔) compared to the standard Bio-Balls®, is possible using flocked fabric as the biofilter media. It appears that the overall influencing parameters that control the volume based bio-conversion of media materials are (a) the available-to-the-bacteria surface area of the particular media and (b) the flow rate of ammonia-water that is trickled through the media material. The ammonia bio-remediation effectiveness of flocked fabric surfaces increases as the surface area (per volume) of the flocked fabric surfaces increases. However, this effect is not exactly proportional. The bioconversion rate value falls to less than 90% of the expected doubling value of bio-reaction rate.
[0091] In additional experiments, the ammonia bioconversion rate of all tested media increases as the flow rate of ammonia containing water through the media decreases. This effect is independent of the surface area of the media being tested. A trend was observed in that the higher the surface area of the media enclosed in the 0.0297 m 3 media chamber, the less is the effect of flow rate on bioconversion effectiveness. For example, for Bio-Ball media (surface area 17.8 m 2 in 0.0297 m 3 of chamber volume), the bioconversion effectiveness increase by changing from a 1.5 gpm to 0.5 gpm flow rate is 0.0253 ppm ammonia/day. The same change in flow rate for higher surface area media such as flocked media (surface area from 185.3 to 47.6 m 2 /0.0297 m 3 chamber volume) ranges from 0.0006 to 0.0031 ppm ammonia/day increase in bioconversion rate.
Example 8
Effect of Nutrients on Ammonia Removal Effectiveness of Flocked Media
[0092] It was found that the presence of nutrients in the tank water increases the growth rate of nitrosomonas and nitrobacter bacteria. During the inoculation period glucose (1 gram per liter) and disodium phosphate (0.1 gram per liter) were introduced as nutrients in the bio-filter re-circulation tank along with the ammonium hydroxide. In the no-nutrient studies, only ammonium hydroxide is injected into the bio-reactor (reservoir) tank. The concentration of ammonium hydroxide in the tank was initially set at 10-11 mg/liter.
[0093] The composition of the bioreactor tank solution during the inoculation period in the presence and absence of nutrients is presented in Table 10.
[0000]
TABLE 10
Composition of Bioreactor Tank Solution (per 300 L total volume).
Chemical Ingredient
Without Nutrient
With Nutrient
Ammonium Hydroxide
85 ml
85 ml
Glucose (Carbon Source)
None added
1 gram/liter
Disodium Phosphate
None added
0.1 gram/liter
(Phosphate Source)
[0094] After the inoculation period, 0.1 gm glucose and 0.01 gm of di-sodium phosphate was added daily until the experiment is over. It has been found that during the actual bio-reaction tests around 60-70% of the above nutrients were consumed.
Effect of Nutrients on the Ammonia Depletion Rates
[0095] The effects of nutrients on ammonia removal rates obtained by flocked media are shown in FIG. 13 . The configurations of flocked media studied are presented in Table 11. All the readings are noted at the flow rate of 0.5 gpm. It has been found that nutrients have a positive effect on ammonia removal rates.
[0000]
TABLE 11
Flocked Fiber Media Configurations Used in FIG. 11.
Point on Graph
Type of Netting
Flock Fiber
A
20 Holes/in 2
18D Nylon
B
8 Holes/in 2
18D Nylon
C
8 Holes/in 2
18D Nylon
U
8 Holes/in 2
Not Flocked
[0096] It is found that the presence of nutrient improves the rate of ammonia removal of flocked media by 27-35%. Nutrients in the bath tend to maximize the growth rate of bacteria on the media surfaces; the biomass layer build-up was found to be much thicker when the bio-reaction was made to occur in the presence of nutrients. These results show that the flocked media's effectiveness is not hindered by nutrients in the tank water. Nutrients in the tank water are common in actual aquaculture and other waste-water treatment operations. From these results, the successful use of flocked media systems in aquaculture and other waste-water treatment applications is anticipated.
Example 9
Dynamic Response of Flocked Media
[0097] Dynamic concentration flux in a bio-reactor tank system is a response of the bioreactor to fluctuations in pollutant concentrations in the system. It is important to check the flocked media's response to these fluctuating ammonia concentrations before using it for aquaculture bio-filtration system. In aquaculture systems, fish food is added to the tank 3-4 times a week. This food injection causes an almost immediate increase in the ammonium ion concentration in the tank. The bioreactor media should respond to these concentration changes quickly and should keep the concentration of ammonium ion under control. If media doesn't respond quickly enough to these changes the fish product in the tank may become ill or be killed.
[0098] To test dynamic response of flock media, 18D nylon fiber flocked, 20 holes polyester netting (1200 m 2 ) was selected. Set volumes of ammonium hydroxide were injected after each 24 hours; the ammonium ion drop rate was subsequently noted. These experiments were carried out at a flow rate of 0.5 gpm. The dynamic response of flocked media is shown in FIG. 14 .
[0099] Point A indicates the injection of ammonium hydroxide into the tank whereas point B indicates the drop in concentration of ammonium ion in 24 hours. It is clear from the graph that to every injection of ammonium hydroxide into the tank, flocked media behaves in similar manner and reduces ammonium ion concentration at a similar depletion rate range i.e. between 1.6-1.7 ppm/day. This study shows that flocked media can handle any rapid concentration changes that may occur in the aquaculture tank and hence maintain the concentration limits of ammonium ion within safe limits.
Example 10
Ammonia Bioconversion Effectiveness of Adhesive Coated (only) Netting Media Layers in the Test Module's Media Chamber
[0100] To provide a “control and baseline” for the bioconversion effectiveness behavior of flocked netting media materials, experiments were carried out on adhesive coated (not flocked) netting and fabric material as media. In these experiments, the BMTM chamber of the biofilter test module was completely packed with adhesive coated (only) netting media panels (not flocked). In one experiment, 67 layers of adhesive coated netting were placed in the BMTM media test chamber. Here, the media test chamber was only partially filled. 63 panel layers was the same number of media layers used in the test chamber when flocked netting was tested. In another experiment, 151 panels of adhesive coated only polyester netting (8 holes/square inch) were fitted into the biofilter media test module. This test chamber was fully packed. Following the developed experimental procedure, the ammonia depletion rate of these two media configurations (partial and fully packed media chamber) was determined. These data are summarized in Table 12.
[0101] It was observed that only 0.7 ppm ammonia per day was bioconverted in the partially filled media chamber while 1.1 ppm of ammonium ion concentration was depleted per day by fully packed media chamber. All data were for a flow rate of 0.5 gpm. This increased bioconversion effectiveness is most likely due to the increase in surface area in the fully packed (151 layers) media chamber. On another point, however, while both the same number of media panels were placed in each of the testing chambers, (comparing the flocked netting and adhesive coated netting configurations) the 67 non-flocked adhesive coated panels did not completely fill the media chamber. These panels were not uniformly positioned in the chamber. They were folded and bent leaving much open volume/space compared to the 151 layer adhesive coated netting (fully packed) chamber experiment. The flow of water through this 67 media panel containing chamber was not uniform. In comparison, when the 67 layers of flocked 8 holes/sq. inch netting was tested, it completely filled the media chamber; water flow here was more uniform throughout the media holding chamber. Finally, Table 12 includes data showing the positive effect of that flocked netting has on greatly increasing the surface area and bioconversion effectiveness of this netting based media. FIG. 12 was prepared to more clearly show the effect of surface area of flocked fabric surfaces on the bioconversion reaction rate.
[0000]
TABLE 12
Bioconversion Effectiveness of Adhesive Coated Netting (a).
Panels in Media
Bulk Surface
Bioconversion
Media material
Chamber
Area
Rate (ppm
(netting base)
(number)
(m 2 /m 3 )
ammonia/day)
Adhesive Coated
67
325
0.7
(part) (b)
Adhesive Coated
151
732
1.1
(full) (b)
Flocked netting (b)(c)
67
2800
2.5
Flocked netting (c)(d)
63
1200
2.2
Flocked netting (c)(d)
87
1687
2.4
(a) All data at 0.5 gpm water flow rate.
(b) 8 holes/sq, inch netting.
(c) Flocked with 18 D, 0.180″ long flock fibers.
(d) 20 holes/sq. inch netting.
[0102] It is observed that 0.7 ppm of ammonia per day was depleted for polyester (adhesive coated only) netting compared to a drop of 2.5 ppm per day for the flocked fabric with the same netting as its base.
Example 11
Ammonia Bioconversion Capability of Fully Flocked (not netting) Textile Fabric
[0103] An experiment was carried out to determine the ammonia depletion rate of planar, nylon fiber flocked panels of textile fabric. The effect of a fully flocked, not a netting material, fabric panel was determined. Here 100% scoured cotton was used as the base fabric. Note here that the base fabric material is not biochemically or chemically important since the fabric is coated with the flock adhesive that encapsulates the fabric. This woven cotton fabric was coated (primed) with acrylic adhesive using a paint roller. It was then dried for 12 hours. The dried fabric was then given a second coat of adhesive (second priming) and later dried again in air for 12 hours. These two coatings of adhesive layer made cotton fabric quite stiff. Nevertheless, the adhesive coated fabric was again coated (wet adhesive) and then flocked using 18D nylon 0.180″ long fibers on both sides. The flocked fabric was dried at room temperature for 12 hours. Finally, these air-dried flocked fabric panels then were heated in a curing oven at 80° C. for 2 hours. The cured flocked panels were vacuumed and then washed for two days in running tap water to remove surfactants and other impurities induced into the system by the (water based) acrylic flocking adhesive.
[0104] Washed panels were then dried and placed in the media test chamber for bacteria inoculation and bioconversion testing in the Biofilter Media Test Module (BMTM). A total of 59 panels, both sided flocked, were placed in the bioreactor chamber. The bulk surface area of this flocked fabric media was 6240 m 2 /m 3 . As typically carried out, the media was then inoculated for 8 days followed by measuring the ammonium ion depletion rate. The flow rate for this test was 0.5 gpm. Here, it was observed that ammonium ion was depleted at the rate of 3.9 ppm per day. This configuration yielded a high ammonia depletion rate. The only problem encountered was that of fabric panel stiffness. Fabric panels that were prepared were quite stiff in the dry state but became a softer when immersed in water. The flocked polyester netting materials (8 holes/square inch) were also stiff during their biofiltration operation. A summary of the bioconversion rate data for these “Control” media materials is presented in Table 13.
[0000]
TABLE 13
Summary of Ammonium Depletion Bio-reactivity of Base and
“Sample Control” Materials Used in this Study (a).
Ammonium Ion
# of Ply
Bulk Surface
Depletion Rate
Base Media Material
Layers
Area (m 2 /m 3 )
(ppm/day)
Adhesive Coated Netting
67
325
0.7
(Loose Packed)
Adhesive Coated Netting
151
732
1.1
(Full Packed)
Flocked Netting (b)(c)
67
2800
2.5
Both Side Planar Flocked
59
6240
3.9
Fabric Panels
(not netting) (b)
Adhesive Coated Fabric
210
1453
1.2
(not netting) (not flocked)
(a) all tests at 0.5 gpm flow rates
(b) 18D nylon flock, 0.180″ long
(c) 8 hole/sq. in. netting.
(d) Some of these data are also presented in Table 12.
[0105] From Table 13 it is obvious that the adhesive coated (not flocked) netting, no matter how many layers are packed into the media chamber, cannot match the bioconversion effectiveness of the flocked (planar) fabric or the flocked netting. This is because much more “surface area” can be packed into the media test chamber volume when the media is made using flocked fiber surfaces. However, a comparison of the two-sided flocked (planar) fabric media and the flocked netting media presents some useful considerations. First as mentioned previously, the fully flocked media panel (not netting) was found to be much better in its bioconversion properties compared to the similarly flocked netting. This flocked planar fabric is superior bioconversion-wise to the adhesive coated “control” media panel even though 210 panels per packed into the media chamber. Again, flocked surfaces/media have always been found to have enhanced bioconversion effectiveness.
[0106] Regarding the flat panel, (not netting media configuration), another factor is worthy of note. Because of water flow requirements, this planar fabric media configuration can only be arranged in the media chamber as parallel plates or a rolled up cylinder. It must be positioned in the test module's media chamber as an open-ended, slotted, assembly that is oriented parallel to the flow of water. This is the only orientation that will still allow water to smoothly flow through it. This feature may not cause any problems for some biofilter designs. On the other hand, the flocked netting fabric media configuration can be arranged in many ways. Flocked netting fabric can be stacked in the media (flow through) chamber as, (1) parallel plates, (2) perpendicular layers, (3) folded layers or as rolled up cylinders. The inherent nature of the netting (open holes) allows for this versatile media orientation. This orientation versatility is not readily available with the “solid flocked fabric” configuration. A folded or stacked layer of this flat (planar) flocked fabric will greatly restrict the flow of water through the plane of the fabric. Regardless, these results clearly demonstrate the overall versatility of flocked media in designing ammonia-in-water bioreactors.
[0107] It might be desirable in the actual design of operating biofiltration systems to have the media in one single piece as a roll or continuous sheet. If re-cycling or rejuvenation of the media is required, the flocked netting media material will be much more adaptable to a refurbishing or cleaning process involving its being flushed out with a spray of water.
Possibilities for Other Textile Fabric Media Configurations
[0108] Another important result from this experiment on testing flat fabric flocked media panels is the possibility that other forms of textile fabric materials, such as velvet, velour, napped, terry-cloth, raised fiber fabric, etc. can be used as effective biofilter media materials. These may prove useful in developing compact, space saving media materials for biofilter applications.
Example 12
PC Plates Flocked with Nylon Fibers
[0109] In one study, it was found that 3/16 inch thick polycarbonate (PC) plates flocked with nylon fibers are an excellent substrate for ammonia converting nitrosomonas and nitrobacter bacteria. During ammonia contaminated water immersion testing, all the flocked samples showed a rapid decrease in ammonia concentration accompanied by an increase in nitrate concentration. All the flocked panels showed a visibly heavy growth of bacteria on their surfaces compared to the controls. Similar studies on textile fabric surfaces, flocked with nylon fibers also showed remarkable bioconversion activity. It appears that flock fiber material with a large surface is an important factor in this observed enhanced bioconversion effect.
[0110] Other embodiments of the bioconversion surface materials disclosed herein, and methods for their application and use, are envisioned beyond those exemplarily described herein.
[0111] As used herein, the term “plurality” refers to two or more items or components. The terms “comprising,” “including,” “carrying,” “having,” “containing,” and “involving,” whether in the written description or the claims and the like, are open-ended terms, i.e., to mean “including but not limited to.” Thus, the use of such terms is meant to encompass the items listed thereafter, and equivalents thereof, as well as additional items. Only the transitional phrases “consisting of” and “consisting essentially of,” are closed or semi-closed transitional phrases, respectively, with respect to the claims.
[0112] Use of ordinal terms such as “first,” “second,” “third,” and the like in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish the claim elements.
[0113] Those skilled in the art should appreciate that the parameters and configurations described herein are exemplary and that actual parameters and/or configurations will depend on the specific application in which the systems and techniques of the invention are used. Those skilled in the art should also recognize, or be able to ascertain, using no more than routine experimentation, equivalents to the specific embodiments of the invention. It is therefore to be understood that the embodiments described herein are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, the invention may be practiced otherwise than as specifically described. | Flocked textile materials are disclosed as a support media for bacteria that actively biochemically convert noxious chemical species. Flocked fibrous netting materials as bioconversion support media are favorable to biological growth and provide excellent liquid (e.g. wastewater) flow through its structure as well as accommodating aeration processes. The disclosed support materials can be geometrically designed and positioned in many ways including stacked sheets/plies, rolled sheets in single or multi-walled tubes, and continuous belts or webs that can be self-cleaning and configured to operate in an automated process control mode. The disclosed support media facilitate development of compact and durable biofilter structures at a low cost. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to the production of continuous glass fibers, e.g., fibers made by melting particulate batch ingredients or minerals, including basalt and the like, and, more particularly, to a method and apparatus for detecting a break in such fibers during the drawing process.
It is intended that the term "scattered," as used herein, denotes forward scattering, backscattering and right angle scattering of the incident radiation.
It is well known in the art that continuous glass fibers can be produced by attenuating a plurality of streams of molten glass into fibers, collecting the fibers into a strand and winding the strand into a package for subsequent use in manufacturing various products. The molten glass flows from a furnace and through a forehearth into a feeder or bushing which has a plurality of orifices formed therein. The molten glass flows from the orifices as streams which are pulled downwardly at a high rate of speed for attenuation into fibers. A plurality of the attenuated fibers are then gathered together into a strand, coated with a sizing and wound onto a collection tube on a winder collet.
During the fiber forming process, a fiber may break and cause a bead of molten glass to form on the undersurface of the bushing at the orifice at which the breakage occurred. Gradually, the bead of molten glass becomes larger and heavier; the increased weight causes it to fall and contact adjacent fibers which causes them to break. If the spacing between the adjacent orifices is extremely small, the bead of molten glass contacts the adjacent forming cone of molten glass, thus causing more fibers to break. If such breakage is not detected, additional fibers will be broken as the bead continues to grow; this breakage will continue until all of the fibers in the fan are broken. The time required to restart the fiber forming process is related to the number of fibers that have broken. Accordingly, a breakage must be detected as early as possible so that suitable corrective measures can be taken to minimize the downtime of the process.
Therefore, it is an object of this invention to provide a reliable method of and apparatus for detecting breakages in glass fibers during the fiber producing process.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a method of detecting breakage of glass fibers, such method comprising the steps of illuminating the fibers with electromagnetic radiation and sensing a variation in the amount of radiation scattered by the fibers as an indication of a break in the fibers.
In addition, the invention provides a glass fiber producing apparatus comprising: a feeder for holding a molten body of thermoplastic material, such feeder having an orificed wall for emitting a plurality of streams of such material; a rotary collector for attenuating the streams into continuous fibers and for winding the fibers into a package; a gathering device located between the feeder and winder for gathering the fibers into a strand before being wound into the package; means for illuminating the fibers with electromagnetic radiation; means for collecting electromagnetic radiation scattered by the fibers; and means responsive to the collected scattered electromagnetic radiation for generating an electrical signal indicative of the amount of light scattered by the fibers. Preferably, the apparatus comprises means for averaging the generated signal over time and means for comparing the averaged signal with a reference signal indicative of the normal amount of radiation scattered by the fibers.
The system of the present invention is well adapted to the fiber forming environment which includes large radiative heat loads from the orificed wall, moisture from prepared sprays and periodic cleaning, binder solids entrained in air circulating around the feeder or bushing, shock-vibration loads due to bushing changes, and similar adverse environmental factors. Moreover, the system does not interfere with normal bushing operation and operator access to the bushing.
In a preferred embodiment, a calibration control is combined with an electro-optical measurement instrument to provide a system having automatic compensation of the entire electro-optical train without interruption of the measurement process for detecting a breakage of the fibers during the fiber forming process. The electro-optical instrument includes a plurality of light-emitting diodes which provide a source of substantially monochromatic electromagnetic radiation and optics for collecting and focusing radiation onto a detector. The radiation is directed through a sampling volume where it impinges upon the fibers that are to be monitored by scattering techniques. The calibration control includes an element rotatably positioned in the path of the electromagnetic radiation, optically upstream of the sampling volume, such that the radiation is periodically blocked and sampled.
Although, the present invention is described herein in a backscattering embodiment, it should be understood that the novel aspects of the invention have much broader application and may be applied to forward and side scattering systems for the detection of breakages in glass fibers.
Other objectives, advantages and applications of the present invention will be made apparent by the following detailed description of the preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram showing the incorporation of the present invention into an apparatus for producing a plurality of glass fibers.
FIG. 2 is a diagrammatic view showing the preferred orientation according to the present invention of a sensor relative to the longitudinal axis of the fibers.
FIG. 3 is a detailed plan view of an apparatus for use with the present invention.
FIG. 4 is a detailed view in elevation of the apparatus shown in FIG. 3.
FIG. 5 is a schematic block diagram showing a control system according to the present invention in a microcomputer based system.
FIG. 6 is a diagrammatic view of an apparatus for use with the present invention that scans the fibers to be monitored.
FIG. 7 is a diagrammatic plan view of the apparatus shown in FIG. 6 illustrating the angular orientation of the scanning.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the incorporation of the present invention into an apparatus for producing a plurality of glass fibers. In a typical fiber forming process, raw materials or batch are provided to a melting furnace 12 by suitable supply means 14 at a rate which is sufficient to maintain the mass flow rate of molten glass 16 being extracted and flowed along forehearth 18 to a fiber forming feeder or bushing 20. From bushing 20, molten glass 16 flows into a plurality of streams through a grid of orifices 21 formed in the bottom of bushing 20, such orifices may have projecting tips or may be tipless. Normally, bushing 20 is electrically heated to control the temperature, thereby controlling the viscosity of the issuing streams of molten glass. The streams of molten glass issuing from orifices 21 are pulled at a high rate of speed for attenuation into individual fibers 22. Attenuated fibers 22 pass downwardly in a generally conical pattern to a gathering member 24 which forms strand 26. Gathering member 24 also may supply a suitable sizing fluid to strand 26 in the known manner, or a separate applicator means may be employed. From gathering member 24, strand 26 moves to a winder collet 28 wherein it is wound on a collection tube to form a package. Winder collet 28 is driven by a motor 30 or any other suitable means and, generally, the speed of motor 30 is regulated by a speed controller 32. A temperature controller 36 regulates the amount of electrical energy provided by power source 34 to heat bushing 20, thereby maintaining bushing 20 at a predetermined temperature.
Electro-optic sensor 38 is positioned between bushing 20 and gathering member 24 such that its emitted beam of light 40, falls upon the unsized fibers of interest in the electro-optically defined sampling volume 48. Emitted light 40 is backscattered from fibers 22 and a portion thereof, which is indicated generally by numeral 41, is collected by sensor 38. Sensor 38 is connected to a control circuit 39 which, in turn, may be connected to an alarm circuit 42 to alert an operator that a break has occurred.
Sampling volume 48 is defined as the joint intersection of the emitted beam of light and the radiation collection optics according to the following equation:
I·W=constant
where I is the LED beam intensity in watts/square centimeter and W is the solid angle of reception in steradians. Both I and W are dependent on position relative to the optical system. In essence, sampling volume 48 is that region of space where light from the LED source (numeral 60 in FIGS. 4 and 5) may both fall on fibers 22 and be received by the collection optics (numeral) 63 in FIGS. 4 and 5).
With reference to FIG. 2, the angle between the line of illumination 52 and the fibers of interest 22 should be adjusted so that a maximum amount of light backscattered from preferred fibers will reach the collection optics and be utilized. The amount of emitted light 52 reaching the collection optics is maximized when sensor 38 is tilted on its axis such that emitted light 52 is incident perpendicularly upon the center 53 of the fibers.
FIGS. 3 and 4 illustrate one embodiment of electro-optic sensor 38 for use with the present invention from a top view and side view, respectively. Sensor 38 has a housing 54 which is attached by suitable fasteners to mounting plate 56 which, in turn, is mounted in any suitable position adjacent the fiber fan. A quantity of light, indicated by numeral 52, is generated by three light-emitting diodes 60; light 52 from light-emitting diodes 60 is focused into a substantially collimated beam by plano-convex lens 62 after which it exits from housing 54 through aperture 58. Lens 62 is positioned so that its flat side is closest to diodes 60. The collimated beam of monochromatic light may also be generated by a laser or other suitable device. The wavelength of the monochromatic light emitted by diodes 60 may be, for example, 0.9 microns. However, it should be understood that the beam may contain more than one wavelength, in which case, the wavelength or wavelengths of interest would be separated from the collected radiation by conventional filtering techniques.
The light backscattered by the fibers, which is indicated by numeral 72, is passed through collection optics 63 which comprises plano-convex lenses 64 and 66, positioned such that their convex sides are adjacent. Collection optics 63 focuses the backscattered light, after which it passes through an infrared filter 68 onto photodetector 70. The amount of backscattered light received by photodetector 70 is dependent upon the axial response of the system which is related to the focal length of collection optics 63 and the distance of sensor 38 from fibers 22. In the preferred embodiment, the diameter of lens 64 is chosen from the approximate formula which specifies that the arc tangent of the diameter (D) of lens 64 divided by the distance (d) from a plane through the center of lens 64 to the center of sampling volume 48 is greater than or equal to 5° (arc tan D/d≧5°). The output of photodetector 70 is fed to a preamplifier which is part of electrical circuit 74; circuit 74 also contains a driver circuit for diodes 60.
A calibration element 76 is pivotably mounted on pivotal axis 81 such that it can be moved into a closed position indicated by the dotted lines at numeral 78 so that a calibration of the electro-optical portions of sensor 38 can be performed at predetermined intervals. Calibration element 76 is moved into and out of its closed position by screw drive mechanism 79, which is driven by motor/gearhead 80. Calibration element 76 contains fiber optics 71 with ends 73 and 75. The operation of calibration element 76 is discussed hereinafter in detail.
An air hose or coupling 82 supplies air into housing 54 from an air supply (not shown) for blowing dust particles and the like away from the collection or viewing aperture 58 and for cooling electronic circuit 74 to prevent drift. Sensor 38 is also provided with an L-shaped heat shield 84 to protect it from the heat radiated from the tip plate of bushing 20. Heat shield 84 is attached to the top front part of housing 54 by suitable fasteners such that the short leg of L-shaped heat shield 84 is located in front of housing 54 above aperture 58.
With reference to FIG. 5, the signal processing from sensor 38, including how the automatic compensation of gain and zero is implemented by control system 39 in a microcomputer based system, is explained. LEDs 60 are excited by driver circuit 90, which, in turn, is actuated by signals from LED clock 92. The signals from clock 92 reach driver circuit 90 via analog multiplexing switch 94, which is under the control of microcomputer 96. Multiplexing switch 94 may also be connected to other LED driver circuits. Radiation from LEDs 60 is collected by beam forming lens 62, whence it falls upon a representative fiber sample in the electro-optically defined sampling volume 48. Backscattered radiation is received by collection optics 63, passed through infrared filter 68 and focused on photodetector 70. The low level output signal from photodetector 70 is amplified by preamplifier 100 and supplied to multiplexing electronic switch 102 which receives its control signal from microcomputer 96. Multiplexing switch 102 may also be connected to other preamplifiers. Multiplexing switch 102 is connected to postamplifier 104 in which the signal is further amplified and then provided to synchronous detector 106. Clock 92 and synchronous detector 106 are operated in synchronism, as is well known in the art, to permit more reliable signal processing, particularly for low level signals in the presence of high, quasi-static background radiation, such as that found in the vicinity of a luminous bushing.
Synchronous detector 106 filters and applies DC offsets to the signal and provides an output signal, symbolized by V f , to analog multiplexing switch 110 which is under the control of microcomputer 96. Signal V f is in direct proportion to the amount of light backscattered by the plurality of representative fibers in sampling volume 48. When the output terminal of multiplexing switch 110 is connected to synchronous detector 106, by proper logic from microcomputer 96, V f is inputted to voltage to frequency converter 114 (V/F converter 114). V/F converter 114 produces an output signal whose frequency is in direct proportion to the analog voltage inputted, this form being optimum for digital processing, as is well known and understood by those skilled in the art.
Signal V f is compensated for zero and gain variations of the electro-optical system to ensure accurate and reliable results. The variations in the gain of the electro-optical transfer functions can be caused by numerous factors, for example, if the quantity of light produced by the LEDs is reduced by a factor of two, then it follows that the net signal V f will also be reduced by a factor of two. The gain may also vary if the collection optics are contaminated by foreign matter. For example, if only fifty percent of the light falling upon the collection optics is transmitted, then it follows that the net signal V f would be reduced by a factor of two. The zero or baseline signal of the system, V b , i.e., the value of V f when all of the representative fibers in sampling volume 48 are completely removed and no material is inserted in their place, may not reliably approach a true zero voltage but rather some background signal. The origin of V b may be stray light, ambient light or electromagnetic pickup of any kind.
V b has been found to be both small and fairly constant and can be made to approach zero by utilizing zero potentiometer 116, which is connected to multiplexing switch 110 by analog multiplexing switch 118 which is under the control of microcomputer 96. Multiplexing switch 118 may be connected to additional zero potentiometers. If V b should change, it is a simple matter to adjust zero potentiometer 116 so that V f approaches zero when the fibers to be measured are removed.
The compensation for electro-optical system gain is accomplished by periodically rotating calibration element 76 downward to its closed position 78. Referring to FIGS. 3 and 5, the mechanical operation of calibration element 76 is accomplished by exciting motor/gearhead 80 which, in turn, operates a screw drive mechanism 79 such that calibration element 76 is operated around pivotable axis 81. Motor/gearhead 80 is driven by a signal provided by microcomputer 96. Microcomputer 96 may also provide actuation signals to additional motor/gearheads.
When calibration element 76 is in its closed position 78, the beam of light from LEDs 60 falls on end 73 of fiber optics 71. A precisely known fraction of the incident radiation then emanates from the other end 75 of fiber optics 71, to collection optics 63. The radiation then passes through filter 68 onto photodetector 70 which generates an electric signal. The signal proceeds along the same signal path as a normal signal from the representative fibers in sampling volume 48. Thus, it is evident that the entire electro-optical transfer function is used so that variations in any component ae determined and ultimately compensated.
The signal V f that is inputted to V/F converter 114 is derived from three conditions: (1) a true signal from representative fibers; (2) a zero signal when no fibers are present; and (3) a calibration signal. All of the signal conditions are produced under the control of microcomputer 96 in accordance with a program determined by program and scratch pad memory 120.
The mathematical operation of automatic compensation of the transfer function implemented by microcomputer 96 to produce an automatically-compensated indication proportional to mean fiber diameter can be generally expressed as follows: ##EQU1## where V f ': final, compensated signal which is proportional to the amount of light backscattered by the fibers;
V f : total amount of light backscattered by the fibers in sampling volume 48;
V b : signal with no fibers present;
V ref : scaling or multiplying signal; and
V cal : signal with calibration element 76 in closed position 78.
Clearly, the operation of the apparatus of the present invention in implementing equation (1) is to acquire the total signal V f , subtract off the background V b , multiply by a signal V ref , and then divide by the calibration V cal . V b is a reference signal derived from zero potentiometer 116 to make the readings of sensor 38 agree with separately determined calibration values. Evidently, if the transfer function were reduced by a factor of 50%, then the net signal V f minus V b would have been reduced by a factor of 2. However, dividing by the calibration signal V cal results in V f ' indicating the same response to the representative fibers in sampling volume 48 as when the transfer function is at its original value.
It has been found that calibration updating of the sensor of approximately once per hour is satisfactory to control the electro-optic transfer function to very precise levels. The initiation of the calibration update is under microcomputer control and in some embodiments takes place at hourly intervals; however, there are other protocols under which the calibration update may be implemented as explained hereinbelow.
The multiplexing functions provided by the various multiplexing switches allow microcomputer 96 to process signals from a plurality of sensors at a single bushing, or a plurality of sensors monitoring a plurality of bushings with one or more sensors monitoring each bushing.
In a typical fiber forming operation, winder collet 28 is brought up to speed after initiation by an operator or by winder speed controller 32. When a predetermined amount of time or, better, weight of glass has been wound onto the package, the run is terminated. At this point, while the new collection tube is being brought into position and a new run started, control circuit 39 receives a signal either from an operator, or from speed controller 32, to go through an automatic calibration. If desired, a protocol may be employed to send the sensor into an automatic calibration, when there is a breakage of the fibers. This protocol will provide the advantages of protecting the internal elements of sensor 38 during the correction of the problem causing the breakage and allowing sensor 38 to utilize downtime for performing the calibration of the transfer function rather than during normal operation.
Microcomputer 96 averages V f ' over time to minimize the effects of any transient aberrations in a fiber or fibers, thereby providing a more meaningful signal, V out , for detection purposes. By averaging V f ' over time, the amount of light backscattered by the fibers is derived from multiple replications of measurements along the lengths of the fibers. Microcomputer 96 then compares V out with a reference signal to determine if less than a predetermined amount of light is being backscattered by the fibers. If V out is less than the reference signal, microcomputer 96 provides a signal to activate alarm 42, thereby alerting an operator that a break has occurred in the fibers.
The reference signal, which must be determined empirically for each process, is chosen to allow for a limited degree of drift in the fiber forming process. Such drift may be caused, for example, by slight changes in winder speed or busing temperature which results in a change in the average diameter of the fibers and hence a change in V out . If suitable controls are utilized to stabilize the process, thus producing fibers of uniform diameter, the dead band range may be reduced to a minimum.
In another embodiment, microcomputer 96 also determines the rate of change of V out and compares it with a second reference signal which is indicative of the maximum rate of change of V out allowed before alarm 42 is activated to indicate a break. The second reference signal, as with the first reference signal, must be determined empirically for each process. Therefore, microcomputer 96 activates alarm 42 to signal that a break has occurred if either V out is less than a first reference signal or the rate of change of V out is greater than a second reference signal.
A plurality of sensors may be utilized to monitor a single bushing if the size of the bushing warrants such; the output of each sensor would be provided to microcomputer 96 where it would be processed as described hereinabove.
In another embodiment, which is shown diagrammatically in FIGS. 6 and 7, the sensor scans across fibers 133 and generates a signal representative of the radiation backscattered from the fibers. The outside dimensions of the bushing are shown in FIG. 7 by numeral 135. LED 136 provides a quantity of light that is formed into a beam by beam forming optics 138 and brought to bear on beam mirror 140. Beam mirror 140 transmits the beam through collection optics 142 onto scanning mirror 144 which is driven at a rate of about one revolution per second by a small motor 146. Scanning mirror 144 transmits the beam to fibers 133, and backscattered radiation 148 from fibers 133 within sampling volume 149 proceeds coaxially backward to scanning mirror 144 through collection optics 142 onto photodetector 150.
The signals generated by photodetector 150, as scanning mirror 144 sweeps the beam across fibers 133, are then synchronously detected and processed by microcomputer 96. The sensor produces a signal that is a function of the scan angle, which is contained within the limits of ±P (FIG. 7), as defined by the size of mirror 144 and the distance therefrom to fibers. The signal produced by the sensor is also a function of the fiber axes relative to optical axis 152 of the sensor, as discussed hereinbefore. In this embodiment, microcomputer 96 compares V out with a reference signal to determine if fibers are missing at a particular location, such missing fibers being indicated by a significant change in the magnitude of V out . If microcomputer 96 detects a break, it provides a signal to alarm 42 to alert the operator.
When scan mirror 144 has reached the position indicated by numeral 154, the beam impinges upon calibration element 156 from which is precisely known fraction of the incident radiation emanates to scan mirror 144 and then through collection optics 142 onto photodetector 150 for compensation of the transfer function, as discussed above. An electro-optic sensor provides a signal to the controller (control circuit 39 in FIG. 1) to indicate that scan mirror 144 is in its calibrate position 154, thereby causing the microcomputer to enter its calibration routine. Other means can be used for detecting when scan mirror 144 is in its calibration position 154, such as, for example, a microswitch responsive to the position of the shaft of motor 146.
In alternative embodiments, the sensor may scan the sampling volume by pivoting or rotating about an axis, or it may move linearly along the bushing, such as on a conventional pair of rails or tracks.
It is to be understood that variations and modifications of the present invention may be made without departing from the scope of the invention. It is also to be understood that the scope of the invention is not to be interpreted as limited to the specific embodiment disclosed herein, but only in accordance with the appended claims when read in the light of the foregoing disclosure. | A method and apparatus for detecting breakage of glass fibers comprising illuminating the fibers with electromagnetic radiation and sensing a variation in the amount of radiation scattered by the fibers as an indication of a break of said fibers. | 6 |
[0001] This invention relates to a track for a tracked vehicle and particularly to an improved suspension arrangement for the leading idler wheel and front roller member.
BACKGROUND OF THE INVENTION
[0002] Track vehicles generally include a pair of tracks on each side where the track includes a belt for rolling over the ground, a rear driving wheel around which the belt is wrapped for driving the belt and the front idler wheel around which the belt is wrapped so that the belt is tensioned between the front and rear wheels. It is common to provide a telescoping frame arrangement supporting the front idler wheel relative to the rear wheel so that the extension of the telescoping system acts to tension the belt. Between the front and rear wheels is mounted a plurality of rollers which are supported on the frame and extend downwardly into engagement with the bottom run of the belt so as to support the belt relative to the ground. In many cases such rollers are mounted in pairs on a walking beam arrangement allowing pivotal movement of the pair about a horizontal axis in between the pair of rollers.
[0003] In many cases, generally used for slower speed systems over smoother terrain, the wheels and rollers are mounted rigidly relative to the frame so that there is no suspension movement apart from the flexing of the belt. However higher speed and higher variations in terrain generally require that the front idler wheel and the rollers are mounted for suspension movement relative to the frame and typically theses elements may be mounted on pivot arms with suitable resilient compression springs for resisting the upward movement of the element relative to the ground. Gas bag springs are commonly used for supporting the pivot arms. Many different configurations of rollers and supports for the rollers are known.
[0004] In U.S. Pat. No. 3,774,708 of Purcell assigned to Caterpillar Tractor and issued in November 1973 is disclosed a track of this general type but in the embodiment shown both the leading and trailing wheels are idler wheels and the belt is driven in the so called “DELTA” configuration by a drive wheel which is located above the rear idler wheel so that the belt is shaped into a generally triangular arrangement wrapped around the front and rear idler wheels and over the drive wheel.
[0005] In this patent the front idler wheel is mounted on a rocker rotatably mounted to the frame of the track. On the same rocker is mounted the first undercarriage bogey or roller member carrying a pair of rollers or bogey wheels in a conventional oscillating or walking beam arrangement.
[0006] The rest of the bogey wheels are provided as oscillating bogies and are mounted on rockers at spaced positions between the first pivoting roller member and the rear idler wheel. The connection by a rocker between the idler wheel and the first bogey, where the rocker is pivotally mounted about a horizontal transverse axis on the frame, allows upward movement of the front idler wheel to be transferred as corresponding proportional downward movement of the first bogey and vice versa.
[0007] One significant disadvantage of this arrangement is that large dynamic loads on the idler wheel, generated by engagement with the ground, are transferred directly to the first pair of bogeys. The present inventors have found that this arrangement is significantly disadvantageous in that this proportional downward movement of the first bogey increases the local pressure of the belt or rubber track on the ground and significantly increases the oscillation of the whole track and therefore the machine. This oscillation significantly applies undesirable vibration to the whole machine interfering with operator comfort and interfering with the traction efficiency of the track.
SUMMARY OF THE INVENTION
[0008] It is one object of the present invention to provide an improved suspension for a vehicle track of this general type.
[0009] According to a first aspect of the invention there is provided a track for a tracked vehicle comprising:
a frame construction for supporting the vehicle relative to the track; an endless rotatable belt for rolling over the ground; a drive wheel connected to a source of drive power engaging and driving the belt; a front idler wheel carried on the frame construction and arranged to engage the belt and support the frame construction relative to the belt; a roller member carried on the frame construction rearward of the front idler wheel and arranged to engage the belt and support the frame construction relative to the belt; the front idler wheel being mounted on the frame construction for upward and downward suspension movement in response to change in ground level; the roller member being mounted on the frame construction for upward and downward suspension movement in response to change in ground level; and a linkage connected between the front idler wheel and the roller member for transferring upward movement of the front idler wheel from the ground into downward force on the roller member tending to move the roller member downwardly toward the ground and vice versa; wherein the linkage includes a resilient spring actuable to absorb some upward movement of the front idler wheel so as to avoid transfer of a proportional downward movement of the roller member.
[0019] The type of vehicle with which the present invention is concerned can vary widely from low speed earth working vehicles to higher speed mildly vehicles. However the present invention is particularly but not essentially concerned with vehicles for arctic conditions where there can be significant rock outgrowths and intervening snow cover where it is desirable to prevent the track from digging into the snow.
[0020] The term “belt” used herein is not intended to be limited to any particular construction or material from which the belt is formed. Thus the belt can be a rubber continuous belt or can be formed of segmented metal plates, depending upon requirements. However the suspension is primarily designed for rubber belts more suitable for arctic conditions.
[0021] Preferably the resilient spring comprises a gas bag which is compressed to absorb the movement of the front idler wheel, since such gas bag springs are convenient, resistant to damage and adjustable. However other types of springs can also be used.
[0022] Preferably the front idler wheel is mounted on the frame construction for pivotal movement about a horizontal axis transverse to the length of the belt.
[0023] In this arrangement the front idler wheel is preferably mounted on a mounting lever which extends substantially forwardly from the frame construction such that the front idler wheel is mounted substantially directly in front of the pivot axis for the upward and downward movement.
[0024] Preferably the linkage includes an actuating lever extending from the pivot axis generally opposite to the mounting lever with the resilient spring or gas bag spring at the end of the actuating lever and compressible relative to the roller member. In this way the gas bag spring provides resilient suspension for both the wheel and the roller member.
[0025] Preferably the roller member is mounted on a mounting lever which extends substantially rearwardly from a pivot axis on the frame construction and the pivot axis of the front idler wheel is above the pivot axis of the roller member with the resilient gas bag spring located between the rear end of the actuating lever and the mounting lever of the roller member.
[0026] Preferably the roller member includes a pair of rollers mounted on a common walking beam pivotally carried on a central support where the gas bag is located between the actuating lever and the central support of the walking beam.
[0027] Preferably the drive wheel comprises a rear wheel of the belt and the belt extends substantially straight between the drive wheel at the rear and the front idler wheel in the standard or flat configuration rather than the so-called Delta configuration.
[0028] Preferably the frame construction includes a telescoping tensioning section for moving the front idler wheel and the roller member forwardly relative to a rear frame section carrying the drive wheel.
[0029] Thus the arrangement defined above provides an oscillating rocker lever for the front idler wheel which is connected through a spring acting as an elastic and damping element to the rocker lever of the first set of bogey wheels. The first set of bogey wheels and the idler wheel can be mounted on the front end of a telescoping tensioning system.
[0030] A similar symmetrical arrangement can be provided, for reverse movement of the vehicle, also at rear idler wheel in front of the drive wheel which is mounted on a pivotal rocker arm which is also connected by a gas bag spring to the pivotal rocker arm of the rearwardmost set of bogey wheels or rollers.
[0031] Thus the oscillating rocker arm of the front idler wheel and its connection through a resilient spring to the front set of bogeys avoids the generation of large harmful dynamic loads on the idler wheel from interaction of the undercarriage with the ground. High energy and high forces applied to the front idler wheel due to significant changes in ground height are absorbed by the spring system so that excess energy is absorbed into the gas bag spring to reduce the energy transferred to the pivot lever or rocker arm of the front set of bogies.
[0032] Tests made according to the present invention show a significant increase in the operators comfort and a significant decrease in the ground pressure applied by the belt at the location of the first set of bogies to minimize the dynamic loads of the undercarriage elements and local pressure of the track.
[0033] A further advantage of this arrangement is that a proper adjusting of the elastic and dampening element provided by the gas bag is possible to get better stability of the machine and better maneuverability.
[0034] It will be appreciated that the application of excess loads to the track and therefore to the ground by the downward movement of the first set of bogeys is significantly reduced thus decreasing the tendency of this part of the track to dig downwardly into the ground and particularly into soft snow.
[0035] Thus the present invention reduces the tendency of the track to become buried in snow by aggressive downward forces in the event that the leading idler wheel is forced upwardly by engagement with a projecting rock or other aggressive changes in ground height.
[0036] In addition the reduced tendency of the track to oscillate vertically also acts to reduce the tendency for side to side oscillation of the vehicle due to changes in forward traction on one side or other of the vehicle. Thus the vehicle tends to travel in a straighter line than normally occurs where the traction of one or other of the tracks varies significantly due to its temporary increase in engagement force with the ground.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] One embodiment of the invention will now be described in conjunction with the accompanying drawings in which:
[0038] FIG. 1 is a side elevational view of a track according to the present nvention.
[0039] FIG. 2 is a top plan view of the track of FIG. 1 .
DETAILED DESCRIPTION
[0040] A single track of a vehicle is shown in FIGS. 1 and 2 and includes a frame construction 1 of the track which is attached to the main body of the vehicle so as to support the vehicle relative to the track. The frame construction includes a fixed rear section 1 and a movable front section 2 which can be extended forwardly by the action of a hydraulic cylinder 3 mounted inside the fixed rear section 1 . Thus a tensioning effect can be obtained by applying hydraulic fluid to the cylinder 3 tending to push the forward end of the frame structure forwardly relative to the rear end. A belt 5 is wrapped around a rear driving wheel 4 carried on the rear frame section 1 and also around a front idler wheel 6 carried on the movable front section of the frame 2 . Thus it will be appreciated that the belt is tensioned between the front idler wheel and the rear drive wheel and is drive by the rear drive wheel engaging the suitable projecting members on the inside of the track.
[0041] The front or leading idler wheel 6 is mounted on a rocker arm 7 pivotally mounted on the frame section 2 at a transverse pivot shaft 7 A. From the shaft 7 A, the arm 7 extends forwardly and slightly downwardly so that the axle 6 A of the front idler wheel 6 is located just below the pivot shaft 7 A of the lever or rocker arm 7 . The rocker arm 7 carries an abutment 8 which engages an abutment member 8 A on the front of frame section 2 so as to prevent downward movement of the arm 7 and therefore of the front wheel 6 beyond the predetermined angle. Thus normally the tensioning in the belt caused by the forward movement of the front section 2 of the frame forces the arm 7 in a counter clockwise direction into engagement with the abutment 8 A. However upward forces on the front wheel 6 caused by changes in ground height cause the axle 6 A to move upwardly thus rotating the rocker arm 7 in a clockwise direction around the shaft 7 A. Suitable elastomeric elements can be provided at the abutment 8 A so as to reduce impact forces when the front roller 6 moves downwardly as the upward forces on the belt and the roller are removed due to changes in ground height. The frame also carries a plurality of bogey wheels 11 arranged in pairs so that there are three pairs arranged one behind the other behind the leading idler wheel.
[0042] A second or rear idler wheel 15 is mounted in front of the drive wheel 4 and provides a rear point of engagement of the tract with the ground, the drive roller for being mounted in conventional manner to raise height. The rear idler wheel 15 is mounted on a rocker arm 14 symmetrical relative to the rocker arm 7 of the front idler wheel and carried on a symmetrical pivot shaft 14 A.
[0043] Each of the pairs of bogies is carried on a walking beam 10 pivotally mounted on a shaft 10 A so that one of the rollers 11 is mounted in front of the pivot shaft 10 A and one is mounted behind. Thus each of the pairs allows upward and downward pivotal movement of the pair in opposite directions about the pivot shaft 10 A in a conventional walking beam arrangement. The pivot shaft 10 A carries a central support 10 B through which downward force on the pair of bogies can be applied from the frame. Thus loading from the frame is transferred to the central support of each pair of bogies without loading being shared between the two bogies of the pair depending upon ground height.
[0044] Each of the center support members 10 B of the bogies includes a top plate on which is mounted an elastic spring member in the form of a gas bag spring. The gas bag spring thus acts as dampening device and also as a resilient spring so as to absorb forces tending to compress the spring.
[0045] In respect of the front pair of bogies, the upper end of the gas bag spring 12 is mounted on a support plate of a lever 7 B which forms a rear extension of the rocker arm 7 . Thus the rocker arm 7 and the actuating lever 7 B form a common element pivotally mounted on the frame at the shaft 7 A so that upward movement of the axle 6 A of the wheel 6 causes downward movement of the actuating lever 7 B on the top of the gas bag spring 12 .
[0046] Thus there is a coupling acting to transfer upward movement of the front idler wheel 6 into downward forces on the center support 10 B of the first set of bogies thus tending to force the first set of bogies downwardly as the front wheel rises. However some of the energy from the upward movement is absorbed by compression of the spring 12 and the rebound energy from the compression is also dampened by the action of the gas bag spring. The front wheel 6 and the first set of bogies therefore acts as a common suspension member pivotal relative to the frame at the shaft 7 A with each being able to pivot upwardly and downwardly about the shaft 7 A and the transfer of forces to the other. However the presence of the gas bag spring prevents a vigorous upward movement of the front wheel 6 from being transferred into vigorous downward movement of the front set of bogies in a directly proportional movement which could otherwise cause rapid downward movement of that section of the belt causing it to engage or bury into the ground.
[0047] The rear idler wheel 15 and its rocker 14 is arranged symmetrically relative to the front idler wheel so that the rear rocker 14 includes an actuating lever 14 B engaging the top of the gas bag spring 12 of the rear set of bogies.
[0048] The intermediate set of bogies includes a similar gas bag spring which is engaged directly onto the frame at the fixed section 1 .
[0049] Each set of bogies includes a mounting lever 13 which extends from the shaft 10 A forwardly to a pivot shaft 13 A on the relevant section of the frame.
[0050] In respect of the front wheel 6 and the front set of bogies, the pivot shaft 13 A of the front pivot lever 13 of the front set of bogies is located substantially directly below the pivot shaft 7 A of the rocker 7 so that both are commonly carried on the front section 2 of the frame and can be moved forwardly by the action of the cylinder 3 . The levers 13 thus act as a trailing link carrying the center support 10 B for upward and downward movement there of on the pivoting link 13 .
[0051] The front wheel 6 has a larger diameter substantially equal to the diameter of the drive wheel 4 thus supporting the upper run of track above the frame and above the bogeys. The bogies are a relatively small diameter so they are positioned underneath the frame and the bottom run of the track. The trailing or rear idler wheel 15 has a larger diameter than the bogies 11 and is positioned behind the hydraulic cylinder 13 at the rear part of the frame 1 . The large diameter of the rear idler wheel 15 ensures and optimum of the bending arc of the rubber track 5 at its trailing point of engagement with the ground as it extends upwardly and rearwardly to the drive wheel 4 . It will be noted from the plan view of FIG. 2 that each of the elements is arranged in pairs either side of a central support so that the idler wheel 6 is defined by two wheel components one on each side of the frame including the cylinder 3 . Similarly each of the rollers 11 and the and the rear idler 15 are formed of pairs of elements. Also the gas bags 12 are arranged as pairs one on each side of the frame so as to balance the structure side to side relative to the frame.
[0052] Since various modifications can be made in our invention as herein above described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without department from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense. | A track for a tracked vehicle has a front idler wheel carried on a frame and a front double roller member carried on the frame construction rearward of the front idler wheel. The front idler wheel and the roller member are independently pivotally mounted on the frame by pivotal levers for upward and downward suspension movement in response to change in ground level. An actuating lever extends rearwardly from the front idler wheel over the pivotal lever of the double roller and a gas bag spring is located between the actuating lever and the double roller to absorb some upward movement of the front idler wheel so as to avoid transfer of a proportional downward movement to the roller member. | 1 |
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates in general to liquid distributors and in particular to a new and useful progressive distributor device for a liquid medium which includes a housing for receiving a plurality of movable pistons which operate in a working cycle to discharge liquid.
Progressive or piston distributors of this kind are employed in various industries. If lubricant distribution is needed, the distributor's purpose is to feed the lubricant to a point of lubrication, such as an engaged tooth of a transmission, at a given time and in the necessary amount. The substance is supplied to the progressive distributor under pressure, and this pressure is at the same time used for displacing floating pistons in the distributor. While displacing such a piston from one of its end postions into the other, the lubricant or other substances present in the respective cylinder space is expelled by the leading end of the piston. The amount displaced per working stroke of the piston into the conduit leading to a point of use thus demands on the stroke length and the piston diameter. The pistons act both as working pistons and as control pistons. As a rule, the substance displaced under pressure by the first piston is conducted to flow to, and displace, a second piston. The second piston controls the motion of the third piston in the same way, and so on. As soon as the last piston, after the others, has performed its motion, for example, downwardly, it reverses the control to the effect of now moving the first piston upwardly, for example, and thus to displace the lubricant present at the other end of the piston. Such progressive or piston distributors thus act substantially as metering pumps. With a proper arrangement of the control passages of the piston and the housing, the working cycles uphold themselves automatically as long as lubricant under pressure is supplied. It follows from the foregoing that, for example, two points of use may be supplied with the liquid substance, namely one during the upward motion of the piston and the other during the downward motion thereof. If three pistons are provided, six points of use may be supplied, for example, except that two or more discharge lines at one end of the pistons would be united or branched. It therefore depends on the specific application how may pistons are provided in such a distributor.
Since the various end spaces and annular spaces in the cylinders must be hydraulically connected to each other, as already mentioned, in a way which insures that with a continuing supply pressure the working cycle will continue and automatically recur, the hydraulic connections, mostly designed as internal passages, of a progressive distributor become more complicated, the more pistons the distributor has. The result is that in practice, any number of pistons cannot be provided. Typically, such a progressive distributor will comprise four to six pistons, for example. This also necessarily determines or limits the number of discharge bores of such a progressive distributor.
There are applications, particularly in the lubricating technique, requiring a supply of the liquid substance or lubricant to a great number of locations. This problem can no longer be solved by branching the discharge line, particularly if only a definite amount per working stroke is available and a plurality of points of lubrication are to be supplied simultaneously with this, or even a larger amount. Such problems can be solved only by providing a plurality of progressive distributors. Each of them must be connected to a supply line and separately mounted. In addition, the various discharge lines must be laid. This is considerably expensive, already in the manufacture of the distributors, and because of the space needed.
SUMMARY OF THE INVENTION
A first object of the present invention is to further develop a progressive distributor of the above mentioned kind, and adapt it for solving even more extensive problems of distributing the fluid, in terms of manufacture, mounting, occupied space and cost.
In prior art progressive distributors of this kind, the pistons, for example three of them, are arranged side by side in a row. This gives a distributor a lengthwise configuration and requires a corresponding space. Moreover, the various passages, especially those connecting the last piston with the first one, are relatively long. This is expensive, since the passages are narrow bores.
Another object of the invention therefore is a further development of the distributor to make it as compact as possible, in order to minimize the cost of producing the various connecting passages and bores.
Accordingly, a further object of the invention is to provide a progressive distributor device for a liquid medium, particularly a lubricant, operating with a recurrent working cycle, comprising a plurality of distributors each having a housing and at least three consecutively displaceable working pistons mounted in cylinders of each housing and extending in parallel, said distributors being juxtaposed and hydraulically connected to each other in a manner so that for the working cycle, a first working piston of a first one of said distributors control the second working piston of a last one of said distributors, and a first working piston of said last distributor controls a second working piston of a next to the last one of said distributors, a second working piston of each of said distributors connected to control a third piston of another distributor, with said third piston controlling a fourth piston of its distributor.
The individual distributors are of such design, that 2,3,4 or even a substantially larger number of them can be assembled into a battery, i.e. they are capable of forming distributor batteries of any size, without requiring an adaptation to such a size. This makes possible a certain standardization and thus manufacture in substantially larger numbers and at lower cost. The storage requirements are also considerably reduced. Also repairs become simpler and quicker. For example, if a piston in a large battery fails, it suffices to replace the respective progressive distributor, and there is no need for removing the entire distributor battery. Repair costs are thereby quite considerably reduced. Further, such a distributor assembly may, at anytime, be enlarged as desired. To simplify the description, the term "lubricant distributor" or "lubricant" is employed hereinafter, without the intention of thereby introducing a limitation on the type of fluid or type of distributor covered by the invention.
The individual distributors are hydraulically coupled to one another in a suitable manner, and are most advantageously directly juxtaposed, to minimize the space needed. With an ingenious design, connecting lines between the individual distributors of the battery may be saved, only proper seals must be provided between the distributors. Limits are set on the size of such a battery by the internal resistance to flow, for example, which must not exceed a value which would prevent a control of the first distributor by the last one.
A particularly preferred embodiment of the invention provides for each piston to be shaped with a neck at either end to maintain upper and lower end spaces in each cylinder, and with two circular grooves to form upper and lower annular spaces of the piston, the upper annular space of the first piston of each distributor being associated with a first connecting passage leading to a first housing junction surface, and the upper end space of the second piston being associated with a second connecting passage which is aligned with the first passage and leads to a second housing junction surface which is parallel to the first surface. A third connecting passage is provided which extends in parallel with the aligned connecting passages between the first and the second housing junction surfaces, with end parts adjoined to the first and last distributors respectively. Each distributor having a return passage for establishing hydraulic communication between the ends of the connecting passages, with the lower end spaced and annular spaces of the pistons being hydraulically connected in a corresponding manner. If in such an assembly, the second housing junction surface of every lefthand distributor is joined to the first housing junction surface of the next distributor at the right, the three passages as well as the upper and lower end spaces and annular spaces are hydraulically correctly associated with each other. Upon juxtaposing the desired number of distributors in the described manner, with the mentioned hydraulic passages connecting with each other, the first end part is connected from the left to the first distributor and the second end part is connected from the right to the last distributor, so that the passages of hydraulic communication become closed in themselves. This ensures that independently of the number of distributors forming the battery, all the pistons of the battery will consecutively execute a working stroke in one direction, and that, after the displacement of the last piston, the movements will be reversed, so that consecutive working strokes in the opposite direction will follow. There is a prerequisite, however, that each individual distributor will be hydraulically designed to perform a continuously recurring cyclic work if only alone connected to the two end parts. A development of the invention provides that the distributors are placed on a common base plate which has a connection for a pressure supply line and a main supply passage communicating with, a distributing passage being branched from the main supply passage to each distributor, which distributing passage is hydraulically connected to one of the two annular spaces of each of the pistons. With this design, a single pressure supply line is needed, and the supply is branched in the interior of the base plate, and then also within each of the distributors of the battery, to feed the pressurized fluid to the individual cylinder spaces in a manner necessary for maintaining the working cycles.
In another embodiment of the invention, it is provided that the pistons of each distributor are mounted in a cylinder insert which forms a first housing part and is tightly fitted in a cavity of a corresponding cross section of a second housing part with the axes of the pistons being arranged to either mark corners of a polygon or line in at least two rows. Such a design leads to a particularly inexpensive manufacture while preserving compact construction at the same time. The particular advantage is, however, that the passage connecting one annular space to the other or to an end space and inversely, can be provided in the joint between the tightly fitting surfaces of the cylinder insert and the second housing part. For example, grooves may be provided, preferably in the surface of the insert, which are then covered by the opposite surface of the housing part and form flow passages. In addition, supply and discharge conduits can then be combined in a simple way by a specific arrangement of the pistons within the insert.
Still another embodiment of the invention provides that each distributing passages forks to form two passages of inflow bores with each inflow bore extending substantially perpendicularly to a longitudinal axis of the cylinder insert, and intersecting about tangentially all of the cylinders accommodating the pistons of the insert. This not only shortens the flow passages and thus reduces resistance to flow, but also simplifies the making of these passages. This simplification is made possible by the particular arrangement of the pistons in the cylinder insert.
A further embodiment of the invention provides that each distributor had a discharge bore for each piston cylinder which opens into a housing surface of an adjacent distributor and applies against the base plate, the base plate having passages which are aligned therewith and lead to a connection for a discharge line. The discharge bores leading from the various cylinder spaces may be united by twos or in larger numbers, provided this does not affect the working cycle. Such a combination must be provided within the cylinder insert and/or in the surrounding housing part.
To solve the second problem mentioned above, it is provided, in accordance with the invention, and in a piston distributor as set forth to solve the first problem, by providing that the cylinder insert forming the first housing part is tightly fitted to the cavity of the second housing part, with the piston axes forming the corners of a polygon or lying in at least two rows. Since in such a distributor, the pistons are no longer arranged in a row, but, for example, in a triangular, quadrangular, or polygonal configuration, or at least partly in at least two rows, such as six in two rows, the housing can be made substantially shorter (the last mentioned case results in half the housing length), so that a desired more compact construction is obtained. A short housing then means short flow passages which are simpler to make. The flow passages may still be simplified and made less expensive, at least partly, by designing the housing in two parts, as mentioned, so that the various flow passages may be provided in the joint between the two housing parts. They are then formed partly by one and partly by the other housing part. For various reasons, but particularly because of the necessary supply and discharge passages, an arrangement of the piston axes in a symettrical form thus in an equilateral triangle, a square or an equilateral pentagon, for example, is not necessarily advantageous. Also, it may be more advantageous to arrange the pistons in two rows of three, rather than in a hexagon.
A development of the invention provides that the cylinder insert is press fit or force fit into the second housing part. Such a force fit results in a satisfactory tightness between the two housing parts, without the necessity of further sealing, such as with seal rings. Depending on the circumstances, the cylinder insert may be secured in the second housing part in addition against axial displacement by means of plugs screwed in from both sides. The inner end face of such a plug may then advantageously serve the purpose of closing the associated end spaces in the cylinder and thus define the height thereof, considered in the piston direction. With a shrink fit or press fit, a circular cylindrical shape is particularly suitable.
Another development of the invention provides that, to form inflow and discharge passages to and from the piston cylinders, the cylinder insert includes radial bores which open, at least partially, into grooves provided in the outer surface of the insert, with transverse bores of second housing part communicating with at least one of the transverse bores and the grooves of the cylinder insert to permit the uninterrupted flow. Both the transverse, particularly radial, bores and the grooves which, if longitudinal grooves are concerned, preferably are shorter than the cylinder insert, can be made in a simple and inexpensive way. For example, the grooves may be made by investment casting, so that any finishing work is unnecessary.
In still another development of the invention, it is provided that at least one of the inflow and discharge bores of the cylinder insert directly hydraulically communicates with one of the inflow and discharge bores of the second housing part, and extends substantially perpendicularly to a longitudinal axis of the cylinder insert and intersects substantially tangentially, at least two of the piston cylinders. If, with four pistons, this bore is to tangentially intersect with all of the four cylindrical bores accommodating the pistons, and the piston axes are in square arrangement, the diameter of the transverse bore is given by the spacing of the piston axes from each other, by the diameter of the pistons and by the radial depth of intersection.
It follows therefrom that it may be quite desirable to arrange the four axes not in a square but in a rectangle, in order to be able to provide a simple cross bore of larger or even smaller, diameter partly intersecting with all of the cylindrical bores. For the same reason, if three pistons are provided, it may be preferable to arrange them in an isosceles, not equilateral, triangle. Further, with six cylinders, two rows of three bores might be preferable to a hexagonal arrangement. However, if a symmetrical hexagon is desired, two and two adjacent cylindrical bores may be intersected by a cross bore, so that altogether three crossbores will be needed in every plane. It is possible, of course, to provide a hydraulic supply into each piston cylinder through a separate crossbore. With a working fluid however, this may be advisable only in special cases, since with a discharge of such a fluid, each cylindrical bore of a piston is hydraulically connected to a further connecting outflow passage through a crossbore of its own, in each plane.
A further object of the invention is to provide a progressive distributor device which is simple in design, rugged in construction and economical to manufacture.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, further particulars and advantageous developments of the invention are explained in more detail with reference to the accompanying drawings in which:
FIG. 1 is a simplified and partly diagrammatical sectional view taken perpendicularly to the piston axes of a progressive distributor;
FIG. 2 is a diagrammatical development of the progressive distributor according to FIG. 1, taken along a circle II passing through the piston axes and not quite to scale;
FIG. 3 is a diagrammatical sectional view of a progressive distributor of the kind according to FIG. 1, with four pistons taken in a plane III passing through the axes of the two pistons;
FIG. 4 is a view taken in the direction of arrow A of FIG. 3;
FIG. 5 is an enlarged sectional view taken along the line V--V of FIG. 3 of the cylindrical insert;
FIG. 6 is a view similar to FIG. 5 and taken along the line VI--VI of FIG. 3;
FIG. 7 is a diagrammatical development of the distributor taken along a circle VII passing through the axes of the pistons of FIG. 8, with at least two, but generally a plurality of distributors being connected hydraulically and mechanically into a battery; and
FIG. 8 is a simplified, partly diagrammatical sectional view perpendicular to the piston axes of a distributor battery comprising two progressive distributors according to FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings in particular, the invention embodied therein comprises a progressive distributor device formed of a plurality of distributors each having a plurality of pistons movable therein.
Every progressive distributor of the inventive distributor battery comprises a housing 1 (FIG. 3) including at least two parts. Two, three, or even more identically designed progressive distributors of this kind may be combined into distributor battery and they are then advantageously mounted on a common base plate 2 (FIG. 8). In any case, the housing of each of the progressive distributors includes a cylinder insert 3 forming a first housing part, and a second housing part 5 which is provided with a cavity 4 for insert 3.
If the cylinder insert has a circular cross section, as in the shown examples, the cross section of cavity 4 is circular too, of course. Cylinder insert 3 is shorter than second housing part 5 so that two screw plugs 8, 9 may be screwed from the two front sides into tap holes 6,7 of housing part 5, to prop the associated front ends of cylinder inserts 3. The inside end faces of these screw plugs 8, 9 form at the same time closing surfaces for cylindrical bores 10 to 13 which are provided in insert 3. Cylinder insert 3 is preferably shrink fitted in cavity 4 of second housing part 5. This saves special packings at the joint between insert 3 and part 5, which would otherwise be needed to prevent the lubricant from finding an undesirable way from one passage or bore to another. The sectional view of FIG. 3 is taken through the center of cylinder insert 3, only, for reasons of clarity, the contours of bores 12 and 13 are shown in solid lines.
The axes of the four piston 14 to 17 mark corners of a rectangle, particularly a square. They extend symmetrically of the axis of cylinder insert 3 (FIG. 1).
Each piston is designed with two circular grooves 18, 19 by which it is subdivided into three portions 20, 21 and 22, particularly of equal length. On either of its ends, each piston is provided or in particular, formed with a neck 23, 24. The diameter of the neck corresponds to that of the piston in the zones of circular grooves 18, 19. With neck elements 23, 24 considered as upper and lower necks, respectively, the associated cylinder spaces within insert 3 may be designated upper end space 25, and lower end space 26. Consequently, in the showing of FIG. 7, piston 14 would be in its lower end positions. The annular spaces dividing the pistons into the three equal portions are designated 27 and 28, with 27 being the upper annular space and 28 the lower one.
To manage with a single lubricant supplying pressure line for each progressive distributor and with a common supply line for the distributor battery, each distributor, in the shown example, has a single lubricant supply connection 29. Two radial bores 30, 31 extend therefrom in two spaced-apart planes. Their spacing corresponds to the median spacing of two annular spaces 27, 28, minus the maximum stroke of a piston. In consequence, the further extending radial bores 32 and 33 in insert 3, which are aligned with radial bores 30 and 31, connect, or are connectable either to annular spaces 27 or to annular spaces 28 of the four pistons, depending on the instantaneous end position of the pistons. A simultaneous connection to all four pistons or annular spaces thereof is obtained due to the provision that the farther extending radial bores 32 and 33 intersect with all four bores 10 to 13, as shown in FIG. 5. If a distributor battery is concerned, the outer ends of radial bores 30, 31 of each distributor advantageously hydraulically communicate each with an aligned further crossbore 34 provided in, and opening into, a lengthwise bore 35 of base plate 2. The two lengthwise bores 35 then open in a manner shown in FIG. 8, into a common lubricant connection 36. The design, however, may also be in accordance with FIG. 3, namely that a united connection 29 communicates with the crossbore.
In FIG. 7, the common lubricant connection 29, or a corresponding common bore for supplying the pressurized lubricant, is shown as four separate conduits, for reasons of clarity, and the same applies to the two further conducting radial bores 32, 33 of cylinder insert 3. By displacing a piston, as already mentioned, the lubricant present in the respective end space 25 or 26 ahead of the piston is displaced too. It flows first in the radial direction outwardly, through bores designated 37, 38 in FIGS. 7 and 8. These bores are followed by groove-like flow passages 39,40 which extend in the outer surface of cylinder insert 3, particularly in the circumferential and lengthwise directions, to hydraulically connect to two radial bores 41,42 or 43, 44 provided in insert 3 and leading at spaced apart levels of the adjacent pistons. Radial bores 41,42 or 43,44 are so located that in the end position of the piston one of them is always aligned with one of the annular spaces 27,28, depending on which of the end positions has been reached. In such a position, still another radial bore 45, 46 opens into the respective annular space, which radial bore is connectable to a discharge line leading to a point of use. In FIG. 8, three hydraulic connections are shown diagrammatically and in FIGS. 3 and 6, they are shown in a somewhat simplified manner. In instances where the distributor is not employed individually as according to FIG. 3, but in a battery, discharge passages 47, 48 may extend as diagrammatically shown in FIG. 8. Then, in a manner similar to lengthwise bore 35, discharge passages 47, 48 are united in separate lengthwise bores provided in the base plate, and connected to the outside. In this way, discharge passages 47 of all the distributors may be combined to groups, for example, which are connected through common discharge lines each to a point of use. The same applies to discharge passages 48.
The upper end spaces 25 at pistons 15,16 and 17 communicate in the described manner with upper annular spaces 27. In a similar way, the lower end spaces 26 communicate with the lower annular spaces 28 of the three pistons. However, to ensure continuous working cycles, a "crossing connection" is provided, in the shown example between pistons 14 and 15. Due to this connection upper end space 25 at piston 14 hydraulically communicates with the lower annular space 28 of piston 15 while lower end space 26 at piston 14 hydraulically communicates with upper annular space 27 of piston 15.
With four pistons in their upper end positions, the working cycle of a distributor operates as follows:
The lubricant flows from connection 29 through lower annular space 28, flow passages 39, and radial bore 37 to upper end space 25 at piston 14 and displaces this piston into the lower end position thereof. This position is shown in FIG. 7. During its downward motion, piston 14 has displaced the lubricant, which was present in lower end space 26, through radial bore 58, flow passages 40, and upper annular space 27 of piston 15, toward outlet 47 of this piston.
Upper annular space 27 of piston 14 now hydraulically connected to lubricant supply connection 29, and flow passages 39 which hydraulically communicate with annular space 27 conducting the lubricant to upper end space 25 at piston 17, so that this piston also will be displaced downwardly to force the lubricant present in lower end space 26 through flow passages 40 and lower annular space 28 of piston 14 to the outlet 48 thereof. As soon as piston 17 reaches about its lower end position, the way of the lubricant to upper end space 25 at piston 16 is clear, so that piston 16 also moves downwardly and displaces the lubricant present in lower end space of cylinder 11. Finally, piston 15 now moves downwardly too. Because of the crossing connection with piston 14, the lubricant under pressure passes into lower end space at piston 14, so that this piston moves upwardly and displaces the lubricant present in the respective upper end space. Through lower annular space 28 of piston 14, the way for the pressurized lubricant to piston 17 is cleared, so that this piston also is moved upwardly again. Thereupon, piston 16 and 15, in this order, move upwardly and the working cycle is terminated. With a further supply of lubricant under pressure, the next working cycle starts immediately.
In FIG. 3, the two outlets 47, 48 for the lubricant amounts displaced by piston 17 during its motion up or down are shown somewhat schematically. In such a design, a progressive distributor with four pistons has 8 outlets with which 8 points of lubrication can be supplied, provided that none of the discharge lines are united or branched. As already mentioned, however, such discharge conduits may be united, either by twos or by fours, which may be done in a way analogous to that shown in FIG. 5.
The working cycle has been described in the foregoing as applied to the operation of a single distributor. This requires, however, to join a first end part 53 to the first housing junction surface 51 of this distributor 52, and a second end part 55 to the other side of distributor 52, namely to second housing junction surface 54, which is parallel to surface 51. This is an assemblage analogous to that shown in FIG. 8 for a battery. Pistons 14, 17 16 and 15 represent the first, second, third and fourth piston, in this order. The crossing connection is therefore provided between first piston 14 and fourth piston 15. All flow passages 39 and 40 between the second and third pistons as well as between the third and fourth pistons and between the fourth and first pistons are indicated in broken lines. Now, in a distributor suitable for being assembled to a battery, the flow passage 39 from first piston 14 to second piston 17 according to FIG. 8 comprises a first connecting passage 56 opening upwardly into first housing junction surface 51, a second connecting passage 57 aligned therewith which opens into second housing junction surface 54, and a third connecting passage 58 which is parallel to the two aligned passages and extends between the first and second housing junction surfaces. In addition, a first passage 59 is provided in first end part 53 to be applied to the first housing junction surface, and a second return passage 60 is provided in second end part 55. In a battery, the second end part applies to the second housing junction surface 54 of the last distributor, considering the distributor 52 shown in FIG. 8 at the left hand side as the first one and the distributor at the right hand end of a battery as the last one. Consequently, in a battery, all the third connecting passages extend in direct communication with each other, while of the first two connecting passages, only the second passage 37 of a distributor at the left hand side communicate directly with the first connecting passage 56 of the adjacent distributor next to the right.
As a result, the operation or working cycle of such a distributor battery is as follows:
The first piston 14 of a first distributor, i.e. the one at the left-hand side in the shown example, moves and thereby controls the second piston 17 of the last distributor, i.e. the one at the right-hand end in the shown example, to move in the same direction. Thereupon, consecutively, the third piston, the fourth piston, and the first piston of the last distributor work in the manner as described in connection with the single distributor. Then, the last named first piston controls the second piston of the next to the last distributor (counted from the right to the left). In this way, finally the second piston of the first distributor is also moved. As soon as the third and the fourth pistons of the first distributor have executed their strokes, the first piston of the first distributor is reversed, whereby the second half of the total working cycle of the battery is started.
Should it be desired to employ these distributors individually, with definitely no intention of forming a battery, the partitions 61 may be broken through at suitable locations, and one may dispense with passages 56, 57 and 58, as well as with the two end parts 53 and 55.
Advantageously, second housing parts 5 are firmly secured to one another by means of screws for which suitable holes must be provided (not shown) or by dovetail or similar connecting elements formed on the parts. The contacting surfaces must therefore be very well finished and the housing junction surfaces of each second housing part 5 must extend exactly parallel to each other. If necessary, sealing elements (not shown) are provided between adjacent housing parts.
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. | A progressive distributor device for a liquid medium, particularly a lubricant, operating with a recurrent working cycle, comprising a plurality of distributors each having a housing and at least three consecutively displaceable working pistons mounted in cylinders of each housing and extending in parallel, the distributors being juxtaposed and hydraulically connected to each other in a manner so that for the working cycle, a first working piston of a first one of the distributors controls a second working piston of a last one of the distributors, and a first working piston of the last distributor controls a second working piston of a next to the last one of the distributors, a second working of each of the distributors connected to control a third piston of another distributor, with the third piston controlling a fourth piston of its distributor. | 5 |
BACKGROUND OF THE INVENTION
[0001] Micro-electromechanical systems (MEMS) are electrically operated mechanical devices of a size suited for use with and incorporation into integrated circuit devices. Examples of common MEMS include rotatable mirrors, actuators, resonators, motors, and the like. Many of these devices include moving parts whose movements are facilitated by a hinge or flexure that connects the moving part to the remainder of the MEMS. Ideally, the flexures of MEMS will deform in a perfectly elastic manner, i.e. they will twist or bend between known positions. Unfortunately, flexures are subject to a phenomenon known as ‘creep’ wherein the crystalline structure from which the flexures are made is permanently modified, typically through the action of slip between the crystalline planes of the material. Where creep occurs, the flexures no longer move between their predetermined positions. Where creep is extensive, the MEMS will no longer function as intended.
[0002] Some manufactures have tried to reduce creep in MEMS flexures by using binary intermetallic compounds in the fabrication of MEMS flexures in place of unalloyed materials. One approach is the use of electrically conductive intermetallic binary compounds that all include aluminum and mixtures of various electrically conductive binary intermetallic compounds that all include aluminum. These binary compounds of aluminum and mixtures of binary compounds of aluminum impart strain to the crystalline structure of MEMS that can resist, to a degree, the dislocations that result in creep. However, the reduction in creep realized as a result of the use of binary compounds is limited. What is more, the use of incoherent mixtures of different binary intermetallic compounds may, in some instances, actually introduce additional creep between the boundary layers of crystals having distinct phases.
[0003] Other manufacturers have attempted to limit creep in MEMS flexures by modifying the physical structure of the flexures to reduce stresses therein. While helpful, such structures are relatively complex and may make the fabrication of MEMS devices and their associated circuitry more difficult and more expensive. Accordingly, there is a need for other ways of limiting creep
DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is an exemplary MEMs that includes a flexure structure with substitutionally alloyed intermetallic compounds;
[0005] FIG. 2 is an exemplary embodiment of the substitutionally alloyed intermetallic compounds;
[0006] FIG. 3 is an exemplary embodiment of the substitutionally alloyed intermetallic compounds;
[0007] FIG. 4 is a schematic view of a sputtering mechanism for depositing substitutionally alloyed intermetallic compounds having a single target; and,
[0008] FIG. 5 is a schematic view of a sputtering mechanism for depositing substitutionally alloyed intermetallic compounds having multiple targets.
DETAILED DESCRIPTION
[0009] In the following detailed description of the invention, reference is made to the accompanying drawings that form a part hereof and in which is shown, by way of illustration, specific embodiments in which the invention may be practiced. In the drawings, like numerals describe substantially similar components throughout the several views. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments may be utilized and structural, logical, and electrical changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims and equivalents thereof.
[0010] FIG. 1 is an exemplary MEMs 10 that includes a flexure structure with substitutionally alloyed intermetallic compounds that comprises a substrate 12 to which are attached a pair of supports 14 . Flexures 16 extend from supports 14 to structure 18 . When a voltage is applied to the structure 18 , an electromagnetic field is created between the structure 18 and capacitive plate structure 19 . The electromagnetic field formed between the structure 18 and structure 19 causes the structure 18 to move, thereby inducing bending and/or torsional stresses in the flexures 16 . These stresses may give rise to creep, especially in the presence of elevated temperatures, in the flexures 16 . As is understood by those skilled in the art, creep is a plastic deformation of a material generally resulting from a relative shift between the planes of a crystalline structure, particularly between the respective crystalline grains that make up the overall structure.
[0011] It is known in the metallurgical arts to introduce alloying materials to interrupt the otherwise regular crystalline structure of a material. Regular crystalline structures have a more pronounced susceptibility to creep as the regular structure of the crystal lattice more readily defines a glide plane along which creep may occur. Where an alloying material is added to a material, the crystalline structure of the material is disrupted and glide planes are not so readily defined. FIG. 2 is an exemplary embodiment of the substitutionally alloyed intermetallic compounds. The larger atom of the alloying material introduces an irregularity or strain into the crystalline structure of the material that acts to prevent dislocation motion along the plane 28 . The use of an alloying material having a generally smaller atomic size than the atoms of the base material as shown in FIG. 3 , similarly introduces an irregularity or strain into the crystalline structure of the base material and also prevents dislocation motion along plane 28 . One embodiment of the present invention introduces alloying materials to preexisting binary intermetallic compounds to form compounds having three or more components in a manner that substantially preserves the preexisting crystalline structure, while at the same time introducing disruptions there into to interrupt glide planes along which creep may occur. In this manner, the physical properties of the base material are substantially unchanged and yet the resistance to creep is greatly enhanced. The resulting alloyed material is a ternary, quartemary or multi-component intermetallic compound having a generally coherent crystalline structure.
[0012] Where a binary intermetallic compound (base material) is represented by the generic chemical formula A x B y in which A and B are elements from the periodic table and x and y are the respective proportions of each element, the suitable substitutional alloy according to some embodiments will have formulas such as A x (B (y-s) C s ), (A (x-s) C s )B y or (A (x-s) C s )(B (y-t) D t ), where C and D are elemental alloying materials from the periodic table and s, t are the respective proportions (or fractions) of each of these elements. For one embodiment the fraction “s” is in the range of 0 to 50%, and for another embodiment, the fraction “s” is in the range of 1% to 20%. For some embodiments, the fraction “t” is in the range of 0 to 50%, while for other embodiments, the fraction “t” is in the range of 1% to 20%. In certain preferred embodiments, the substituted alloying element(s) will form substantially the same crystal structure with the components of the base material as did the element the alloying materials are replacing. By way of example, in an embodiment involving the binary intermetallic compound Nb 3 Sn, it is possible to substitute Ta for a portion of the Nb. Both Ta and Nb form an intermetallic compound with Sn with the A15 crystal structure. The formula for the resulting ternary substitutional intermetallic compound is (Nb (3-s) Ta s )Sn. It should be noted that while the preceding example was of a ternary compound, quaternary compounds and compounds having five (5) or more components are also contemplated.
[0013] In one embodiment, alloying materials for use in forming MEMS are chosen such that in the resulting ternary or quarternary substitutionally alloyed materials the substitutes are incorporated coherently into the crystal lattice. In order to facilitate the specification of a particular crystalline structure, it is has been found useful to select as a base material binary intermetallic compounds that may exist over a broad range of compositions as opposed to those compounds that exist over a relatively narrow range of compositions such as, for example, stoichiometric or line compounds. It has been found that crystalline structures including, but not limited to structures designated as A15, B2, C14, C15, L1 0 , and L1 2 accommodate a useful breadth of compositional variance.
[0014] In one embodiment, some examples of binary intermetallic compounds in the Al 5 crystalline system and having a useful compositional breadth may include, but are not limited to: Ti 3 Ir, Mo 3 Ir, Nb 3 OS, Cr 3 Ge, AlMo 3 , Cr 3 Os, Cr 3 Pt, V 3 Si, Nb 3 Al, Nb 3 Ir, Ti 3 Pt, Nb 3 Pt, Nb 3 Au, Cr 3 Ir, V 3 Ga, Nb 3 In, V 3 Ir, V 3 Pt, and V 3 Rh. In this embodiment, some examples of substitutes for the major component include, but are not limited to: Cr, Mo, Nb, Os, Re, Ta, Ti, V and Zr. In this embodiment, some examples of substitutes for the minor component include, but are not limited to: Al, As, Au, Co, Ga, Ge, Hg, In, Ir, Ni, Os, Pd, Pt, Rh, Ru, Sb, Si, Sn and V. One example of a substitutionally alloyed intermetallic compound having an A15 crystalline structure is V 3 (Pt (1-s) Rh s ). In this case, Rh is substituted for Pt in the compound V 3 Pt. Another example is (Nb (3-s) Mo x )Al y , where Mo is substituted for Nb.
[0015] In another embodiment, some examples of binary intermetallic compounds in the B2 system having a useful degree of breadth may include, but are not limited to: BeCo, BeCu, AlIr, DyIn, TiCo, MgPd, NiGa, OsHf, HfRh, HoIn, CuPd, AuCd, TiOs, InPd, MgSc, PdZn, OsV, HgLi, AgLi, AlCo, AgMg, RuV, FeAl, CoGa, FeRh and CoFe. In this embodiment, some examples of substitutes for the components of these binary compounds may include, but are not limited to: Ag, Al, Au, Ba, Be, Bi, Ca, Cd, Ce, Co, Cs, Cu, Dy, Er, Eu, Fe, Ga, Gd, Ge, Hf, Hg, Ho, In, Ir, La, Li, Lu, Mg, Mn, Nb, Nd, Ni, Os, Pb, Pd, Pr, Pt, Rb, Rh, Ru, Sc, Si, Sm, Sr, Ta, Th, Te, Th, Ti, Tm, V, Y, Yb, Zn and Zr.
[0016] In yet another embodiment, some examples of binary intermetallic compounds in the C14 system having a useful degree of breadth may include, but are not limited to: HfRe 2 , Fe 2 Ti, YbMg 2 , Be 2 W, Fe 2 Ta, Os 2 Hf, TiMn 2 , Fe 2 Nb, NbMn 2 , Mn 2 Hf, BeFe 2 and ZrMn 2 . In this embodiment, some substitutes for the major component in these exemplary binary intermetallic compounds in the C14 system may include, but are not limited to: Al, Be, Co, Cr, Fe, Li, Mg, Mn, Os, Re, Rh, Ru and Zn. Some substitutes for the minor component in the exemplary intermetallic binary compounds C14 crystalline system may include: Am, Ba, Be, Ca, Cr, Dy, Er, Eu, Fe, Gd, Hf, Ho, La, Lu, Mg, Mo, Nb, Nd, Np, Os, Pr, Ru, Sc, Sm, Ta, Th, Th, Ti, Tm, V, W, Y, Yb and Zr.
[0017] In another embodiment, some examples of binary intermetallic compounds in the C 15 system having a useful degree of breadth may include, but are not limited to: Au 2 Na, CeIr 2 , CePt 2 , Co 2 Hf, Co 2 Ta, Co 2 Zr, Cu 2 Be, LaPt 2 , LiPt 2 , NdPt 2 , PrPt 2 , Pt 2 Eu, Pt 2 Gd, Rh 2 Er, ScNi 2 , SmPt 2 , ThIr 2 and ZrMo 2 . Some substitutes for the major components in the exemplary intermetallic compounds in the C15 crystalline system may include, but are not limited to: Ag, Al, Au, Be, Bi, Co, Cr, Cu, Fe, Ir, Mg, Mn, Mo, Ni, Os, Pd, Pt, Rh, Ru, V, W and Zn. Some substitutes for the minor components in the exemplary intermetallic compounds in the C15 crystalline system may include, but are not limited to: Ag, Am, Ba, Be, Bi, Ca, Ce, Cs, Dy, Er, Eu, Fe, Gd, Hf, Ho, K, La, Li, Lu, Mg, Na, Nb, Nd, Np, Pb, Pm, Pr, Rb, Sc, Sm, Sr, Ta, Th, Th, Ti, Tm, Y, Yb and Zr.
[0018] In another embodiment, some examples of binary intermetallic compounds in the L1 0 crystalline system having a useful degree of breadth may include, but are not limited to: CoPt, HgPb, VRh, IrV, AuCu, PtZn, FePt and CdPd. Some substitutes for the components of these exemplary intermetallic compounds in the L1 0 crystalline system may include, but are not limited to: Al, Au, Bi, Ca, Cd, Co, Cr, Cu, Eu, Fe, Ga, Hf, Hg, In, Ir, Mg, Mn, Na, Nb, Ni, Pb, Pd, Pt, Rh, Ru, Sn, Ta, Ti, V, Yb, Zn and Zr.
[0019] In yet another embodiment, some examples of binary intermetallic compounds in the L1 2 crystalline system having a useful degree of breadth may include, but are not limited to: CoPt 3 , FePd 3 , GeNi 3 , CrIr 3 , GaFe 3 , TaIr 3 , ZrIr 3 , PbPd 3 , YPd 3 , ErPd 3 , TiRh 3 , TiPt 3 , ZnPt 3 , GaNi 3 , NbRh 3 , GaPt 3 , TiPd 3 , TaRh 3 , CrPt 3 , HfRh 3 , VRh 3 , AuCu 3 , MnNi 3 , PdCu 3 , NbIr 3 , VIr 3 , Co 3 V, Fe 3 Pt, PtFe 3 , Au 3 Pd, Cr 2 Pd 3 , PtCu 3 , IrMn 3 , AuPd 3 , FeNi 3 and Au 3 Cu. Some substitutes for the major component in these exemplary binary intermetallic compounds in the L1 2 crystalline system may include, but are not limited to: Ag, Al, Au, Bi, Cd, Ce, Co, Cu, Fe, Ga, Hg, In, Ir, La, Lu, Mg, Mn, Nd, Ni, Np, Pb, Pd, Pr, Pt, Rh, Ru, Sm, Sn, Zn and Zr. Some substitutes for the minor component in these exemplary binary intermetallic compounds in the L1 2 crystalline system may include, but are not limited to: Al, Am, Au, Ca, Cd, Ce, Co, Cr, Cu, Dy, Er, Eu, Fe, Ga, Gd, Ge, Hf, Ho, In, Ir, La, Li, Lu, Mg, Mn, Na, Nb, Nd, Np, Pa, Pb, Pd, Pr, Pt, Rh, Sb, Sc, Si, Sm, Sn, Sr, Ta, Th, Th, Ti, Tm, V, Y, Yb, Zn and Zr.
[0020] In substitutionally alloying binary or other intermetallic compounds to form ternary, quarternary, or other compounds having five or more components, other considerations that should be taken into consideration are the toxicity, reactivity, and usefulness of the constituent materials. While in some embodiments materials such as thallium, americium, arsenic, cadmium, beryllium, mercury, neptunium, promethium, protactinium, lead, tellurium, or thorium may be successfully alloyed for use in MEMS, it may be desirable in some circumstances to omit such toxic materials. Similarly, where materials are highly reactive, these materials may complicate the manufacture of MEMS and accordingly in some embodiments, it may be desirable to omit these materials. It is to be understood however, that many reactive materials may be successfully alloyed for use in MEMS. Examples of some reactive materials that may be omitted in favor of more stable constituents include barium, calcium, cesium, potassium, lithium, magnesium, rubidium, sodium, and strontium. What is more, some materials, such as gold, are readily attacked by standard etching materials and other chemicals commonly used in the manufacture of MEMS and other devices. In addition, some materials, such as gold, present contamination issues in some fabrication processes. Accordingly, while gold and other similarly situated materials may be successfully used in alloying materials for use in MEMS, it may simplify the manufacture of MEMS to omit this material
[0021] Some examples of embodiments of substitutionally alloyed intermetallic compounds having an A15 crystalline structure that have been optimized with respect to toxicity, reactivity, and susceptibility to commonly used fabrication materials and which have a desirable breadth may include, but are not limited to Ti 3 Ir, Mo 3 Ir, Nb 3 OS, Cr 3 Ge, AlMo 3 , Cr 3 Os, Cr 3 Pt, V 3 Si, Nb 3 Al, Nb 3 Ir, Ti 3 Pt, Nb 3 Pt, Cr 3 Ir, V 3 Ga, Nb 3 In, V 3 Ir, V 3 Pt, and V 3 Rh. Some exemplary substitutes for the major components of these substitutionally alloyed intermetallic compounds having an A15 crystalline structure may include, but are not limited to Cr, Mo, Nb, Os, Re, Ta, Ti, V and Zr. Some exemplary substitutes for the minor components of these substitutionally alloyed intermetallic compounds having an A15 crystalline structure may include, but are not limited to Al, Co, Ga, Ge, In, Ir, Ni, Os, Pd, Pt, Rh, Ru, Sb, Si, Sn and V.
[0022] Some examples of optimized intermetallic compounds having a B2 crystalline structure and which have a desirable breadth may include, but are not limited to AlIr, DyIn, TiCo, NiGa, OsHf, HfRh, HoIn, CuPd, TiOs, InPd, PdZn, OsV, AlCo, RuV, FeAl, CoGa, FeRh and CoFe. Some exemplary substitutes for the components of these substitutionally alloyed intermetallic compounds having the B2 crystalline structure may include, but are not limited to Ag, Al, Bi, Ce, Co, Cu, Dy, Er, Eu, Fe, Ga, Gd, Ge, Hf, Ho, In, Ir, La, Lu, Mn, Nb, Nd, Ni, Os, Pd, Pr, Pt, Rh, Ru, Sc, Si, Sm, Ta, Th, Ti, Tm, V, Y, Yb, Zn and Zr.
[0023] Some examples of optimized intermetallic compounds having a C14 crystalline structure and which have a desirable breadth may include, but are not limited to HfRe 2 , Fe 2 Ti, Fe 2 Ta, Os 2 Hf, TiMn 2 , Fe 2 Nb, NbMn 2 , Mn 2 Hf and ZrMn 2 . Some exemplary substitutes for the major components of these substitutionally alloyed intermetallic compounds having the C14 crystalline structure may include, but are not limited to Al, Co, Cr, Fe, Mn, Os, Re, Rh, Ru and Zn. Some exemplary substitutes for the minor components of these substitutionally alloyed intermetallic compounds having the C14 crystalline structure may include, but are not limited to Cr, Dy, Er, Eu, Fe, Gd, Hf, Ho, La, Lu, Mo, Nb, Nd, Os, Pr, Ru, Sc, Sm, Ta, Th, Ti, Tm, V, W, Y, Yb and Zr.
[0024] Some examples of optimized intermetallic compounds having a C15 crystalline structure and which have a desirable breadth may include, but are not limited to CeIr 2 , CePt 2 , Co 2 Hf, Co 2 Ta, Co 2 Zr, LaPt 2 , NdPt 2 , PrPt 2 , Pt 2 Eu, Pt 2 Gd, Rh 2 Er, ScNi 2 , SmPt 2 and ZrMo 2 . The substitutes for the major component in the C15 system are: Ag, Al, Bi, Co, Cr, Cu, Fe, Ir, Mn, Mo, Ni, Os, Pd, Pt, Rh, Ru, V, W and Zn. Some exemplary substitutes for the minor components of these substitutionally alloyed intermetallic compounds having the C15 crystalline structure may include, but are not limited to system are Ag, Bi, Ce, Dy, Er, Eu, Fe, Gd, Hf, Ho, La, Lu, Nb, Nd, Pr, Sc, Sm, Ta, Th, Ti, Tm, Y, Yb and Zr.
[0025] Some examples of optimized intermetallic compounds having a L1 0 crystalline structure and which have a desirable breadth may include, but are not limited to CoPt, VRh, IrV, PtZn and FePt. Some exemplary substitutes for the components of these substitutionally alloyed intermetallic compounds having the L1 0 crystalline structure may include, but are not limited to Al, Bi, Co, Cr, Cu, Eu, Fe, Ga, Hf, In, Ir, Mn, Nb, Ni, Pd, Pt, Rh, Ru, Sn, Ta, Ti, V, Yb, Zn and Zr.
[0026] Some examples of optimized intermetallic compounds having a L1 2 crystalline structure and which have a desirable breadth may include, but are not limited to CoPt 3 , FePd 3 , GeNi 3 , CrIr 3 , GaFe 3 , TaIr 3 , ZrIr 3 , YPd 3 , ErPd 3 , TiRh 3 , TiPt 3 , ZnPt 3 , GaNi 3 , NbRh 3 , GaPt 3 , TiPd 3 , TaRh 3 , CrPt 3 , HfRh 3 , VRh 3 , MnNi 3 , PdCu 3 , NbIr 3 , VIr 3 , Co 3 V, Fe 3 Pt, PtFe 3 , Cr 2 Pd 3 , PtCu 3 , IrMn 3 and FeNi 3 . Some exemplary substitutes for the major components of these substitutionally alloyed intermetallic compounds having the L1 2 crystalline structure may include, but are not limited to Ag, Al, Bi, Ce, Co, Cu, Fe, Ga, In, Ir, La, Lu, Mn, Nd, Ni, Pd, Pr, Pt, Rh, Ru, Sm, Sn, Zn and Zr. Some exemplary substitutes for the minor components of these substitutionally alloyed intermetallic compounds having the L1 2 crystalline structure may include, but are not limited to Al, Ce, Co, Cr, Cu, Dy, Er, Eu, Fe, Ga, Gd, Ge, Hf, Ho, In, Ir, La, Lu, Mn, Nb, Nd, Np, Pd, Pr, Pt, Rh, Sb, Sc, Si, Sm, Sn, Ta, Th, Ti, Tm, V, Y, Yb, Zn and Zr.
[0027] Substitutionally alloyed intermetallic compounds used in the formation of MEMS may be applied or formed using any of a number of known methodologies including, but not limited to physical or chemical vapor deposition, ion beam assisted deposition, ion beam sputtering deposition, thermal evaporation deposition, electron-beam evaporation deposition, atomic layer deposition, ion plating and reactive sputtering, cathodic arc deposition, atomic layer epitaxy, molecular beam epitaxy, and successive ionic layer adsorption and reaction. In one embodiment illustrated in FIG. 4 , substitutionally alloyed intermetallic compounds are applied to a substrate during the fabrication process using a physical deposition or sputtering process in which the constituent parts of the chosen substitutionally alloyed intermetallic compound are sintered to form a target. Source or target 50 is shown in use in a typical sputtering or physical deposition chamber 40 wherein material 52 from the source 50 is deposited on a substrate 54 .
[0028] In another embodiment, the constituent parts of the chosen substitutionally alloyed intermetallic compound are combined, melted and cast to form target 50 for use in a physical deposition process. See FIG. 4 .
[0029] As seen in FIG. 5 , in yet another embodiment, elemental targets are used to form a multi-layer, film or object that is later annealed to yield a suitably substitutionally alloyed ternary, quarternary, or other intermetallic compound having five or more components. In this embodiment, multiple targets or sources 51 are used to transfer materials 52 to the substrate 54 . In the latter embodiment, where the energy levels and properties of the materials in question are suitable, annealing may be omitted.
CONCLUSION
[0030] Although specific embodiments have been illustrated and described herein, it is manifestly intended that this invention be limited only by the following claims and equivalents thereof. | A micro-electromechancial system has a moveable element supported by a flexure, the flexure being formed of a substitutionally alloyed intermetallic compound. The substitutionally alloyed intermetallic compound includes a base intermetallic compound having a major component and a minor component; and at least one of a first substituent and a second substituent. The first and second substituents are substituted coherently for the major and minor components of the base intermetallic compound, respectively, in amounts sufficient to reduce creep in the resulting substitutionally alloyed intermetallic compound without substantially modifying the crystalline structure of the base intermetallic compound. | 2 |
This application claims the benefit of U.S. Provisional Application No. 60/027,905, filed Oct. 9, 1996.
BACKGROUND
a. Field of the Invention
This invention relates to pollution control equipment used for reducing particulate matter, nitrogen oxides ("NOx"), sulfur dioxide ("SO 2 "), and mercury ("Hg") emissions from the burning of fossil fuels.
b. Description of the Related Art
Electric utilities, and industrial plants typically burn fossil fuels like coal to produce electric power and heat for process requirements. Burning fossil fuel produces an emissions stream containing a number of noxious substances as by-products. These substances include fine particulate matter, mercury and oxides of nitrogen and sulfur. Fine particulate matter has been shown in a recent study to contribute to the early deaths of 64,000 people in the United States alone. Oxides of nitrogen, generally known as NOx, result in the formation of ground level ozone, O 3 , which is toxic when inhaled. Oxides of sulfur, generally known as SO 2 , are also a problem. Both NOx and SO 2 compounds contribute to the formation of acid rain, which is harmful to plant life, animal life, and property. Mercury, in very small concentrations, has been shown to be highly toxic to humans.
The typical methods of reducing fine particulate matter emissions is by the use of an electrostatic precipitator (ESP) or fabric filter bag houses. The typical methods of reducing SO 2 emissions are wet or dry scrubbers, burning low-sulfur coal, and employing flue gas desulfurization (FGD) apparatuses. Burning low-sulfur coal reduces the particulate collection efficiency of the ESP, and is generally more expensive than ordinary coal. FGD equipment is very expensive to build and operate. The typical method of reducing NOx emissions is the use of special low NOx burners to cool the combustion temperature to a point where the bonds of N 2 present in the combustion air are less likely to be broken. This has the disadvantage of making combustion less efficient and increases particulate emissions. Expensive selective catalytic and non-catalytic reduction systems using ammonia and urea injection have also been tried. These devices are very expensive to purchase and operate. They can also require large amounts of space at the plant site to install. Altogether, current methods for reducing fine particle, SO 2 and NOx emissions can increase the cost of electricity produced at an electric utility by over fifty percent.
Stauffer, in U.S. Pat. No. 4,925,639, that issued on May 15, 1990, disclosed a process for removing NOx from flue gas and making HNO 3 as a useful by-product. The process involved cyclically subjecting the gas to scrubbing with nitric acid and then electrolyzing the dissolved nitric oxide to form more nitric acid. This process has the disadvantage that it only treats one type of pollution.
A few have tried to remove multiple pollutants from a flue gas stream. Plaks et al., in U.S. Pat. No. 5,601,791, that issued on Feb. 11, 1997, discloses a process and apparatus that neutralizes "acid gases" such as SO 2 inside an existing ESP. Plaks et al. spray a neutralizing agent upstream from the ESP collecting plates to collect particulates, neutral salts, and unreacted neutralizing agent. The material collected on the plates is then washed using a spray in the manner of a wet ESP. This process and apparatus does not purposefully create and collect the acids, which are valuable industrial materials. Instead, the resulting effluent is sent to a landfill for disposal.
Sparks et al., in U.S. Pat. No. 4,885,139, that issued on Dec. 5, 1989, discloses a method for removing SO 2 and other "acid gases" from flue gas by a multi-stage ESP within a single housing. In that method, a neutralizing agent is sprayed upstream from the ESP collecting plates, forming neutral salts which dry before being collected by the plates. In this manner SO 2 and particulates are removed from the flue gas. However, like Plaks et al., no effort is made to form H 2 SO 4 from the SO 2 , and the effluent must be sent to a landfill for disposal. Nor do either of them refer to the removal of NOx or the formation of HNO 3 in this manner.
The deleterious health effects of these noxious pollutants become better understood as more medical research is completed. As a result, environmental regulations world-wide are being made more stringent. Although mercury emissions from fossil fuel fired boilers are not yet regulated, this is likely to change as research has shown that over 20 percent of mercury emissions in the United States come from coal fired power plants. When the environmental regulations become more stringent, the cost of compliance increases. More expensive pollution control equipment must be purchased and maintained which does not provide any monetary return to the plant owner.
While environmental compliance costs continue to rise, there is a movement toward consolidating ownership of power plants world-wide and increasing competition.
As a result, capital expense budgets are often slashed in an effort to keep the cost of producing electricity low. A pollution control process and apparatus that can provide a monetary return to the owner while reducing particulate, NOx, and SO 2 emissions would solve several serious problems at the same time.
To date, a limited number of plants have been able to sell collected particulate matter commercially. Of the gases, only SO 2 has been converted to useful products that can provide a monetary return. It has been used in the manufacture of gypsum and in the recovery of elemental sulfur. Also, dilute acids have been manufactured from exhaust gases by catalytic reactions. These methods are limited, and are not widely used.
For the foregoing reasons, there is a need for a process and apparatus for reducing particulate, NOx, and SO 2 emissions from the combustion of fossil fuel while producing an end product that is commercially useful and eliminating the need to dispose of an environmentally undesirable by-product.
SUMMARY
The present invention is directed to a process and apparatus that satisfies the need to reduce particulate, SO 2 , NOx and Hg emissions from combustion of fossil fuel while producing a commercially useful end product. A process that reduces particulate, NOx, SO 2 and Hg emissions comprises the steps of oxidizing NOx and SO 2 to produce the acids HNO 3 and H 2 SO 4 , and oxidizing Hg to HgO using a barrier, pulse, corona, or electron beam electrical discharge apparatus, collecting the acids and particulates in a wet ESP, separating the particulates from the wet ESP effluent, then separating and concentrating the acids for industrial use. The converting apparatus and wet ESP are preferably installed inside an existing ESP casing to conserve space. These and other features, aspects, and advantages of the present invention will become better understood with reference to the following drawing and description.
DRAWINGS
FIG. 1 is a cut-away view of an ESP casing with the dry ESP sections, electrical converter, and wet ESP sections inside, and with the wet ESP effluent separating and processing apparatuses shown in block diagram form.
FIG. 2 is a cut-away view like in FIG. 1 but showing more details.
FIG. 3 is a detail view of flat plate, barrier discharge electrodes.
FIG. 4 is a width-wise sectional view of a flat plate, barrier discharge electrode surrounded by high dielectric strength insulating material.
FIG. 5 is a length-wise sectional view of a flat plate, barrier discharge electrode surrounded by high dielectric strength insulating material.
FIG. 6 is a side view of an electrode assembly having spaced electrode conductors surrounded by high dielectric strength insulating material.
FIG. 7 is a perspective view of the electrical converter assembly stacks inside an ESP casing.
FIG. 8 is a process diagram of the processing apparatus for separating and concentrating HNO 3 and H 2 SO 4 .
DESCRIPTION
The present invention is a process and apparatus for reducing particulate, NOx, (including NO 2 ), SO 2 and Hg emissions from the combustion exhaust of fossil fuel fired plants which produces commercially valuable acids as reaction products. Turning to FIG. 1, flue gas 10 is created by the combustion of fossil fuel in a boiler. Fuels that are typically used in electric utilities and industrial plants include coal and oil, but may comprise other substances like gas, tires, trash, or biomass. Flue gas emissions 10 enter a electrostatic precipitator casing (ESP) 15 and a standard dry ESP section 14 removes approximately 90% of the particulate ash.
In the preferred embodiment, the last fields of the existing dry ESP are removed to make room for the electrical converting apparatus 100 and wet ESP section 120. The converting apparatus 100 oxidizes NOx, SO 2 , and Hg present in the flue gas to HNO 3 , H 2 SO 4 , and HgO. The acids, and most of the fine particles not collected by the dry ESP 14 are collected in the wet ESP 120. The wet ESP 120 also collects HgO, NO 2 gas, and SO 2 gas. Having had most of the NOx, SO 2 , and particulate matter removed, the flue gas exits the precipitator 20 with greatly reduced amounts of NOx, SO 2 , and Hg and almost no particles. As an alternative to the preferred embodiment, the converter 100 and wet ESP 120 can be installed outside the existing ESP casing 15. Yet another alternative is to follow the converter 100 and wet ESP 120 sections with an additional converter and wet ESP section, either inside or outside the ESP casing 15, in order to obtain a desired conversion efficiency.
The effluent from the wet ESP 120 is collected as a mixture and travels to a separator apparatus 140, where the particulates and HgO 144 are removed. The separator apparatus may comprise a settling tank, a filter, a centrifuge, or any combination of the three as is commonly practiced in the art.
The remaining mixture travels to a processing apparatus 160, that separates the HNO 3 and H 2 SO 4 , and concentrates them for industrial use. The result is concentrated H 2 SO 4 200 and concentrated HNO 3 210.
Turning to FIG. 2, the composition of the flue gas 12 before the dry ESP 14 is primarily particulate ash, N 2 , CO 2 , H 2 O, O 2 , SO 2 , NOx, Hg and other trace heavy metals. After the dry ESP 14 and before the converter apparatus 100, the composition of the flue gas 16 is primarily fine particles, N 2 , CO 2 , H 2 O, O 2 , SO 2 , NOx, Hg and other trace heavy metals.
The electrical converter apparatus 100 is a series of flat plate, barrier discharge electrodes formed in stacks 106. The electrodes are energized by a power supply 102 that converts station-provided, three-phase power into high voltage alternating current power. The power supply is electrically connected to the converter apparatus. The voltage supplied to the converter is preferably between about 15,000 and about 50,000 volts RMS at a frequency between about 50 Hz and about 10 kHz. The preferred embodiment operates at about 1 kHz. Operating at a higher frequency reduces the size and cost of the high voltage transformer required.
In using barrier electrical discharge, high voltage alternating current is applied to electrodes which are separated by a gas space and a dielectric barrier. The voltage can be applied in any one of several waveforms, including but not limited to sine, square, triangle, and pulsed voltages. Other types of electrical discharge apparatuses that may be employed for converting NOx and SO 2 to acids include, but are not limited to, pulse, corona, and electron beam discharge. Neither barrier electrical discharge nor the other named energy sources have been used to reduce both NOx and SO 2 in the fossil fuel boilers of electric utilities and industrial plants before. That it is useful in these applications is surprising and unexpected.
The major chemical reactions in the conversion of NOx to HNO 3 are as follows:
______________________________________(1) O.sub.2 + e → O + O + e(2) H.sub.2 O + e → OH + H + e(3) NO + O → NO.sub.2(4) NO.sub.2 + O → NO.sub.3(5) NO.sub.2 + OH → HNO.sub.3(6) NO.sub.3 + NO.sub.2 → N.sub.2 O.sub.5(7) N.sub.2 O.sub.5 + H.sub.2 O → 2HNO.sub.3______________________________________
The major chemical reactions in the conversion of SO 2 to H 2 SO 4 are as follows:
______________________________________(1) SO.sub.2 + O → SO.sub.3(2) SO.sub.2 + OH → HSO.sub.3(3) HSO.sub.3 + OH → H.sub.2 SO.sub.4(4) SO.sub.2 + HO.sub.2 → HSO.sub.4 → H.sub.2 SO.sub.4(5) SO.sub.3 + H.sub.2 O → H.sub.2 SO.sub.4______________________________________
The composition of the flue gas 18 after the electrical converter but before the wet ESP 120 is primarily fine particles, N 2 , CO 2 , H 2 O, O 2 , a fraction of the original SO 2 , a fraction of the original NOx (predominantly in the form of NO 2 ), HgO, H 2 SO 4 and HNO 3 . Note that the converter apparatus 100 converted Hg present in the flue gas to HgO that is readily collected in the wet ESP 120.
An evaporative cooling spray injection apparatus 122 sprays water, an acid mixture, or both into the flue gas just before it reaches the wet ESP 120. This spray acts to cool the flue gas to a temperature below the sulfuric and nitric acid dew points so that acid aerosols will form in the gas stream. This permits subsequent collection of acids in the wet ESP section. Spraying a dilute nitric and sulfuric acid spray also scrubs additional SO 2 and NO 2 from the flue gas. Like the dry ESP 14, the wet ESP 120 comprises a plurality of plates 128 between which are high voltage, preferably rigid, electrodes. In the preferred embodiment, the plates are sub-cooled below the temperature of the flue gas, for example, by the use of cooling water 124 provided at the station. In this manner the acids in the composition of the flue gas 18 tend to condense on the surfaces of the wet ESP plates 128. This apparatus is known as a "condensing" wet ESP. Very little of the pollutants in the composition 18 exit the ESP 20 and go into the environment through the stack 22.
The effluent from the wet ESP 126 is primarily a slurry or mostly-liquid mixture of dilute H 2 SO 4 , dilute HNO 3 , scrubbed SO 2 , fine particles, and HgO. It travels to a separation apparatus 140. The mixture is separated by a settling tank, centrifuge, or filter 142. The resulting solids 144 are removed and safely disposed of or recycled. The remaining dilute acids 148 are transported by an optional pump 146 to a processing apparatus 160 that separates the acids and concentrates them to produce HNO 3 200 and H 2 SO 4 210.
FIG. 3 shows a converter cell comprising a high voltage, flat plate electrode 101 connected to the high voltage power supply 102 (not shown) secured at a distance from two flat plate grounded electrodes 103. Although the flat plate electrode configuration is the preferred embodiment, other embodiments are also possible. They include cylindrical high voltage electrodes and flat plat ground electrodes, and cylindrical high voltage electrodes centered in the middle of cylindrical ground electrodes. The plates are preferably mounted in a vertical position to prevent plugging with particulate matter. The high voltage electrodes 101 and ground electrodes 103 may have identical construction, and differ only in that one is wired to the power supply 120 and the other is wired to ground. In operation, the high voltage and ground electrodes would alternate along the entire row, and have ground electrodes at the end. Another configuration is to have alternating electrodes attached to opposite ends of the secondary windings of a high voltage, mid point ground transformer. The significant requirement is that a high voltage gradient exist between the electrodes.
FIGS. 4 and 5 are cut-away sectional views of the preferred flat plate electrodes. The electrode itself 112 may be made of any conductive metal. Instead of using flat plates, conductive wire mesh screens, conductive inks or epoxy strips may also be used. The high dielectric barrier 114 is important for providing sufficient energy to convert NOx and SO 2 into the chemical species that will result in the formation of HNO 3 and H 2 SO 4 . The material is applied over all the surfaces of the electrodes. The preferred embodiment uses mica as the dielectric material. However, quartz, alumina, titania, fused silica, and ceramic may also be used.
FIG. 6 is an alternative to the flat plate electrode 112. This embodiment uses a flat, spaced electrode conductor 116 surrounded by the high dielectric barrier 114.
FIG. 7 shows a perspective view of converter stack assemblies 106a, 106b, and 106c installed inside a precipitator casing 15. The assemblies comprise short rows of plates, preferably about 90 cm in length, with the plates preferably spaced from each other by about 1.3 cm. The plates themselves are preferably about 104 cm in height and less than about 30 cm in width. The plates are high voltage plates 101 and either ground or opposite polarity high voltage plates 103. The arrangement of the plates may comprise alternating ground 103 and high voltage plates 101, alternating across the rows with ground plates 103 on the end. Alternatively, each high voltage plate 101 may be surrounded by two ground plates 103 on either side.
The rows are supported by a mechanical structure (not shown) and suspended by insulators 108a and 108b from the top of the casing 15 so that the plane of the plates is parallel to the flow direction of the flue gas within the casing. In this manner, a maximum amount of the flue gas is treated by the converter with a minimum pressure drop across the apparatus. A plurality of rows may be mechanically fastened together, one on top of the other, to form a stack 106 that reaches substantially from the top to the bottom of the casing, which is typically about nine to about twelve meters in height. Although not shown, the plates of each row, and each row, are electrically connected to provide the desired input power from the power supply 102.
A plurality of stacks 106 may be used and installed side by side to substantially cover the width of the casing. The number of plates, rows, and stacks shown in FIG. 7 are for illustration only, and it is appreciated that different quantities of plates, rows, and stacks may be required for different sized casings.
FIG. 8 is a schematic diagram of the preferred embodiment of a processing apparatus 160 for separating and concentrating HNO 3 , and H 2 SO 4 148 from the dilute acids output from the separator 140. The schematic only shows the mass flow, and not the energy flow, but it is understood by those skilled in the art that heat exchangers and condensers can be used in these apparatuses to facilitate the desired separation and concentration of acids. Other apparatuses and processes are also suitable for separating and concentrating the acids, as is understood by those skilled in the art. The elements are hydraulically connected, in that fluids may be conveyed by acid-resistant pipes, hoses, and containers. Pumps are shown in various places, however they are optional and could be replaced by gravity feed or other fluid conveying means.
In FIG. 8, the preferred embodiment processing apparatus 160 has three distinct sections: a denitration apparatus 170, H 2 SO 4 concentration apparatus 180, and HNO 3 concentration apparatus 190. In the denitration apparatus 170, the dilute acids 148 enter a processing tower 172 that has two outputs. A first output is hydraulically connected to a stripping column 174 input. The stripping column 174 output is hydraulically connected to a pump tank 176 input. The pump tank 176 output is hydraulically connected to an acid pump 178 input. From the acid pump 178 output flows weak, dentritated H 2 SO 4 181.
In the H 2 SO 4 concentration apparatus 180, weak dentritated H 2 SO 4 181 flows into a separator 182 having two outputs. The separator 182 input is hydraulically connected to the denitration unit acid pump 178 output. The separator 182 first output is hydraulically connected to a transfer pump 184 input. The transfer pump 184 output is hydraulically connected to a pump tank 186 input. The pump tank 186 output is hydraulically connected to an acid pump 188 input. From the acid pump 188 output comes concentrated H 2 SO 4 200, suitable for industrial use. Distillate H 2 O 183 flows from the separator 182 second output.
In the HNO 3 concentration apparatus 190, concentrated H 2 SO 4 200 enters a first input of a processing tower 192. The processing tower 192 first input is hydraulically connected to the H 2 SO 4 concentration apparatus acid pump 188 output. The processing tower 192 second input is hydraulically connected to the denitrating apparatus processing tower 172 second output to supply weak HNO 3 to the HNO 3 concentration apparatus 190. From a second output of the processing tower 192 comes concentrated HNO 3 210, suitable for industrial use. The processing tower 192 first output is hydraulically connected to a stripping column 194 input. The stripping column 194 output is hydraulically connected to a pump tank 196 input. The pump tank 196 output is hydraulically connected to an acid pump 198 input. The acid pump 198 output is hydraulically connected to the H 2 SO 4 concentration apparatus separator 182 input.
It will be apparent to those skilled in the art that various changes and modifications can be made without departing from the spirit of the present invention. Accordingly, it is intended to encompass within the appended claims all such changes and modifications that fall within the scope of the present invention. | A process and apparatus for reducing particulate, nitrogen oxides ("NOx"), sulfur dioxide ("SO 2 "), and mercury ("Hg") emissions from the combustion exhaust of fossil fuel fired plants while producing an end product that is commercially useful, comprising the steps of oxidizing Hg, NOx and SO 2 using a barrier, pulse, corona, or electron beam electrical discharge apparatus to produce HgO and the acids HNO 3 and H 2 SO 4 , collecting the HgO, acids and particulates in a wet ESP, and separating the particulates from the collected acid mixture, then separating and concentrated the acids for industrial use. | 1 |
CROSS-REFERENCE
[0001] The present application claims priority to U.S. Provisional Patent Application No. 60/950,966 filed on Jul. 20, 2007, entitled “Cover for a Vehicle”, the entirety of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to protective covers for a vehicle.
BACKGROUND OF THE INVENTION
[0003] Certain vehicles, for example recreational vehicles, are normally covered with protective covers during storage or when they are being towed by a vehicle. The covers provide protection against the elements of nature, such as protecting the colors from fading in the sunlight. The protective covers also keeps snow and dirt thrown from the towing vehicle from contacting the vehicle to prevent surface damage and corrosion of the metal parts.
[0004] Accordingly, many different types of covers for recreational vehicles are known, all of which generally provide protection for the vehicle during transportation or storage thereof. Conventionally, covers are designed to snugly fit over the particular vehicle to be covered. Each cover is designed for one vehicle design and thus either does not fit, or provides less protection when placed over another vehicle of different design, even when the two vehicles have similar designs.
[0005] Soft, lightweight covers are often used as they can easily be folded up and stored away when not in use. Such conventional covers generally comprise a large upper portion made of a nylon or similarly weatherproof material which is sized and fitted to slide overtop of the entire upper body portion of the vehicle. In the example of a snowmobile, the cover generally covers the forward fairings of the external shell and the seat portion. Typically, the wheels or skis and track of the vehicle are left uncovered by this type of cover, however the cover may alternatively cover one or more of these. A system of straps or attachments were used to keep the cover from blowing off the vehicle.
[0006] In some instances, the difference between two vehicle designs is the rear portion of the seat. For example, a first snowmobile could be designed for trail riding with a short seat designed to accommodate the driver alone. A second snowmobile could also be designed for trail riding but have an extended seat with a back rest designed to accommodate a driver and one or more passengers. The front portions of the snowmobiles are substantially the same, as well as the driver's area; they differ toward the rear of the vehicle only. As a result, two separate covers had to be manufactured and stocked in order to have at least one cover for each vehicle readily available. If either the manufacturer or the retailer wishes to have each cover available in different colours, or with optional features such as a vent, the problem is further exacerbated.
[0007] U.S. patent application Ser. No. 11/671,694, filed Feb. 6, 2007, the contents of which are incorporated herein by reference, discloses a family of snowmobiles having engine compartments with the same configuration but tunnels of different widths. Therefore, these two snowmobiles with different tunnel widths each require a complete cover, separately designed to fit the contour of both the engine compartment and the tunnel portion of the respective snowmobile, even though their engine compartments have the same shape.
[0008] Other recreational vehicles, including ATVs or three-wheeled motorized vehicles such as the Spyder™ three-wheeled vehicle marketed by Bombardier Recreational Products Inc., may present the same problem. For example, a particular model of ATV or three-wheeled motorized vehicle may have a modular component rearward of the driver's seat that can accommodate either a passenger seat or a cargo rack. In each of the two configurations, the vehicle will require a separate cover designed to snugly fit the particular modular rear component.
[0009] As can be seen, manufacturers have to produce multiple covers corresponding to each model of vehicle in each of its available configurations, and dealers have had to maintain an inventory of the multiple covers, in order to have an appropriate cover readily available for purchase regardless of the particular vehicle configuration owned by the consumer. A vehicle cover requires a significant amount of material and occupies a significant amount of space even when folded for storage, and an entire cover must be manufactured and stored even when its shape differs from another cover in only one small part. Thus, while these multiple vehicle covers protect the vehicles and are convenient for the vehicle owner, the multiple required designs result in an increase in manufacturing costs and storage costs.
[0010] Therefore, there is a need for a vehicle cover having reduced manufacturing cost and occupying reduced storage space.
SUMMARY OF THE INVENTION
[0011] It is an object of the present invention to ameliorate at least some of the inconveniences present in the prior art.
[0012] It is also an object of the present invention to provide a family of vehicle cover sections that can be combined to form covers that fit a variety of recreational vehicles having different configurations.
[0013] One aspect of the present invention provides a family of vehicle cover sections comprising at least one first cover section comprising a flexible material and at least two second cover sections comprising a flexible material. One of the at least two second cover sections is non-permanently connectable to the at least one first cover section to form therewith a first vehicle cover configured to generally fit the contour of at least an upper portion of a first vehicle having a first configuration. The first vehicle cover is removably attachable to the first vehicle. Another of the at least two second cover sections is non-permanently connectable to the at least one first cover section to form therewith a second vehicle cover configured to generally fit the contour of at least the upper portion of a second vehicle having a second configuration. The second vehicle cover is removably attachable to the second vehicle. The second configuration is different from the first configuration.
[0014] In a further aspect, the family of vehicle cover sections further comprises at least one third cover section having first and second ends. The first end of the at least one third cover section is non-permanently connectable to the at least one first cover section. The second end of the at least one third cover section is non-permanently connectable to at least one of the at least two second cover sections. The at least one third cover section is disposed between the at least one first cover section and the at least one of the at least two second cover sections when non-permanently connected thereto.
[0015] In a further aspect, each of the non-permanent connections is one of a zipper, snaps, Velcro™ and buttons.
[0016] In a further aspect, the non-permanent connection is at least one of a zipper, snaps, Velcro™ and buttons.
[0017] In a further aspect, the first configuration is a first seat configuration and the second configuration is a second seat configuration.
[0018] In a further aspect, the first seat configuration is configured to receive a single rider and the second seat configuration is configured to receive two or more riders.
[0019] In a further aspect, the first seat configuration is configured to receive two riders and the second seat configuration is configured to receive three riders.
[0020] In a further aspect, the first vehicle comprises handlebars. Each of the at least two second cover sections is connectable to the at least one first cover section at a location disposed rearward of the handlebars when the first vehicle cover is removably attached to the first vehicle.
[0021] In a further aspect, the first vehicle is a snowmobile comprising skis. The first vehicle cover generally fits the contour of the skis when the first vehicle cover is removably attached to the first vehicle.
[0022] In a further aspect, the first vehicle is a snowmobile comprising skis. The first vehicle cover does not cover the skis when the first vehicle cover is removably attached to the first vehicle.
[0023] Another aspect of the present invention provides a method of providing a cover for a vehicle. The cover is removably attachable to the vehicle. The cover is configured to generally fit the contour of at least an upper portion of the vehicle. The method comprises: providing a first cover section comprising a flexible material; selecting a second cover section from a family of second cover sections comprising a flexible material, the family of second cover sections comprising at least two second cover sections having different shapes; and non-permanently connecting the first cover section to the second cover section thereby to form the cover for a vehicle.
[0024] In a further aspect, the first cover section is selected from a family of first cover sections. The family of first cover sections comprises at least two first cover sections having different shapes.
[0025] In a further aspect, non-permanently connecting the first cover section to the second cover section comprises: providing a third cover section comprising a flexible material, the third cover section having a first end and a second end; non-permanently connecting the first cover section to the first end of the third cover section; and non-permanently connecting the second cover section to the second end of the third cover section, such that the third cover section is disposed between the first cover section and the second cover section.
[0026] Another aspect of the present invention provides a vehicle cover comprising a first cover section comprising a flexible material and a second cover section comprising a flexible material. The second cover section is selected from a family of second cover sections. The family of second cover sections comprises at least two second cover sections having different shapes. The second cover section is non-permanently connected to the first cover section.
[0027] In a further aspect, the vehicle cover further comprises a third cover section comprising a flexible material. The third cover section has a first end and a second end. The second cover section is non-permanently connected to the first cover section by non-permanently connecting the first cover section to the first end of the third cover section and non-permanently connecting the second cover section to the second end of the third cover section.
[0028] In a further aspect, the second cover section is non-permanently connected to the first cover section at a joint. The joint is disposed rearwardly of the handlebars of the vehicle when the vehicle cover is disposed on the vehicle.
[0029] In a further aspect, the first cover section comprises: a front wall shaped to generally fit the contour of a front end of a vehicle; a top wall shaped to generally fit the contour of a top of a forward portion of the vehicle, the top wall having a rearward edge; a left side wall shaped to generally fit the contour of at least an upper portion of a left side of the forward portion of the vehicle, the left side wall having a rearward edge; and a right side wall shaped to generally fit the contour of at least an upper portion of a right side of the forward portion of the vehicle, the right side wall having a rearward edge. Each of the at least two second cover sections comprises: a rear wall shaped to generally fit the contour of a rear end of a vehicle; a top wall shaped to generally fit the contour of a top of a rearward portion of the vehicle, the top wall having a forward edge; a left side wall shaped to generally fit the contour of at least an upper portion of a left side of the rearward portion of the vehicle, the left side wall having a forward edge; and a right side wall shaped to generally fit the contour of at least an upper portion of a right side of the rearward portion of the vehicle, the right side wall having a forward edge. The first cover section is non-permanently connected to the selected second cover section by non-permanently connecting the rearward edges of the top wall, left side wall and right side wall of the first cover section respectively to the forward edges of the top wall, left side wall and right side wall of the second cover section.
[0030] In a further aspect, a portion of the first cover section is a first seat-covering portion adapted to generally fit the contour of at least a portion of a seat of the vehicle. A portion of the first cover section is a first seat-covering portion adapted to generally fit the contour of at least a portion of a seat of the vehicle. A portion of the selected second cover section is a second seat-covering portion adapted to cover at least a portion of the seat of the vehicle. The first cover section is non-permanently connected to the selected second cover section at an intersection of the first seat covering portion and the second seat-covering portion.
[0031] In a further aspect, the selected second cover section further includes at least one strap for removably attaching the vehicle cover to the vehicle.
[0032] Another aspect of the present invention provides a vehicle cover comprising a first cover section. The first cover section has: a front wall for covering a front end of a vehicle; a first portion disposed rearwardly of the front wall, the first portion having a first height and a first width; a second portion disposed rearwardly of the first portion, the second portion having a second height greater than the first height and a second width greater than the first width; a third portion disposed rearwardly of the second portion, the third portion having a third height less than the second height and a third width less than the second width; and a first half of a non-permanent fastener disposed rearwardly of the third portion. The vehicle cover comprises a second cover section. The second cover section has: a second half of the non-permanent fastener; a fourth portion disposed rearwardly of the second half of the non-permanent fastener, the fourth portion having a fourth height substantially equal to the third height and a fourth width less than the third width; and a rear wall for covering the rear end of the vehicle. The first cover section is non-permanently connected to the second cover section by connecting the first half of the non-permanent fastener to the second half of the non-permanent fastener, thereby forming the vehicle cover. The third portion and the fourth portion together defining a seat portion adapted to cover the seat of the vehicle.
[0033] In a further aspect, the first and second halves of the non-permanent fastener are disposed rearwardly of the handlebars of the vehicle when the vehicle cover is disposed on the vehicle.
[0034] For purposes of this application, the term “configuration” means the arrangement of parts. For example, the seating configuration refers to the arrangement and shape of the seat for the driver or rider, and the presence or absence and position of seats for one or more riders as passengers. As a second example, the configuration of a vehicle generally may refer to one or more of the seating configuration, the arrangement of the fairings of the vehicle, the presence, absence, dimensions or shape of other features such as cargo racks, storage boxes, wheels or skis, or any other features that affect the overall external shape of the vehicle.
[0035] Embodiments of the present invention each have at least one of the above-mentioned aspects, but do not necessarily have all of them. It should be understood that some aspects of the present invention that have resulted from attaining the above-mentioned objects may not satisfy these objects and/or may satisfy other objects not specifically recited herein.
[0036] Additional and/or alternative features, aspects, and advantages of embodiments of the present invention will become apparent from the following description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] For a better understanding of the present invention, as well as other aspects and further features thereof, reference is made to the following description which is to be used in conjunction with the accompanying drawings, where:
[0038] FIG. 1 is a side elevation view of a first snowmobile having a first seating configuration;
[0039] FIG. 2 is a side elevation view of a second snowmobile having a second seating configuration;
[0040] FIG. 3 is a side elevation view of a third snowmobile having a third seating configuration;
[0041] FIGS. 4A through 4H are schematic illustrations of vehicle covers according to an embodiment of the present invention;
[0042] FIG. 5A is a side elevation view of a first three-wheeled motorized vehicle having a first seating configuration;
[0043] FIG. 5B is a side elevation view of a second three-wheeled motorized vehicle having a second seating configuration;
[0044] FIG. 6 is an isometric view of an ATV with a variety of interchangeable modular sub-assemblies;
[0045] FIG. 7 is an elevation view of a joint between two vehicle cover sections according to an embodiment of the present invention;
[0046] FIG. 8 is a schematic illustration of a vehicle cover according to another embodiment of the present invention;
[0047] FIG. 9A is a bottom plan view of a snowmobile having a cover fastened thereto; and
[0048] FIG. 9B is a side elevation view of a snowmobile having a cover fastened thereto.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0049] Vehicle covers in accordance with embodiments of the present invention will be described with respect to their use with snowmobiles, ATVs and three-wheeled motorized vehicles. The present invention can also be applied to other types of vehicles, such as motorcycles.
[0050] There will now be described a family of snowmobiles on which the vehicle cover according to the present invention can be used. FIG. 1 illustrates a snowmobile 10 . The snowmobile 10 includes a forward end 12 and a rearward end 14 which are defined consistently with a travel direction of the vehicle. The snowmobile 10 includes a frame 16 comprising an engine cradle portion 18 and a tunnel 20 . The tunnel 20 generally consists of one or more pieces of a suitable sheet metal such as steel, stamped into an inverted U-shape. It should be understood that the tunnel 20 may be made with materials other than steel, and that it can be formed into the desired shape by methods other than stamping, without departing from the spirit of the invention. The tunnel 20 is connected to the engine cradle portion 18 and extends rearwardly along the longitudinal axis of the snowmobile 10 . While hidden behind a front fairing 22 , an engine, not shown, provides motive force for the snowmobile 10 .
[0051] Two front skis 26 are attached to the front portion of the frame 16 through a front suspension system 28 . A handlebar 38 is positioned forward of a seat 168 . The handlebar is operatively connected to the skis 26 to steer the skis 26 , thereby providing directional control of the snowmobile 10 .
[0052] An endless drive track 40 is disposed under the tunnel 20 of the frame 16 with the upper portion of the drive track 40 accommodated within the tunnel 20 . The endless drive track 40 is operatively connected to the engine 24 through a transmission system (not shown), to provide propulsion to the snowmobile 10 . The endless drive track 40 is mounted to the tunnel 20 via a rear suspension assembly 44 . The rear suspension assembly 44 includes rear suspension arms 46 and 48 , a pair of slide rails 50 and idler wheels 52 . Rear suspension arms 46 and 48 connect the slide rails 50 and idler wheels 52 to the tunnel 20 of the frame 16 . The slide rails 50 generally position and guide the endless drive track 40 , and typically include a sliding lower surface made of polyethylene to reduce contact friction between the slide rails 50 and the drive track 40 . The rear suspension assembly 44 also includes one or more shock absorbers 54 which each further include a coil spring 55 surrounding the individual shock absorbers 54 .
[0053] At the front end 12 , the snowmobile 10 includes an external shell consisting of fairings 56 that enclose and protect the engine 24 and transmission. The fairings can be decorated to render the snowmobile 10 more aesthetically pleasing. The fairings 56 include a hood 58 and one or more side panels 60 that can be opened to allow access to the engine 24 and the transmission when this is required, for example, for inspection or maintenance. The side panels 60 can be opened away from the snowmobile 10 along a vertical axis, independently from the hood 58 , which pivots forward about a horizontally extending axis. A windshield 62 , which may be connected either to the fairings 56 , as shown, or directly to the handlebar 38 , acts as wind deflector to lessen the force of the air on the driver when the snowmobile is moving.
[0054] A straddle-type seat 68 is positioned atop and mounted to the tunnel 20 . In the seating configuration shown in FIG. 1 , the straddle-type seat 68 provides a seating position 70 for a single driver. Two footrests 72 , generally extending outwardly from the tunnel 20 , are positioned on either side of the straddle seat 68 to accommodate the driver's feet and provide a rigid platform for the driver to stand on when maneuvering the snowmobile 10 . A backrest 74 is also provided for supporting the back of the driver.
[0055] FIG. 2 illustrates a second snowmobile 110 . The snowmobile 110 differs from the snowmobile 10 of FIG. 1 only in its seating configuration. The straddle-type seat 168 of snowmobile 110 has a first seating position 70 for the driver, and a second seating position 170 for a first passenger. The backrest 74 is positioned rearward of the seating position 170 to support the back of the first passenger, and grab handles 76 are provided for the first passenger to grip while seated on the seating position 170 . The remaining features of snowmobile 110 are the same as those of the snowmobile 10 of FIG. 1 , and are labelled with the same reference numbers. Therefore, these will not be described in further detail.
[0056] FIG. 3 illustrates a third snowmobile 210 . The snowmobile 210 differs from the snowmobiles 10 and 110 only in its seating configuration. The straddle-type seat 268 of the snowmobile 210 has a first seating position 70 for the driver, a second seating position 170 for a first passenger, and a third seating position 270 for a second passenger. The backrest 74 is positioned rearward of the third seating position 270 to support the back of the second passenger, the grab handles 76 are positioned to be gripped by the second passenger while seated on the third seating position 270 , and a looped strap 78 is provided for the first passenger to grip while seated on the seating position 170 . The remaining features of snowmobile 210 are the same as those of snowmobile 10 , and are labelled with the same reference numbers. Therefore, these will not be described in further detail.
[0057] There will now be described a family of three-wheeled motorized vehicles on which the vehicle cover according to the present invention can be used. FIG. 5A shows a first three-wheeled motorized vehicle 410 . The vehicle 410 has a straddle seat 412 located at least partially rearwardly of a center of the vehicle 410 and disposed along the longitudinal centerline thereof. The straddle seat 412 has a first portion 420 for accommodating a driver, and a second portion 422 for accommodating a passenger behind the driver. The second portion 422 is higher than the first portion 420 to permit the passenger to see in front of the vehicle 410 over the driver. A pair of handles 424 are provided on either side of the second portion 422 for the passenger to hold onto. It is contemplated that the straddle seat 412 could be disposed at a different longitudinal location depending on the particular ergonomics of the vehicle 410 . It is also contemplated that the straddle seat 412 could only have the first portion 420 for the driver.
[0058] A steering assembly is disposed forwardly of the straddle seat 412 to allow a driver to steer the two front wheels 414 . The steering assembly has handlebars 426 connected to a steering column 428 . The steering column 428 is connected to the two front wheels 414 , such that turning the handlebars 426 turns the wheels 414 . The handlebars 426 are provided with handles 430 for the driver to hold. The right handle 430 can twist and acts as the throttle controller for the engine (not shown). It is contemplated that the throttle could also be controlled by a separate lever disposed near one of the handles 430 . A brake actuator, in the form of a hand brake lever 434 , is provided near the right handle 430 for braking the vehicle 410 .
[0059] A pair of driver foot pegs 436 are provided on either sides of the vehicle 410 below the first portion 420 of the straddle seat 412 for a driver to rest his feet thereon. Similarly a pair of passenger foot pegs 438 are provided on either side of the vehicle 410 below the second portion 422 of the straddle seat 412 for a passenger to rest his feet thereon. Another brake actuator, in the form of a foot brake lever 440 , is provided on a right side of the vehicle 410 below the first portion 420 of the straddle seat 412 for braking the vehicle 410 .
[0060] Each of the two front wheels 414 is mounted to the frame (not labelled) of the vehicle 410 via a front suspension (not shown) in a known manner. Each of the two front wheels 414 has a tire 446 thereon which is suitable for road use. The tires 446 are preferably inflated to a pressure between 138 kPa and 345 kPa. A fairing 448 is disposed over each tire 446 to protect the driver from dirt and water which can be lifted by the tire 446 while it is rolling. Each of the two front wheels 414 is also provided with a brake 450 .
[0061] The rear wheel 416 is mounted to the frame via a swing arm 456 . The swing arm 456 preferably has two arms pivotally mounted at a front thereof to the frame and between which the rear wheel 416 is rotatably mounted at the rear of the two arms. A shock absorber 458 is disposed between the swing arm 456 and the frame 442 . The rear wheel 416 has a tire 460 thereon which is suitable for road use. Preferably, the tire 460 is wider than the tires 446 . It is contemplated that the tire 460 could have a smaller width or the same width as the tires 446 . It is also contemplated that the rear wheel 416 could have two or more tires disposed next to each other thereon and still be considered a single rear wheel. The tire 460 is preferably inflated to a pressure between 138 kPa and 345 kPa. A fairing 462 is disposed over the tire 460 to protect the driver from dirt and water which can be lifted by the tire 460 while it is rolling. The rear wheel 416 is provided with a brake 464 . Power is transmitted from the engine to the rear wheel 416 via a belt drive (not shown) or any other suitable means.
[0062] A vehicle body 478 is attached to the frame in order to protect the components mounted to the frame and to make the vehicle 410 aesthetically pleasing. Components necessary to make vehicle 410 suitable for road use, such as lights 480 and a rear view mirror 482 , are mounted to the vehicle body 478 .
[0063] FIG. 5B shows a second three-wheeled motorized vehicle 510 . The second three-wheeled motorized vehicle 510 differs from the three-wheeled motorized vehicle 410 of FIG. 5A only in the addition of a backrest 522 positioned rearward of the second portion 422 of the seat 412 , to support the back of the passenger. The remaining features of the second three-wheeled vehicle 510 are the same as those of the three-wheeled vehicle 410 of FIG. 5A , and are labelled with the same reference numbers. Therefore, these will not be described in further detail.
[0064] There will now be described a family of ATVs on which the vehicle cover according to the present invention can be used. FIG. 6 shows an ATV 610 . The ATV 610 has a frame (not shown) which supports a body 604 . The frame rotatably supports front and rear suspension systems 606 to which are mounted front and rear wheels 608 , in a manner well known in the art. The wheel preferably have low-pressure balloon tires (i.e, between 1.5 and 4 psi)
[0065] A driver seat 612 is mounted to the frame generally above an engine (not shown). The driver seat 612 can support a driver in a straddle position with a leg on each side of driver seat. Footrests 614 are mounted laterally to the sides of the ATV 610 . Connected to the frame is a steering assembly 616 , including handlebars 618 , for steering the ATV 610 .
[0066] Primary cargo storage on the ATV 610 is provided by front cargo racks 620 and rear cargo racks 622 mounted to the body 604 substantially over the axles of the wheels 608 . The front cargo rack 620 may have one or more portions over the fenders of the front wheels 608 . Likewise, the rear cargo rack 622 may have one or more portions over the fenders of the rear wheels 608 . Optionally, the front cargo rack 620 and rear cargo rack 622 may be integrally formed with the body 604 .
[0067] The ATV has a receptacle 624 mounted to a rear portion of the vehicle permitting a variety of different modular components, to be interchangeably connected to receptacle at the rear portion of the vehicle, as will be described below.
[0068] The receptacle 624 is adapted to receive and releasably engage a modular component in the manner described in U.S. patent application Ser. No. 10/796,371, filed Mar. 8, 2004, which is incorporated herein by reference in its entirety. The modular component may be interchangeably mounted on the ATV 610 , and can be removed by an owner and replaced by a modular component of a different type whenever a different feature is desired or deemed useful. For example, the modular component may be a rear passenger seat 630 , a cargo container 640 , a flatbed 650 , a work bench 660 (with or without the illustrated vise grip), or a rear cargo rack 670 . The modular component may be electrically and electronically connected to the ATV 610 via a wire 644 connected to the modular component, a connector 642 , 643 adapted for being disconnected when the modular component is removed and a wire 645 connected to the vehicle's electrical circuit, for example to power a brake light 641 mounted on the modular component.
[0069] For each of the vehicle types discussed above, it should be understood that each of the configurations requires a vehicle cover having a different shape, despite the many similarities between the vehicles. For example, the snowmobiles 10 , 110 and 210 require three different covers, even though the vehicles themselves are substantially the same shape except for the respective seating configurations. In particular, the front portions of the snowmobiles 10 , 110 and 210 are the same.
[0070] Therefore, in accordance with an embodiment of the present invention, a plurality of front and rear vehicle cover sections are provided as will be discussed in greater detail below. A vehicle cover for a particular vehicle is formed by selecting the appropriate front vehicle cover section to snugly fit the front portion of the vehicle, selecting the appropriate rear vehicle cover section to snugly fit the rear portion of the vehicle, and fastening together the selected sections with a non-permanent fastener to form a vehicle cover that snugly fits the contour of the entire vehicle.
[0071] The front and rear cover portions are made of nylon but could be made of any other suitable weatherproof material. They are lightweight and flexible so they can be easily folded up and stored away when not in use.
[0072] FIGS. 4A-4H illustrate schematically how a family of snowmobile cover sections in accordance with one embodiment of the invention can be interconnected to provide snugly fitting covers for a number of different configurations of snowmobiles. It will be understood that the same principles can be applied in an analogous manner to covers for the various configurations of three-wheeled motorized vehicles and ATVs previously described.
[0073] Referring generally to FIGS. 4A-4H , a snowmobile cover fitted to a particular snowmobile is formed by selecting an appropriate front cover section corresponding to the configuration of the front portion of the snowmobile, selecting an appropriate rear cover section corresponding to the configuration of the rear portion of the snowmobile, and fastening the selected front cover section to the selected rear cover section at a joint. The construction of the joint will be described in further detail below.
[0074] Referring to FIG. 4A , the snowmobile 310 has a front configuration A and a rear configuration A′. It is therefore fitted with a cover 312 , formed by selecting the front cover section 314 , corresponding to front configuration A, selecting the rear cover section 316 , corresponding to rear configuration A′, and joining them together at the joint 318 .
[0075] Referring to FIG. 4B , the snowmobile 320 has a front configuration B and a rear configuration B′. It is therefore fitted with a cover 322 , formed by selecting the front cover section 324 , corresponding to front configuration B, selecting the rear cover section 326 , corresponding to rear configuration B′, and joining them together at the joint 328 .
[0076] Referring to FIG. 4C , the snowmobile 330 has a front configuration C and a rear configuration C′. It is therefore fitted with a cover 332 , formed by selecting the front cover section 334 , corresponding to front configuration C, selecting the rear cover section 336 , corresponding to rear configuration C′, and joining them together at the joint 338 .
[0077] Referring to FIG. 4D , the snowmobile 340 has a front configuration D and a rear configuration D′. It is therefore fitted with a cover 342 , formed by selecting the front cover section 344 , corresponding to front configuration D, selecting the rear cover section 346 , corresponding to rear configuration D′, and joining them together at the joint 348 .
[0078] Referring to FIG. 4E , the snowmobile 350 has the same front configuration A as the snowmobile 310 of FIG. 4A and the same rear configuration D′ as the snowmobile 340 of FIG. 4D . It is therefore fitted with a cover 352 , formed by selecting the front cover section 314 used in cover 312 of FIG. 4A , selecting the rear cover section 346 used in cover 342 of FIG. 4D , and joining them together at the joint 358 .
[0079] Referring to FIG. 4F , the snowmobile 360 has the same front configuration B as the snowmobile 320 of FIG. 4B and the same rear configuration C′ as the snowmobile 330 of FIG. 4C . It is therefore fitted with a cover 362 , formed by selecting the front cover section 324 used in cover 322 of FIG. 4B , selecting the rear cover section 336 used in cover 332 of FIG. 4C , and joining them together at the joint 368 .
[0080] Referring to FIG. 4G , the snowmobile 370 has the same front configuration C as the snowmobile 330 of FIG. 4C and the same rear configuration B′ as the snowmobile 320 of FIG. 4B . It is therefore fitted with a cover 372 , formed by selecting the front cover section 334 used in cover 332 of FIG. 4C , selecting the rear cover section 326 used in cover 322 of FIG. 4B , and joining them together at the joint 378 .
[0081] Referring to FIG. 4H , the snowmobile 380 has the same front configuration D as the snowmobile 340 of FIG. 4D and the same rear configuration A′ as the snowmobile 310 of FIG. 4A . It is therefore fitted with a cover 382 , formed by selecting the front cover section 344 used in cover 342 of FIG. 4D , selecting the rear cover section 316 used in cover 312 of FIG. 4A , and joining them together at the joint 388 .
[0082] The joint between the front and rear cover sections may be fastened by a zipper, snaps, buttons, Velcro™ or any other suitable fastener. It is contemplated that more than one type of fastener may be used on the same joint. For example, the selected front and rear cover sections may be fastened together by a zipper, buttons or snaps, which may be covered by a flap of material fastened with Velcro™. Referring to FIG. 7 , a joint 702 is shown between a front cover section 704 and a rear cover section 706 . In this example, the joint is fastened using buttons. The first half of the fastener, the buttons 708 , is provided on the rear cover section 706 . The second half of the fastener, the button holes 710 , is provided in the front cover section 704 . Because the nature of the joint 702 results in the front and rear cover sections overlapping, the joint 702 is arranged such that the front cover section 704 is disposed outwardly of the rear cover section 706 when the cover is placed on the vehicle. If the rear cover section 706 were disposed outwardly of the front cover section 704 , it would be possible for air to be caught by the joint 702 and potentially become trapped inside the vehicle cover when the vehicle is being towed on a trailer with the vehicle oriented in a forward direction.
[0083] The construction of the front cover sections 314 , 324 , 334 , 344 and the rear cover sections 316 , 326 , 336 , 346 will now be described. The front and rear cover sections are sized and fitted so that when they are joined the resulting vehicle cover can slide over the top of the entire upper body portion of the snowmobile, generally covering the forward fairings of the external shell and the rear seat portion. The skis and track may be left uncovered by this type of cover, as seen in FIGS. 4A , 4 C, 4 E and 4 G, or the front section of the cover may extend downward to cover the skis as seen in FIGS. 4B , 4 D, 4 F and 4 H. Similarly, for an ATV or a three-wheeled motorized vehicle, the cover may optionally cover the wheels of the vehicle or leave them uncovered.
[0084] Referring to FIGS. 9A and 9B , the snowmobile cover and some of its features have been renumbered for ease of understanding and to illustrate the general applicability of the present invention. The snowmobile cover is discussed above, including a number of different combinations of front and rear cover sections. FIGS. 9A and 9B illustrate one particular combination of front and rear cover sections, but it should be understood that the same principles apply generally to any combination.
[0085] Referring to FIGS. 9A and 9B , each front cover section has a top wall 916 and left and right side walls 918 to generally follow the contour of the snowmobile 900 and provide a snug fit for the forward portion of the snowmobile 900 . Each rear cover section has a top wall 920 and left and right side walls 922 to generally follow the contour of the snowmobile and provide a snug fit for the rearward portion of the snowmobile. In addition, each front cover section has a front wall 924 and each rear cover section has a rear wall 926 , to generally follow the contour of the respective end of the snowmobile. Referring also to FIGS. 1-3 generally, it should be understood that some parts of the snowmobile 900 are larger than others. This necessitates that some parts of the snowmobile cover 902 be larger than others in order to snugly fit on the snowmobile 900 , as shown in FIGS. 9A and 9B . The front wall 924 may be pointed or blunt according to the shape of the particular snowmobile. Disposed rearwardly of the front wall 924 is a first portion of the snowmobile cover 902 having a first height h 1 and a first width w 1 adapted to snugly fit over the front fairings of the snowmobile 900 . The snowmobile cover 900 then slopes generally upwardly and rearwardly to a second portion having a second height h 2 and a second width w 2 , respectively larger than the first height h 1 and a first width w 1 , adapted to snugly fit over the windshield and handlebars of the snowmobile 900 . The snowmobile cover 902 then slopes generally downwardly and rearwardly to a third portion having a third height h 3 and a third width w 3 , respectively smaller than the second height h 2 and the second width w 2 , adapted to snugly fit over a part of the seat of the snowmobile 900 . Disposed rearwardly of the third portion is a fourth portion having a fourth height h 4 approximately equal to the third height h 3 , and a fourth width w 4 , slightly smaller than the third width w 3 , adapted to snugly fit over a part of the seat of the snowmobile 900 . Disposed rearwardly of the fourth portion is the rear wall 926 , which is contoured to snugly fit over the rearward end of the snowmobile 900 . It should be understood that the same principle can be applied to covers for other types of vehicles, such as all-terrain vehicles (ATVs), and three-wheeled motorized vehicles, in which case the cover would have the appropriate shape corresponding to the features of the vehicle being covered, to ensure a snug fit.
[0086] The joint 912 between the front and rear cover sections is formed by joining the rearward edge 928 of the front cover section 908 to the forward edge 930 of the rear cover section 910 , as will be described in greater detail below. The joint 912 is situated along the seat, rearwardly of the handlebars and forwardly of the rear of the snowmobile, between the third portion and the fourth portion of the snowmobile cover 902 . Because the seat of the snowmobile 900 has generally smaller dimensions than the front fairings, windshield and handlebars, the length of the joint 912 required to fasten the front cover section 908 to the rear cover section 910 is correspondingly shorter, resulting in reduced cost of manufacture and increased convenience in fastening and unfastening the respective cover sections compared to, for example, a longer joint situated along the windshield portion of the snowmobile. It is contemplated that the joint may alternatively be located forwardly or rearwardly of the illustrated location, without departing from the scope of the invention. It should be understood that the same principle can be applied to covers for other types of vehicles, such as all-terrain vehicles (ATVs), and three-wheeled motorized vehicles, in which case the joint would be situated along a part of the vehicle that is generally narrower or smaller than other parts of the vehicle, such as the seat portion, to provide a joint of reduced length.
[0087] Thus, using only four different front cover sections 314 , 324 , 334 , 344 , and only four different rear cover sections 316 , 326 , 336 , 346 , snugly fitting covers can be provided for snowmobiles having the eight different configurations shown. It should be understood that as many as 16 total permutations are possible with four front cover sections and four rear cover sections, thus properly fitted covers can be provided for as many as 16 different vehicle configurations using the same four front cover sections and four rear cover sections. It should also be understood that the number of different front and rear cover sections shown here is merely exemplary, and the invention may be practiced with more or fewer front cover sections and rear cover sections.
[0088] In addition, it should be understood that the differences in vehicle configuration between the vehicles are not limited to the seating configurations, but can include the presence or absence of a cargo rack or storage box rearward of the rear seat, different front fairing designs, or any combination of these.
[0089] Referring to FIG. 8 , the front cover section 802 may be connected to the rear cover section 804 by connecting a middle cover section 806 therebetween, for example if the only or primary difference between two vehicle configurations is the length of the vehicle. Thus a first joint 808 is formed between the front cover section 802 and the middle cover section 806 , and a second joint 810 is formed between the middle cover section 806 and the rear cover section 804 . Both joints 808 and 810 may employ one or more suitable fasteners such as a zipper, snaps, buttons, Velcro™ or any other suitable fastener in the manner described above. It is also contemplated that the joints may employ different fasteners, for example snaps may be used for joint 808 and a zipper may be used for joint 810 . In this manner, the proper orientation of the middle cover section 806 is assured, because only the front edge of the middle section 806 can be successfully fastened to the front cover section 802 and only the rear edge of the middle section 806 can be fastened to the rear cover section 804 .
[0090] Referring to FIGS. 9A and 9B , the snowmobile cover 902 may be secured to the snowmobile 900 by lateral straps 904 , 906 which extend from one side of the opening in the snowmobile cover 902 , and are adapted to transversely extend beneath the snowmobile 900 for fastening engagement with the snowmobile cover 902 on the opposite side of the snowmobile 900 . The cover may have as many as three or four straps 904 , 906 . One or more straps 904 may be attached to the front cover section 908 , forward of the joint 912 , and one or more straps 906 may be attached to the rear cover section 910 , rearward of the joint 912 , to ensure that the snowmobile cover 902 is adequately secured to the snowmobile 900 . This method of securing a cover to a snowmobile is described in greater detail in U.S. Pat. No. 6,964,448, which is incorporated herein by reference in its entirety.
[0091] The cover 902 may alternatively or additionally be secured to the snowmobile 900 by a strap 914 which extends around the perimeter of the snowmobile cover 902 , having ends which meet at a point, such as the rear of the snowmobile 902 , for fastening together. The strap can then be drawn taut to hold the perimeter of the snowmobile cover 902 as close to the snowmobile 900 as possible, thereby preventing wind or snow from entering the snowmobile cover 902 or blowing the snowmobile cover 902 off the snowmobile 900 . This method of securing a cover to a snowmobile is described in U.S. Pat. No. 6,964,448.
[0092] The cover may alternatively be secured to the vehicle in the following manner, described in U.S. Pat. No. 6,964,448. A single continuous fastening strap extends around at least the rear half of the perimeter of the lower opening in the cover. Each of the free ends of the fastening strap has a length which permits it to be crossed under the snowmobile and fastened to the lower lip on a lateral side thereof opposite from that of the strap opening from which the free end projects.
[0093] It should be understood that the cover can be attached to the vehicle by these or any other suitable means without departing from the spirit of the present invention.
[0094] Modifications and improvements to the above-described embodiments of the present invention may become apparent to those skilled in the art. The foregoing description is intended to be exemplary rather than limiting. The scope of the present invention is therefore intended to be limited solely by the scope of the appended claims. | A family of vehicle cover sections is disclosed, including at least one first cover section comprising a flexible material at least two second cover sections comprising a flexible material. One of the at least two second cover sections is non-permanently connectable to the at least one first cover section to form therewith a first vehicle cover configured to generally fit the contour of at least an upper portion of a first vehicle having a first configuration. Another of the at least two second cover sections is non-permanently connectable to the at least one first cover section to form therewith a second vehicle cover configured to generally fit the contour of at least the upper portion of a second vehicle having a second configuration, the second vehicle cover being removably attachable to the second vehicle. A method of forming a vehicle cover and a cover formed by the method are also disclosed. | 8 |
TECHNICAL FIELD
This invention pertains to the terrestrial positioning of modules of photovoltaic cells with respect to the sun. The invention is particularly concerned with efficient investment in photovoltaic modules and optimized use of such modules to provide electrical power, such as that for the electrolytic production of hydrogen from water.
BACKGROUND OF THE INVENTION
Photovoltaic (PV) cells are known semiconductor devices that convert light (i.e. by photons impinging on a pn junction) into electrical energy. Of course, sunlight can be used as the source of energy. Amorphous silicon, crystalline silicon, and selenium are examples of materials that are used in devising such cells. The voltage provided by an individual cell may be relatively small but many such cells can be combined as modules in electrical series and/or parallel connections to produce electrical power at voltage and current levels suitable for many applications. The modules are often constructed with flat surfaces to receive the incident light.
Solar hydrogen generation by photovoltaic-electrolyzer (PV-electrolyzer) systems is a potentially important, renewable and environmentally beneficial energy source for hydrogen fueled devices such as fuel cells. Planar modules of clusters of photovoltaic cells can be arranged to produce direct current voltage and current levels for a system of electrolysis cells to produce hydrogen and oxygen from water. In other words, an electrolysis system can be devised to deliver hydrogen gas at a required or design rate. And a photovoltaic system can be designed to provide electrical power for the specified electrolysis system. However, there is a challenge in the design and operation of a photovoltaic system because of the large variation in solar radiant flux density (irradiance) at virtually every location on the surface of the earth.
The planar module, or cluster of modules which is called an array, represents a relatively high investment cost per unit of required power and they require substantial land area in which to receive sunlight. If the PV-electrolysis systems are to be located in populated areas their size is a critical design consideration. So they must be operated to make good use of available sunlight.
Photovoltaic modules are typically installed as arrays of modules with a fixed orientation depending on the site characteristics and cost constraints. One orientation that is used on flat roofs is the so-called horizontal configuration in which the modules face straight up towards the sky. Another fixed configuration, that is considered the best overall fixed configuration for PV installations in North America, is one in which the modules face south and are tilted with respect to the ground at an angle equal to the site latitude. For example, for Detroit, with a latitude of approximately 42 degrees north of the equator, the modules would be tilted at a 42 degree angle with respect to the ground. The angle between the sun's position and the surface of the earth is called the solar altitude angle. Some references recommend using a module tilt angle equal to 90% of the latitude, e.g. a tilt of 38 degrees for Detroit, since this gives higher PV energy output in the summer, when there is more solar energy available. However, this configuration would give less solar energy in the winter, so it may or may not be superior depending on the seasonal energy needs of the user.
On sunny days, so-called two-axis solar tracking—continually orienting the solar modules perpendicular to the rays of the sun throughout each day of the year—produces the maximum energy. This is because the response of a solar module to a ray of light is proportional to the cosine of the angle between a line perpendicular to the module surface and the solar ray impinging on the surface. If the solar radiation is perpendicular to the surface, the maximum power for a given solar flux will be obtained (cosine 0°=1). For solar radiation impinging at 90 degrees from the normal, no power will be produced (cosine 90°=0). While two-axis solar tracking keeps the planar module facing the sun, it does not take into account the variation in solar irradiance due to atmospheric cloud cover and variation in the cloud coverage.
This invention provides a method of operation for a PV module under varying atmospheric conditions, continually positioning the module to make good use of sunlight in both cloudless and cloudy conditions.
SUMMARY OF THE INVENTION
This invention provides a PV directional control method that is applicable to modules of a plurality of solar powered photovoltaic cells, especially modules with planar light-receiving surfaces. The method has general utility to maximize the energy output of solar powered PV cells, and it has particular utility where the module(s) is used to power an electrolyzer system to produce hydrogen and oxygen from water because of the initial and operating costs of the PV systems. The method is aimed at making optimal use of the module(s) and reducing the size and cost of the PV power system as well as the physical space required for its placement and operation. Accordingly, the method of this invention is preferably considered in the design of the module for a particular geographical location.
In most geographical locations there are many daylight hours in which the sun is obscured by atmospheric cloud cover. Even in locations known for abundant sunshine there are times when the solar radiation available to PV cells is substantially reduced by intervening clouds. A PV module performs well in cloudless sunlight using conventional two-axis tracking. But the PV module control method of this invention is based on the unexpected discovery that a PV module receives more solar energy in a horizontal position (facing upwardly) when there is appreciable cloud cover. As will be described in more detail below in this specification, a planar PV module receives more sunlight in a horizontal position when the total solar irradiance is relatively low due to heavy cloud cover. Application of this factor permits more efficient use of the PV module under such operating conditions. This enables a module of given design capacity to be more fully utilized, reducing both the initial cost of the PV system and the space required for powering an electrical load, such as a hydrogen producing electrolyzer.
Accordingly, each PV module is supported so as to be movable through a range of tilted positions following and facing the sun (two-axis solar tracking). But, in addition to the solar tracking mode of operation, the module is also movable to a horizontal position, facing upwardly. And a control method is provided to determine which PV module position gathers the most solar energy at each moment of daylight operation.
In a generalized statement of the control method, the irradiance of the sun is continually measured in, for example, watts per square meter of incident surface (W/m 2 ). By way of example, peak sun irradiance at the surface of the earth may reach peak values of 1000 W/m 2 and this radiation flux density will sometimes be referred to in this specification as “one sun.” The operation of the module is managed according to the value of the measured irradiance. Whenever the measured solar irradiance is below a predetermined value relative to the clear-sky value the module is moved to a horizontal position. Solar radiance measurements at such low levels will occur due to wide-spread cloud cover of the sky. And whenever the measured solar irradiance exceeds the predetermined minimum value for the location, the module is positioned according to two-axis solar tracking for the location, day of year, and time of day.
In accordance with a preferred embodiment of the invention, a proposed PV control method would use a conventional two-axis tracking system with the following additions: 1) it would have one small solar radiation measuring cell fixed horizontally (H), and another fixed with a south-facing latitude tilt (L). At times when there was direct sunshine, the L sensor would have a greater output than the H sensor, and the tracking system would align the solar panels with the sun using well-known technologies and algorithms for maximum output. When H>L, say H>1.3×L, a signal would be generated which would cause (by an algorithm) the solar tracker to position the solar modules to face up towards the sky (horizontal). This would presumably be at times when there was near complete cloud cover. It is estimated that this would provide from 30-80% greater solar energy under overcast conditions than tracking the sun or having a latitude tilt.
In another embodiment of the invention, global, direct and diffuse, radiation is used to determine when to switch from two-axis tracking to the horizontal mode. For example, two solar radiation sensors are mounted horizontally. One sensor (sensor 1) is shaded from direct radiation from the sun (solar disk) and measures the diffuse radiation. This can be accomplished with a shadow band that shades the sensor from direct sunshine as the sun moves across the sky or with a small shading disk attached to a small two-axis tracker. The other sensor (sensor 2) is not shaded and measures the global horizontal radiation. The difference between the two sensors is the direct radiation from the sun. When the sky is heavily overcast, the direct component of the solar radiation is near zero. For such times an array of solar modules would be oriented horizontally to capture the most solar energy under heavily overcast conditions. When the direct component is significant, the regular two-axis tracking of the sun by the array of solar modules would take place to capture the most solar energy under sunny or partly cloudy conditions.
While the energy output of a PV system is optimized during periods of ample sunshine by two-axis movement of the module, the practice of this invention still provides advantages when the module is simply moved between a two-axis tracking mode and a horizontal position mode, depending on the relative solar irradiance.
Other objects and advantages of the invention will be apparent from a detailed description of preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph of the ratio of solar irradiance realized by a PV system for two-axis tracking with the module versus a fixed latitude tilt of the module. The ratio is expressed as peak sun hours, PSH, where PSH equals the number of per day hours with a solar irradiance of 1000 W/m 2 . The data is from the National Renewable Energy laboratory (NREL) solar radiation data site (http://rredc.nrel.gov/solar/pubs/redbook/). The ratios are presented as average monthly data over a year for Detroit and Phoenix.
FIG. 2 is a graph of the fraction of cloudy or partly cloudy days in Phoenix (filled diamond data points) and Detroit (filled square data points) for each month over a twelve month period. The data is from the University of Utah meteorology site (http://www.met.utah.edu/jhorel/html/wx/climate/cldy.html).
FIG. 3 is a graph of the fraction of cloudy days in Phoenix (filled diamond data points) and Detroit (filled square data points) for each month over a twelve month period. The data is from the University of Utah meteorology site (http://www.met.utah.edu/jhorel/html/wx/climate/cldy.html).
DESCRIPTION OF PREFERRED EMBODIMENTS
Expected PV Improvement with a Two-Axis Tracking System
The sun's location in the sky relative to a location on the surface of the earth can be specified by two angles: 1) the solar azimuth angle and the solar zenith angle. The solar azimuth angle is the location of the sun in the sky relative to a line running due north. An azimuthal angle of 180 degrees occurs when the sun is due south and defines solar noon at the location of interest. On a sunny day this will be the time of maximum solar insolation provided there are no clouds. By way of example, the solar insolation of a northern US location, Detroit, Mich. and a southern location, Phoenix, Ariz. will be considered and compared.
For Detroit, Mich. at the winter solstice, the sun rises in the eastern sky at 8 AM at an azimuthal angle of 120 degrees and sets in the western sky at 5:00 PM with an azimuthal angle of 238 degrees, moving only 118 degrees across the southern horizon. At the summer solstice in Detroit, the sun rises at 6 AM (daylight savings time) at an azimuthal angle of 57 degrees and sets at 9:10 PM at an azimuthal angle of 303 degrees, moving over 246 degrees across the southern horizon. The solar zenith angle is the angle between the sun's position and that for a line perpendicular to the earth's surface. It is the compliment of the solar altitude angle, i.e., the solar zenith angle=90°—the solar altitude angle. At solar noon the zenith angle is 71 degrees in Detroit for the winter solstice and 24 degrees for the summer solstice. A two-axis tracking system moves PV modules so that they remain perpendicular to the sun's direct rays as the sun makes its daily movement across the sky (east-west tracking) and also adjusts for the slow change in that movement as the seasons change (north-south tracking).
A two-axis tracking system is most effective in improving PV performance when there are no clouds between the sun and the PV modules. The solar energy striking the earth's surface, called the global solar energy, is made up of two major components: a component directly from the solar disk (direct) and a skylight component from scattered radiation (diffuse). A third component, reflection from the ground (albedo) is generally small unless snow is present, so it will be neglected in this discussion. On cloud-free days 85-90% of the suns energy comes from the direct component, while the other 10-15% is diffuse radiation from the sky (mostly scatted from atmospheric aerosol). On cloudy days nearly all of the solar energy is from the diffuse component. Since diffuse solar radiation is not aligned in a parallel fashion like direct radiation, tracking the sun does not increase (and, as will shown below in this text, can actually decrease) the solar energy from a PV system on cloudy days.
The National Renewable Energy Laboratory (NREL) has compiled a data base for solar energy at 239 U.S. sites over a 30-year period from 1961 to 1990 (http://rredc.nrel.gov/solar/pubs/redbook/). This data base is referred to as the “Solar Radiation Data Manual for Flat Plate and Concentrating Collectors”. Using this data base, FIG. 1 was prepared, and it shows the increase in the solar energy, as measured by the number of peak sun hours (equivalent to the number of hours per day with a solar irradiance of 1000 W/m 2 , abbreviated PSH), using a two-axis tracking system versus that for a fixed latitude tilt (the best overall fixed tilt) for Detroit, Mich. and Phoenix, Ariz.
The two-axis tracking shows an overall increase in solar energy of 30% in Detroit and 38% in Phoenix versus the same PV system without solar tracking. This range of increases is consistent with the claims of a manufacturer of two-axis tracking systems (Wattsun, web site www.wattsun.com). Thus, two-axis tracking can provide about a third more energy from the same area PV modules versus the optimal fixed module tilt (latitude tilt). As shown in FIG. 1 , two-axis tracking provides the most improvement relative to a fixed latitude tilt system for the months with the greatest sunshine, i.e., from April to September with a peak in June in both Detroit and Phoenix.
The Effect of Solar Tracking on Cloudy Days
FIG. 1 shows that a two-axis tracking PV system can produce a dramatic increase in the solar energy produced by a PV system. This improvement is most apparent in June in Phoenix, where it reaches 60% and least in Detroit in December when it is less than 20%. However, it is found that a tracking system works best on sunny days and worst on cloudy days. This is an important consideration, since it will affect the size and cost of a PV system needed to drive an electrolyzer to produce hydrogen for a fuel cell vehicle (FCV). And the PV system needs to be capable of efficient operation in a variety of geographical locations to serve hydrogen fuel cell powered vehicles traveling between such locations. In order to reduce the cost of that system, it would be very beneficial to boost the solar output on cloudy days. Unfortunately, this cannot be done using solar concentrators, since they can only focus direct (parallel) rays from the sun.
However, we have found that pointing the modules straight up towards the sky (horizontally, H condition) during overcast conditions results in significantly more solar irradiance than having the modules tilted towards the obscured sun (directly toward the sun, DTS condition). Moreover, it would be a simple matter to add some hardware and software to a conventional two-axis tracking system so that it will extract the maximum energy from solar modules by tracking the sun on sunny days, but orienting the modules horizontally on cloudy days, or during shorter cloudy periods. We first discovered this while testing the solar module output on cloudy days in the fall of 2004 in Warren Mich. and confirmed our findings in the spring of 2005. Table 1 below shows the results of measurements from two large solar modules (Sharp NT185U1 and Sanyo HIP-G751BA2), a photodiode made by UDT Sensors, Inc. (UDT PIN-10DP/SB), two small solar modules (Connecticut Solar 125 mm×227 mm and Powerfilm MPT3.6-75i), and a pyranometer made by Eppley Laboratories (Eppley Laboratories Black and White Pyranometer, model 8-48) on four overcast days during the fall of 2004 and spring of 2005 in Detroit. The UDT photodiode was calibrated by NREL and was used to compute the solar irradiance (reported as the number of suns, where one sun=1000 W/m 2 ). The UDT photodiode was also validated across a range of conditions by comparison with the Eppley pyranometer which was also calibrated by NREL; Eppley pyranometers are widely used to measure the total solar radiation at the surface of the earth.
As shown in Table 1, for 20 measurements on cloudy days orienting the solar sensors horizontally (H) increases their output by a factor of 1.31 to 1.82 (mean ratio=1.48±0.16) compared to the directly-toward-the-sun (DTS) orientation. This 48% average increase in energy with the H configuration over the DTS configuration is in marked contrast to the results in FIG. 1 , which shows that solar tracking (DTS) increases the PV solar output by 30% versus the best fixed-tilt configuration (latitude tilt) in Detroit over the course of the whole year. Examining the same NREL data base that was used to prepare FIG. 1 revealed that over the course of a year a fixed latitude tilt provides 10-15% more solar energy from a PV module than a fixed horizontal tilt (H configuration) for both Detroit and Phoenix, so the H configuration is not an optimal tilt over a long period. The results in FIG. 1 are dominated by sunny or partly sunny conditions, while the results in Table 1 were obtained under heavily overcast conditions with a solar irradiance of 0.07 to 0.25 suns (a solar irradiance of 1000 W/m 2 is referred to as one sun). It is believed that the increase with the H condition in Table 1 is due to the sensor or module gathering solar energy from the whole cloud-covered (bright) sky, while for the DTS condition the panel is irradiated partly by reflected solar energy from the sky and partly by reflected solar energy from the (dark) ground. The reflected radiation from the darker ground is known to be significantly less than that from the sky.
TABLE 1
Measurements of the solar output from six solar irradiance sensors
for H and DTS configurations on overcast days in Warren, MI.
Zenith
Solar
Horizontal
Directly toward
H/DTS
Angle c
Date
Time
sensor a
Suns b
(H)
sun (DTS)
ratio
(degrees)
Oct. 26, 2004
4:30 PM
UDT
0.13
2.71
mA
1.49
mA
1.82
55
Oct. 26, 2004
4:30 PM
Sharp
0.46
A
0.28
A
1.64
Nov. 3, 2004
1:40 PM
UDT
0.14
2.86
mA
1.81
mA
1.58
58
Nov. 3, 2004
1:40 PM
Eppley
1.1
mV
0.8
mV
1.38
Nov. 11, 2004
1:05 PM
UDT
0.19
4.06
mA
2.3
mA
1.77
60
Nov. 11, 2004
1:05 PM
Eppley
1.5
mV
1.0
mV
1.50
Nov. 11, 2004
1:05 PM
Sharp
0.75
A
0.46
A
1.63
Nov. 11, 2004
1:05 PM
Sanyo
0.50
A
0.32
A
1.67
Apr. 7, 2005
10:40 AM
UDT
0.07
1.45
mA
1.02
mA
1.42
52
Apr. 7, 2005
11:10 AM
UDT
0.25
5.34
mA
3.86
mA
1.38
43
Apr. 7, 2005
11:25 AM
UDT
0.17
3.55
mA
2.58
mA
1.38
45
Apr. 7, 2005
1:00 PM
UDT
0.07
1.49
mA
1.07
mA
1.39
54
Apr. 7, 2005
1:00 PM
Conn. Solar
50.2
mA
38.2
mA
1.31
Apr. 7, 2005
1:00 PM
Power Film
50.2
mA
38.2
mA
1.31
Apr. 7, 2005
1:50 PM
UDT
0.06
1.28
mA
0.98
mA
1.31
55
Apr. 7, 2005
1:50 PM
Conn. Solar
49.2
mA
37.5
mA
1.31
Apr. 7, 2005
1:50 PM
Power Film
3.15
mA
2.20
mA
1.43
Apr. 7, 2005
3:20 PM
UDT
0.12
2.57
mA
1.76
mA
1.46
48
Apr. 7, 2005
3:20 PM
Conn. Solar
104.0
mA
75.7
mA
1.37
Apr. 7, 2005
3:20 PM
Power Film
6.84
mA
4.53
mA
1.51
a UDT = United Detector Technologies Model PIN 10DP/SB photodiode (c-Si based); Sharp = Model NT185U1 module (c-Si based); Sanyo = Model HIP-G751BA2 module (combination of c-Si and a-Si materials); Eppley = Model 8-48 Black and White Pyranometer; Conn. Solar = Connecticut Solar 125 mm × 227 mm module (c-Si based); Power Film = Model MPT3.6-75 module (a-Si based).
b Suns = (measured W/m 2) /(1000 W/m 2 )
c Zenith angle obtained from U.S. Naval Observatory web site, http://aa.usno.navy.mil
An object of this invention is to enable the use of PV energy to drive the electrolysis of water to make hydrogen in a home refueling system for hydrogen fuel cell powered vehicles. It is important to increase the solar energy available from a PV system on cloudy days because the system needs to be sized to produce enough hydrogen to fuel a fuel cell vehicle on the days with the least sunshine (cloudy days), or the convenience of such a system for the customer could be lost. Positioning the panels with an H configuration can provide 30-80% greater energy than tilting the panels toward the sun on cloudy days—a major improvement. On the other hand it is imperative to have the system produce the most energy on sunny days and partly sunny days, so a two-axis tracking system is needed. Therefore, the control method uses a two-axis tracking system that tracks the sun on days when direct sunshine is available, but goes to an H configuration when it is overcast. Determining the increase in total energy that can be gained on overcast days by using the H configuration will require additional data collected over a large number of days and meteorological conditions. However, based on the data in Table 1, it is apparent that when it is overcast and the solar irradiance is less than 250 W/m 2 (<0.25 suns), the H configuration is superior to the DTS configuration.
FIG. 2 shows that there are significant percentages of cloudy or partly cloudy days in Detroit (79%) and even in Phoenix (42%). FIG. 3 considers only cloudy days for the two cities; 50% of the days in Detroit were cloudy and 19% of the days in Phoenix were cloudy. Therefore, the advantages of an H panel adjustment for cloudy days or cloudy periods will be useful a significant percentage of the time and even at sites like Phoenix that are considered sunny. The invention will most likely yield the largest increase in solar energy collection on heavily overcast days, which are an unknown fraction of the cloudy days.
Determining the Positioning of the PV Modules
The practice of the invention requires the use of one or more solar radiation sensors to determine when photovoltaic modules should be tilted in accordance with two-axis solar tracking for optimal absorbance of solar irradiance or when the modules should be positioned horizontally.
In one embodiment of the practice of the invention the irradiance of the sun is continually measured in, for example, watts per square meter of incident surface (W/m 2 ) using a single sensor. As stated above, the peak sun irradiance at the surface of the earth may reach 1000 W/m 2 (“one sun”). The operation of the module is managed according to the value of the measured irradiance. Whenever the measured solar irradiance is below a predetermined value relative to the clear-sky value the module is moved to a horizontal position. Solar irradiance measurements at such low levels will occur due to wide-spread cloud cover of the sky. And whenever the measured solar irradiance exceeds the predetermined minimum value for the location, the module is positioned according to two-axis solar tracking for the location, day of year, and time of day.
Simple algorithms for comparison of measured values of solar irradiance with reference data or with values obtained by other sensors are available or readily devised.
In another embodiment, a preferred embodiment, a photovoltaic cell control method uses a conventional two-axis tracking system (such as one of those made by Wattsun Solar Trackers, Albuquerque, N. Mex.) with the following additions: 1) it would have one small (UDT type) solar cell fixed horizontally (H), and another fixed with a south-facing latitude (in the Northern Hemisphere) tilt (L). At times when there was direct sunshine, the L sensor would have a greater output than the H sensor, and the tracking system would align the solar panels with the sun using well-known technologies and algorithms for maximum output. When H>L, say H>1.3×L, a signal would be generated which would cause (by an algorithm) the solar tracker to position the solar modules to face up towards the sky (horizontal). This would presumably be at times when there was near complete cloud cover. It is estimated that this would provide from 30-80% greater solar energy under overcast conditions than tracking the sun or having a latitude tilt. In the wintertime in Detroit over 80% of the days are cloudy or partly cloudy ( FIG. 2 ) and about two-thirds of the days are cloudy ( FIG. 3 ). During the winter many of the cloudy days are heavily overcast (the types of days studied in Table 1). The average increase in the H/DTS ratio in Table 1 is approximately 50% for heavily overcast conditions. If half of the cloudy wintertime days are the heavy overcast type, the subject tracking system would increase the collected solar energy by approximately 50% over a regular two-axis tracking system for the one-third of the days with the lowest solar insolation. This wintertime increase in solar energy collection in Detroit occurs when additional energy is most needed due to the shorter wintertime daylight periods. If the solar array was providing energy to produce hydrogen from water electrolysis, and if the hydrogen was being used to provide most or all of the hydrogen to refuel a fuel cell vehicle, then the PV system could be sized with less PV area and still make enough hydrogen on cloudy days in the wintertime. (On sunny days in the summer or winter the excess energy produced by the PV system could be used to power the system owner's home electrical needs or be sold back to the utility company). In order to have a system with minimal hydrogen storage and reduced cost, it is important to improve the solar hydrogen system's output on cloudy days when less solar energy is available. This tracking system and algorithm will allow such a system to be built.
In still another embodiment of the practice of the invention, two solar radiation sensors, mounted horizontally, are used to determine when to switch from two-axis solar tracking to the horizontal mode. This method utilizes measurements of global, direct, and diffuse, radiation for this determination. One sensor (sensor 1) is shaded from direct radiation from the solar disk and measures the diffuse radiation. This can be accomplished with a shadow band that shades sensor 1 from direct sunshine as the sun moves across the sky or with a small shading disk attached to a small two-axis tracker. The other sensor (sensor 2) is not shaded and measures the global horizontal radiation. The difference between the two sensors is the direct radiation from the sun. A commercially available product that makes measurements of the global, direct, and diffuse solar components using a single detector is available from Yankee Environmental Systems, Inc, (web site, www.yces.com) and is called a Single Detector Rotating Shadow Band Radiometer (SDR-1). When the sky is heavily overcast, the direct component of the solar radiation is near zero. For such times an array of solar modules would be oriented horizontally to capture the most solar energy under heavily overcast conditions. When the direct component is significant, the regular two-axis tracking of the sun by the array of solar modules would take place to capture the most solar energy under sunny or partly cloudy conditions.
The invention has been described in terms of certain preferred embodiments but it is not limited by the illustrated methods. | An array of solar powered photovoltaic modules is optimally oriented and operated to provide more electrical energy for uses such as powering an electrolyzer system for hydrogen production. The array is positioned with its light receiving surface at an optimal angle, preferably a continually changing angle determined by two-axis solar tracking, when continually measured solar irradiance indicates suitable sunlight, and at a horizontal position when measured solar irradiance indicates excessive atmospheric cloudiness. | 5 |
This invention claims the benefit of priority to U.S. Provisional Application Ser. No. 61/351,632 filed Jun. 4, 2010.
FIELD OF INVENTION
This invention relates to culverts, in particular to apparatus, devices, systems and methods of making spiral cut pipe materials into expandable inserts for damaged channels such as culverts, drainage canals, sewer lines, pipes, and the like, and installing a spiral cut pipe liner insert into the channels, and expanding the insert to become an pipe liner for the damaged channel that can be used under driveways, sidewalks and roadways, and the like.
BACKGROUND AND PRIOR ART
Culverts are permanent structures that are generally installed underneath driveways, sidewalks, and roadways to allow for storm water drainage. These permanent structures are often formed from materials such as concrete, steel, combinations, thereof, and the like, and are intended to last for many years. However, these culverts and pipes do not last forever, and can crumble and collapse after many years of use.
Since the culverts are considered to be permanent solid structure, cracks are only repaired with temporary patches and are not done for long lasting effects. After years of use and damage, the culverts usually need to be replaced when their life has run out. Currently, it is a very costly endeavor to have to physically dig up the driveways, sidewalks, roadways etc. in order to install new culverts when the old ones are needed to be replaced. Additionally, replacing a culvert can take up to a couple of days or more time which can result in the driveways, sidewalks, and roadways around the culverts not able to be used. Culvert repairs can require multiple permits and large amounts of labor and material costs. In addition, businesses and travelers have to detour about the areas where the culverts are being replaced causing further delays and hardships.
Thus, the need for solutions to the above problems with the prior art.
SUMMARY OF THE INVENTION
A primary objective of the present invention is to provide apparatus, devices, systems and methods of fixing damaged culverts by leaving the existing culverts in place.
A secondary objective of the present invention is to provide apparatus, devices, systems and methods of fixing damaged culverts that is substantially less expensive than having to remove and replace the existing culvert.
A third objective of the present invention is to provide apparatus, devices, systems and methods of fixing damaged culverts that takes substantially less time than having to remove and replace the existing culvert.
A fourth objective of the present invention is to provide apparatus, devices, systems and methods of fixing damaged culverts that is substantially less disruptive to vehicle and pedestrian traffic than having to remove and replace the existing culvert.
A preferred embodiment of the culvert insert can include a spiral cut pipe material, with cut sections hooked together along the seam lines with one another. Initially, a PVC type pipe can be cut along a spiral line from one end of the pipe to the other. Next, the separated spiral cut sections (or strips) can be joined together by a sliding hook, into an expandable or contractable pipe insert. The insert can be placed inside of a damaged culvert and then twisted to expand against the interior walls of the damaged culvert. Twisting the insert in a clockwise direction contracts the diameter of the insert, and lengthens the insert. Twisting the insert counter-clockwise at a job site (inside of a damaged culvert) expands the insert against interior walls of the damaged culvert and shortens the length of the insert.
A culvert insert can include an elongated rectangular strip of semi-rigid planar material having longitudinal sides, with at least one side having an elongated hook, and an opposite side having a longitudinal groove running therethrough, where the hook slidably attaches to and slide within the longitudinal groove when the strip is rolled into a spiral wrapped tube.
The elongated rectangular strip can be formed from PVC. The elongated hook can include an elongated seam having one side that is attached to the one side of the rectangular strip, and the seam edge having another side with the hook thereon.
The culvert insert can include a lock attached to at least one end of the spiral wrapped tube that keep the tube in a contracted rolled state. The culvert insert can include an opening in at least one end of the spiral wrapped tube to allow for a lever to be inserted in order to allow the culvert insert to expand.
The elongated seam can include a compressible and expandable O-ring for allowing the one side to slide against an opposite side of the strip.
The hook edge can include a finger portion protruding substantially perpendicular to the strip. The finger portion can include a substantially sharpened tip. The finger portion can include a substantially rounded tip. The finger portion can include an angled tip. The finger portion can include a pair of substantially perpendicular finger portions each facing one another.
A method of repairing a damaged culvert, can include the steps of inserting a rolled up tube into a damaged culvert, releasing the rolled up tube to unravel, expanding the unraveling tube, locking the expanding tube to interior walls of the culvert to form a protective lining for the inside of the culvert.
The method can further include the step of rolling an elongated strip of a rigid material into a spiral shape to form the rolled up tube before the inserting the tube in the culvert. The method can further include the step of slidably interlocking hook edges about longitudinal sides of the strip with one another while the strip is being rolled into the spiral shape.
The method can further include the step of providing a slidable surface on the hook edges, the slidable surface being selected from one of an O-ring, a bushing and a TEFLON® coating.
The releasing step can include the step of removing a lock about the at least one end of the rolled up tube.
The method can include the step of slidably attaching the hook edge into an elongated groove. The hook edges can include a substantially perpendicular finger portion. The hook edges can include a pair of substantially perpendicular finger portions each facing one another.
Further objects and advantages of this invention will be apparent from the following detailed description of the presently preferred embodiments which are illustrated schematically in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective view of the expandable culvert insert in a contracted configuration.
FIG. 1A is an enlarged view of a portion of the expandable culvert insert of FIG. 1 .
FIG. 1B is an end view of the expandable culvert of FIG. 1 in contracted position.
FIG. 2 is another perspective view of the expandable culvert insert of FIG. 1 in an expanded configuration.
FIG. 2A is an enlarged view of the expandable culvert insert portion of FIG. 1 .
FIG. 2B is an end view of the expanded expandable culvert insert of FIG. 2 .
FIG. 3 is a side view of the culvert insert of FIG. 1 in an expanded configuration.
FIG. 3A is a side cross-sectional view of the culvert insert of FIG. 3 along arrows 3 A.
FIG. 4A is an enlarged view of the connecting strip with o-ring seal and connecting strip retaining groove in the expandable culvert insert of FIG. 3A .
FIG. 4B is an exploded view of the connecting strip, o-ring seal and connecting strip retaining groove of FIG. 4A .
FIG. 5A is a cross-sectional view of another connecting strip seam for the invention.
FIG. 5B is a cross-sectional view of still another connecting strip seam for the invention.
FIG. 5C is a cross-sectional view of still another connecting strip seam for the invention.
FIG. 5D is a cross-sectional view of still another connecting strip seam for the invention.
FIG. 6 is a perspective view of culvert installation bridle for the invention.
FIG. 6A is an enlarged view of bridle hook for the bridle of FIG. 6 that is used to secure to a hole in a culvert insert wall.
FIG. 6B is an enlarged view of a cable hooked to a plate for the bridle of FIG. 6 .
FIG. 7 is a cross-sectional view of a damaged culvert being installed with the expandable culvert insert being pulled into the culvert.
FIG. 8 is another cross-sectional view of the damaged culvert with culvert insert in a position ready to be expanded.
FIG. 9 is another cross-sectional view of the culvert insert being expanded into place.
FIG. 10 is a cross-sectional view with the culvert insert fully expanded into place and the ends cut off to conform to the old exterior walls.
FIG. 11 is a front perspective view of a pipe cleaning bucket which is pulled through the old culvert prior to installation of the culvert insert.
in order to clear debris for the installation of the expandable culvert.
FIG. 12 is a rear perspective view of the pipe cleaning bucket of FIG. 11 showing winch cable affixed to the bottom ring.
FIG. 13 is a cross-sectional view of an old damaged culvert with the installation showing cleaning bucket being pulled through to clear debris.
FIG. 14 is a cross-sectional view of an old damaged culvert showing the bucket pulled completely through and debris cleared.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before explaining the disclosed embodiments of the present invention in detail it is to be understood that the invention is not limited in its applications to the details of the particular arrangements shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
A listing of components will now be described.
10 Expandable culvert insert in contracted configuration. 20 Expandable culvert insert in expanded configuration. 30 Axial contraction motion. 40 Radial expansion motion. 50 Lever rod to help the culvert insert to expand. 60 Shipping lock. 70 Shipping lock has been cut to allow the spiral sections to slide against each other. 80 Holes in culvert insert wall to fit lever rod into so that lever can be used to twist and expand culvert insert.
Also used to attach bridle hooks and pull culvert insert into position inside of old culvert.
98 Opposite side of connecting seam 90 Connecting strip seam. 100 Twisting motion that expands culvert insert. 110 Culvert insert wall. 112 one edge of insert wall 118 opposite edge of insert wall 120 O-Ring seal. 130 Connecting strip retaining groove in culvert insert wall. 140 Connecting strip is glued onto culvert insert wall on one side of seam. 150 Connecting strip retaining finger locks connecting strip into to groove in culvert insert wall while allowing the strip to slide along the wall when the culvert insert is twisted to expand. 152 indented outer portion of finger tip 158 enlarged rear base portion of finger tip 160 Optional configuration. Connecting strip molded as part of the culvert insert wall. 170 Rounded lead on retaining finger allows assembly of strip to culvert insert wall. 180 Alternate configuration on retaining finger. 190 Alternate configuration on retaining finger with hook molded to strip. 192 downwardly facing prong finger 198 upwardly facing prong finger 200 Installation bridle bridal used to pull culvert into position before expanding. 210 Bridle hook secures to hole in culvert wall. 220 Bridle cable fixes hook to bridle plate. 230 Bridle plate. 240 Ring fixed to bridle plate to attach winch cable hook onto. 250 Winch cable with hook (prior art). 260 Existing damaged culvert within soil/ground. 265 Soil/ground surrounding culvert 270 Upper and lower legs 272 Lubricant to ease sliding of culvert wall against connecting strip. 280 Culvert cut off to conform to the shape of the existing installation. 290 Pipe cleaning bucket. 300 Bucket. 310 Bucket cables connect bucket to bucket plate. 320 Bucket plate. 330 Ring fixed to bottom of bucket allows bucket to be pulled out of the culvert backwards to empty the bucket or clear a snag. 340 Ring fixed to bucket plate allows bucket to be pulled through old culvert to clear debris. 350 Debris in old culvert installation.
A preferred length of the installed culvert insert for residential use can be approximately 10 feet to approximately 40 feet, and having diameters of approximately 4 inches to approximately 8 feet. Shorter lengths can also be used. For an approximately 30 foot length existing culvert, having approximately 24 inches a preferred embodiment of the culvert can be twisted to approximately 20 inches in width. A single strip can have width of approximately 12 inches to approximately 16 inches in width before being rolled up in a spiral configuration.
For a residential application, the strips can be formed from extruded PVC (polyvinyl chloride) and/or ABS (acrylonitrile butadiene styrene) plastic. Other types of material can be formed from composite material that can include composites, fiberglass, combinations, and the like.
A machine can be used roll up the strips in a spiral pattern where each of the connecting strips is being rolled up into a spiral type roll configuration. For example, a rolling machine can be used for the PVC strips, and/or an extruding machine can be used for PVC, plastics, composites and the like. Likewise, an extruding machine can be used plastics, composites and the like.
FIG. 1 is a perspective view of the expandable culvert insert 10 in a contracted configuration. FIG. 1A is an enlarged view of a portion of the expandable culvert insert 10 of FIG. 1 . FIG. 1B is an end view of the expandable culvert 10 of FIG. 1 in contracted position.
FIG. 2 is another perspective view of the expandable culvert insert 10 of FIG. 1 in an expanded configuration 20 . Axial and radial motion arrows are shown to illustrate that the culvert is getting shorter and wider. FIG. 2A is an enlarged view of the expandable culvert insert portion of FIG. 1 . FIG. 2B is an end view of the expanded expandable culvert insert of FIG. 2 .
FIG. 3 is a side view of the culvert insert 10 of FIG. 1 in an expanded configuration. FIG. 3A is a side cross-sectional view of the culvert insert 10 of FIG. 3 along arrows 3 A.
FIG. 4A is an enlarged view of the connecting strip 110 with O-ring seal 120 and connecting strip retaining groove 130 in the expandable culvert insert 110 of FIG. 3A .
FIG. 4B is an exploded view of the connecting strip 110 , O-ring seal 120 and connecting strip retaining groove 130 of FIG. 4A .
Referring to FIGS. 1-4B , the culvert insert 10 can include an elongated culvert strip 110 having one edge 112 with a connecting strip seam 90 having a hook 130 , fixably attached thereto, and an opposite edge 118 with a longitudinal groove 130 into a side of the culvert wall strip 110 . The connecting seam 90 can have an H-configuration, with one side 92 having a C shape (or parallel arms) 140 that can attach to the one edge 112 of the strip 110 by an adhesive, such as but not limited to glue, contact cement, and the like. As shown in FIG. 4A , parallel arms 14 can sandwich edge 112 of strip 110 therebetween limiting substantial lateral movement of the strip 110 . The opposite side 98 of the connecting seam 90 can have upper and lower legs 270 , with at least the upper leg having an inwardly protruding finger portion 150 . The inwardly protruding finger portion 150 locks the connecting strip seam 90 into the groove 130 in culvert insert wall 110 while allowing one edge 112 of the strip 110 with attached seam 90 to slide along the other edge 118 of the strip 110 when the culvert insert 10 is twisted to expand.
The tip of the finger 150 can have an indented outer portion 152 , and an enlarged rear base portion 158 , where the indented outer portion 152 enhances the sliding of the finger 150 within the groove 130 . A lubricant 272 can be inserted within the right C shape legs 270 to ease in sliding of the culvert strip edge 118 against the inside of the C shape legs 98 of the connecting strip seam 90 .
Referring to FIGS. 1-3 , a shipping lock 60 can be used to adhere at least the adjoining strips at one end of the culvert insert 10 together, which will hold a wound up culvert insert 10 into a generally pipe shaped configuration. The lock 60 can be tape or another type of band that adheres to both adjoining strips. When the culvert insert 10 is to be used, the shipping lock 60 is cut 70 to allow the spiral wrapped strips 110 to slide against each other, and rotate opposite to one another.
A hole 80 in at least one of the walls of the culvert strips 110 can allow use of a lever rod 50 to be inserted into. The lever rod 50 can be moved in the direction of arrow R to help the culvert insert 10 expand into an expanded version 20 . Arrows 40 show the radial expansion of the culvert insert 10 into the expanded position 20 while the axial dimension of the culvert insert contracts as shown by arrows 30 .
Working prototypes of the invention were constructed between August and October 2010, and resulted in demonstrating the H seam functioned and operated to hold the wound strips together in a spiral pipe configuration to be used as a culvert insert.
FIG. 5A is a cross-sectional view of another connecting strip seam 90 for the invention where the tip has an outer rounded lead 170 on the retaining finger which allows easier sliding of the strip 110 to the groove 130 . FIG. 5B is a cross-sectional view of still another connecting strip seam 90 for the invention with an angled side 180 . FIG. 5C is a cross-sectional view of still another connecting strip seam 90 for the invention with an inwardly angled finger 190 . FIG. 5D is a cross-sectional view of still another connecting strip seam 160 for the invention with the connecting seam molded onto one side of the culvert wall 100 . A still another alternative connecting seam can have a two fingers (an upper one 192 and a lower one 198 , each inwardly protruding and facing one another.
FIG. 6 is a perspective view of culvert installation bridle 200 for the invention that can be used to pull the culvert insert 10 into position before expanding. FIG. 6A is an enlarged view of a bridle hook 210 of the bridle 100 of FIG. 6 . FIG. 6B is an enlarged view of a winch cable 250 that is attached to a ring 240 fixed to a bridle plate 230 , where a plurality of bridle cables 220 are attached thereto. At the end of each bridle cable 220 can be a bridle hook 210 .
FIG. 7 is a cross-sectional view of an existing damaged culvert 260 being installed with the expandable culvert insert 10 being pulled into the damaged culvert 260 .
Referring to FIGS. 6-7 , bridle hooks 210 at the end of the plurality of bridle cables 220 can be attached to holes 80 along a circumferential perimeter of the rear of the culvert insert, while the winch cable 250 passes through the inside of the culvert insert 10 and can be pulled in the direction of arrow P through the inside of a damaged culvert 260 located within soil/ground 265 .
FIG. 8 is another cross-sectional view of the damaged culvert 260 with culvert insert 10 centered in a position ready to be expanded.
FIG. 9 is another cross-sectional view of the culvert insert 10 being expanded into an expansion position 20 with the lever rod 50 being inserted into an opening 80 and rotated in order to help culvert insert 10 twist and expand outward. Motion arrows M 1 , M 2 indicate the culvert insert 10 getting shorter in length (arrow 30 ) and wider in diameter arrows 40 .
FIG. 10 is a cross-sectional view with the culvert insert 10 fully expanded into place 20 and the ends of the culvert insert 10 cut off at 280 to conform to the old exterior walls of the damaged culvert 260 .
FIG. 11 is a front perspective view of a pipe cleaning bucket 290 which is pulled through the old culvert prior to installation of the culvert insert 10 . FIG. 12 is a rear perspective view of the pipe cleaning bucket 290 of FIG. 11 showing winch cable 250 affixed to the bottom ring 330 .
The pipe cleaning bucket 290 can include a generally cylindrical bucket 300 formed out of plastic, aluminum, galvanized metal, and the like having perforations therethrough the sidewalls. A winch cable 250 can be attached to a ring 340 that is fixed to a bucket plate 320 by a plurality of bucket cables 310 that connect to a front end of the bucket 300 .
FIG. 13 is a cross-sectional view of an old damaged culvert 260 with the installation showing cleaning bucket 300 being pulled through the damaged culvert 260 to clear debris. FIG. 14 is a cross-sectional view of an old damaged culvert showing the bucket pulled completely through and debris 350 cleared. The pipe cleaning bucket 290 can be pulled through the damaged culvert 260 cleaning debris 350 out of the way in order to allow for the culvert insert 10 to be used.
The embodiment describes a seam pre-attached to one side of the strip 110 , the invention can be formed from extruded and/or a molded and/or welded and/or machined on hook edge of the strip.
While PVC and ABS plastic are described, the invention can be formed from other types of material such as but not limited to CPVC (chlorinated polyvinyl chloride) that has the ability to bend, shape and weld, and the like, as well as be fire retardant can be used. Other types of material can also be used that can provide good structural and memory capability can also be used.
Although a lock has been described to keep the spiral strip in a tube configuration, other types of components, such as bands, and the like, can be used.
While an O-ring has been described, the invention can be used with other types of depressible and slidable components, such as but not limited to bushings and Teflon coatings.
Although the primary applications refer to culverts, the invention can be used in other types of channels, such as but not limited to storm drains, sewer lines, septic inlet and outlet pipes.
Although the invention shows straight channels, culverts, the invention can be used in channels and culverts that have bends, and the like.
Pipe inserts can be joined to each other end to end by a coupler, having a male protruding end and a female receiving end. This would allow for greater lengths of damaged culverts to be repaired. Additionally, the coupling can allow for turns and bends in a damaged culvert.
Although a bridle and winch has been described as pulling the insert into a damaged culvert, other insertion methods and techniques can be used. For example, if the damaged culvert is filled with water, the insert can be floated into position with floats, such as but not limited to buoys or air bags, and the like. Alternatively, another method of installation can allow for the insert to be pushed in by a shovel type truck or shovel type machine, and the like.
While the invention refers to hook edges to form the seams, the invention can be used with other types of slidable/moveable seams, such as but not limited to using shifting/sliding tracks. For example, T or L type members can be slidable within a mateable channel member. Although the finger is described as a longitudinal protruding hook, the finger can be more than a single finger, and can include spaced apart fingers, and the like.
Although a mechanical lever is described, a machine operated torqueing wheel which can be inserted into one end of the insert, with outwardly protruding spokes which pass into the holes in the insert. Rotating the wheel counter-clockwise would assist in expanding the diameter of the insert. For example, up to approximately an 18 degree twist can be all that is needed to twist the insert from a contracted position to an expanded position. Twisting can be at one end or both ends of the insert as needed to expand or contract the diameter of the insert.
While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended. | Devices, apparatus, systems and methods for forming rolled up spiral shaped tubular inserts of interlocking seams of elongated strip material and for inserting the inserts into damaged channels such as damaged culverts, sewer lines, pipes, and the like. The inserts are released to expand outward and unravel until the walls of the unraveling insert abut against interior walls of the damaged channel forming a protective interior wall for the damaged channel. One side of the insert strips can have a hook, and an opposite side of the strips can have a longitudinal groove wherein the hook attaches to and slides within the groove. Slidable surfaces such as bushings, Teflon coatings and O-rings can be used along the interlocking seams to allow for reduced friction as the strip materials are rolled into contracted positions and later expanded out. | 1 |
PRIORITY CLAIM UNDER 35 U.S.C. §119(e)
[0001] This patent application claims the priority benefit of the filing date of provisional application Ser. No. 61/339,860, having been filed in the United States Patent and Trademark Office on Mar. 10, 2010 and now incorporated by reference herein.
STATEMENT OF GOVERNMENT INTEREST
[0002] The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalty thereon.
BACKGROUND OF THE INVENTION
[0003] 1. Technical Field of the Invention
[0004] This invention relates generally to the field of fabrication techniques for the production of electrically conductive structures. More specifically, the present invention relates to the thermoplastic molding of electrical structures which possess desired properties of electrical conductivity, radio frequency (RF) energy reflectivity, and electromagnetic interference (EMI) shielding, while still retaining the basic physical and structural properties of the base (plastic) material. Applications for the present invention include but are by no means limited to the production of component parts of stowable antenna structures to be used with lightweight, portable, satellite communications ground terminals.
[0005] 2. Background and Prior Art
[0006] By way of example to demonstrate the necessity for plastic-formed conductive and reflective electronic components, consider the field of satellite communications. Communication by satellite is essential in remote locations of the world where terrestrial communications networks do not exist. Moreover, when moving about remote locations, satellite communications equipment must be mobile. Smaller, lighter satellite communications equipment affords greater mobility. Satellite communications in the higher frequency bands such as X, K and Ku require a minimum transmit and receive directed gain that is much higher than the non-directional gain of handheld satellite transceivers in the L-band. Therefore, to achieve the necessary directional gain, mobile satellite transceivers in the X, K and Ku bands require directional antenna systems generally comprising parabolically shaped reflecting surfaces.
[0007] Generally speaking, while electronics have become smaller and more efficient over the years, minimum antenna size remains bounded by the physics of electromagnetic radiation and the need for larger physical antenna size (i.e., aperture) to achieve a higher directed gain. It is not uncommon for antenna systems to comprise the least transportable component of modern portable satellite transceivers.
[0008] Efforts have been made to achieve a higher degree of transportability of satellite communications antenna systems. Early efforts employed umbrella-like unfolding antennas comprising Mylar material stretched over lightweight metallic frameworks. Other efforts incorporated parabolic-shaped recesses into the satellite terminal enclosures themselves. Many others efforts involved assembling sections of flat or semi-flat panels into mosaics to achieve a larger reflecting surface. While some of these designs may indeed increase directed gain at low satellite frequencies such as in the L-band, they provide inherently unacceptable directive gain at X, K and Ku bands. The constraint which prior attempts at portable designs face at higher frequencies is their inability to provide true parabolic reflecting surfaces necessary for narrow, focused (i.e., directed) beamwidths required not only for gain, but also for discriminating among adjacent geostationary satellites position in equatorial orbits.
[0009] What the prior art fails to provide and what is needed, therefore, is a means to produce light weight, dimensionally stable and rigid, geometrically accurate, electrically conductive and RF reflective structures for exemplary applications including transportable radio frequency antennas.
OBJECTS AND SUMMARY OF THE INVENTION
[0010] The present invention provides a method for producing resin-based, non-metallic structures having properties of electrical conductivity, radio frequency (RF) reflectivity, and electromagnetic interference shielding.
[0011] It is therefore an object of the present invention to provide a method for incorporating a metalized substrate into a non-metallic molded structure.
[0012] It is a further object of the present invention to provide a method for producing metalized substrates from non-metallic materials.
[0013] It is still a further object of the present invention to provide a method for injection molding non-metallic structures incorporating metallic substrates from both thermoplastic resins and chemically cure-setting resins.
[0014] It is yet still a further object of the present invention to provide a method for producing lightweight and dimensionally stable component parts of radio frequency antennas, EMI shielded enclosures, and the like, using non-metallic base materials.
[0015] Briefly stated, the present invention achieves these and other objects by providing a method for resin-based molding of electrical structures which possess desired properties of electrical conductivity, radio frequency (RF) energy reflectivity, and electromagnetic interference (EMI) shielding, while still retaining the basic physical and structural properties of the base (plastic) material.
[0016] In a fundamental embodiment of the present invention, a method for resin-forming electrically conductive and reflective structures, a metalized substrate is affixed to a surface of a mold cavity where the cavity has the precise shape and volume of the desired molded structure. The metalized substrate is loosely conformed to the surface of the mold cavity. A first resin mixture is flowed into the mold cavity under pressure and fills the cavity while forcing the metalized substrate material into accurate and complete conformance to the mold cavity surface, while (the metalized substrate material) becomes integrally bonded to the resin material. When the resin mixture cools, cures, or otherwise is solid, the structure is removed from the mold.
[0017] Still according to a fundamental embodiment of the present invention, thermoplastic resins are employed to mold structures over an incorporated metallic substrate.
[0018] Yet still according to a fundamental embodiment of the present invention, a metalized substrate is produced by metal deposition on carbon fiber or fiberglass cloth.
[0019] Still yet according to a fundamental embodiment of the present invention, a metalized substrate is pre-impregnated with resin to ensure complete encapsulation of the metalized substrate within the finished molded structure.
[0020] The above and other objects, features and advantages of the present invention will become apparent from the following description read in conjunction with the accompanying drawings, in which like reference numerals designate the same elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 depicts a segmented parabolic satellite terminal antenna produced by the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] The present invention describes a method for fabricating electrically conductive and reflective structures by mold-forming.
[0023] The method of the present invention process comprises the steps of over-molding of a metalized (or otherwise electrically conductive and reflective) fabric that is attached to one surface of a mold, or otherwise suspended in the mold, so that liquid plastic substrate material (or “resin”) flows over it (after the mold is closed), causing the fabric to conform to one surface of the mold and permanently fuse and/or bond to the plastic substrate.
[0024] A major goal of the present invention is to assure that the fabric is completely permeated by the melted resin so that the surface quality of the finished part has essentially the same look and feel that the substrate material would have without the embedded fabric. In other words, the process of making the structure electrically conductive and reflective does not degrade the mechanical fidelity of the structure. Thus, in most applications, the conductive fabric layer would be completely conformal to the mold surface, at just a miniscule depth (a few thousandths of an inch or so) below the structure's surface.
[0025] Candidate fabrics will generally be fairly thin (less than 0.010″) and sufficiently porous to allow pre-impregnation with a molding-compatible resin material prior to molding. Alternatively, the fabric will have suitability for permeation by the substrate material during the course of the injection molding process, as described in detail below.
[0026] The base fabric could be any number of materials appropriate for any number of desired end-use applications. However, current embodiments of the invention employ a non-woven carbon fiber or glass cloth (about 0.003″ to 0.004″ thick) which is first metal coated by one or more chemical vapor or similar deposition processes which coat the individual fibers of the fabric with a microscopically thin layer of metal, with the resulting fabric retaining its mechanical flexibility and porosity, while becoming electrically conductive and RF reflective. In its most basic form, the metalized raw fabric can be placed into the mold, and molded over with the base resin material. Depending on the molding resin material and the process parameters of the molding process (temperatures, injection pressures), at least with thermoplastic materials, this results (in not all, but most cases) in a molded part in which the thermoplastic partially permeates and fuses to one side of the metalized fabric, but the other side (mold surface side) is uncoated, and thus has exposed fabric. It is within the scope of the invention that the uncoated side could be post-coated (with paint, for example) to cover and encapsulate the exposed fabric fibers, but it would seem more desirable to fully encapsulate the entire thickness (through and including both sides) of the fabric during the injection molding step. Thus, steps that pre-impregnate the fabric may be desired and further comprise the scope of the present invention. Pre-impregnation may also be desired even in those cases where the molding step permeates, but does not completely permeate the fabric, in order to provide for a more durable and aesthetically acceptable surface.
[0027] The following describes detailed anticipated and experimentally verified applications of the present invention to a few specific product applications. Referring to FIG. 1 , the application of immediate interest is the production of an 18″ diameter parabolic satellite communications antenna reflector comprised of 6 identical segments 10 that plug into a center hub/feed assembly to form the complete reflector. Each segment (petal) 10 is individually molded via the above process to have an RF-reflective surface sufficient to give the antenna a high efficiency rating (close to that for the same geometry made from solid aluminum).
[0028] The present invention contemplates the thermoplastic injection molding Of the antenna petals 10 (6 petal segments to form an 18″ parabolic reflector). The present invention method places the conductive cloth layer in the mold (using tape or some other temporary means to hold it in place before the plastic is injected over it) so that it covers the reflective surface of the final product, and to similarly mold the thermoplastic over it.
[0029] In preliminary tests, the plastic fuses to the cloth layer, but does not penetrate completely, thus creating a rough (yet still conductive) reflective surface. The present invention therefore employs a further step of creating the desired smooth surface by first coating (or saturating) the conductive cloth (or mold surface which it covers) with a thin layer of liquid epoxy resin (a premixed two part resin that cures over time) or by similarly using a thermoplastic material such as ABS (a candidate material for use in the molding machine as well) dissolved in an appropriate solvent such as acetone to coat the mold or the cloth. Note that the plastic repolymerizes when the solvent evaporates. A successful method for applying the solvent-dissolved (ABS) resin is to mix it to a concentration close to the viscosity of paint, and apply it with a conventional paint spray gun. The material can be applied in one or more layers to either one or both surfaces of the cloth, and then allowed to thoroughly dry before being cut and placed in the injection mold. When the mold subsequently closes and the hot (at about 400 to 700 degree F., depending on the material) thermoplastic is injected into the mold under normal molding pressures (typically over 1000 PSI), the cloth should completely fuse to the injected plastic (which forms the bulk of the finished part) and completely conformed to the working side of the finished part to form a smooth, RF reflective surface.
[0030] Besides the advantage of providing for durable, light-weight parts, the present invention allows for the use of fairly inexpensive raw materials and high production rates due to the fast cycle times of the injection molding process (on the order of 10's of seconds to a few minutes). Note that the injection molding tool could be Teflon coated to prevent excessive adhesion of the epoxy coating (if epoxy is used; however, not necessary if the material used to coat the cloth is the aforementioned resin-dissolved thermoplastic) to the mold surface. Also note that the above technique can similarly be used to produce other desirable articles such as light-weight, durable enclosures (i.e., to house sensitive electronic systems) which have excellent EMI properties very similar to metal enclosures. It should be understood that other means of pre-impregnating the metalized cloth could be used, such as hot pressing a thin sheet of the thermoplastic against the cloth sheet to get the plastic to diffuse into it, thus creating a result similar to that using the plastic resin (created by dissolving the thermoplastic in a solvent). This process could be used in a case where the impregnating plastic may not be readily dissolvable in a solvent. It should finally be noted that it is understood that other materials may be added to the impregnating plastic such as ABS, (and particularly where it is dissolved in a solvent) which enhance the electrical and RF characteristics of the cloth layer (and perhaps other desirable properties), and thus further improve the final product. An example of this would be to add copper or aluminum flake to the ABS solution (ie ABS dissolved in acetone or MEK) before it is sprayed onto the cloth.
[0031] Another step within the scope of the present invention is to pre-form the pre-impregnated cloth (formed by either of the aforementioned wet resin or hot press methods) to the shape of the mold by heating the somewhat solidified rigid sheet to near the melting point of the pre-impregnating plastic material and either compression or vacuum forming it (or forcing it by some other means) into the desired shape to make it more closely conformal to the injection mold surface in preparation for the injection molding (over-mold) step which creates the final product. This would be particularly useful for applications such as EMI enclosures where the final product has steep walls with sharp (90 degree) corners and edges.
[0032] In the above, note that the present invention (using the resin-dissolved thermoplastic steps) has been experimentally tested and proven on Jan. 20, 2010 at C&H Plastics located in Waterville, N.Y. with near-production-quality parts being successfully fabricated. Nickel-coated, non-woven, carbon cloth was pre-impregnated with resin-dissolved ABS and placed in the mold, producing near-perfect formed parts using a number of diverse thermoplastic molding materials. Adjustment of present invention parameters such as melt temperature, mold temperatures, cycle times, plastic additives (such as foaming agents), and plastic coating application methods and layer thicknesses on the metal-coated fiber cloth can be adjusted to optimize product yield and quality. It should be noted that an original assumption that a wet coated (e.g., not completely dried of the solvent carrier) part could be placed in the mold resulted in crazing of the part surface. The assumption that excess solvent such as acetone would evaporate quickly under the extreme heat of the molding process or be absorbed into the melt and evaporate from the part over time after cooling was also not totally accurate. Parts made in this manner seemed to develop a permanent soft surface (sufficiently soft so as to be scratchable with a fingernail) due to an apparent irreversible reaction with the solvent under heating. Thus, it was determined that the present invention comprise the additional step of ensuring the coated fabric be completely dried of all residual acetone before being placed in the mold and over-molded with the hot thermoplastic.
[0033] Even though ABS was the only material tested for pre-impregnation of the metalized cloth, it was determined to be compatible with all of the thermoplastic resins used in the molding machine, producing a complete fusion bond, and excellent quality surface finish in all cases. Initial antenna segments (see 10 , FIG. 1 ) were successfully produced with ABS as the molding plastic. These were actually tested for RF reflectivity on an antenna range and performed as well as identically shaped aluminum reflector antennas. Other molding resins which produce parts with higher strength/rigidity and higher heat deflection/operating temperatures were also successfully molded over the ABS-impregnated cloth. These included nylon, glass-filled nylon, polycarbonate, and polyetherimide (a high performance engineering plastic with a melting temperature of 700 degrees F.). One skilled in the art will readily note that practice of the present invention is not limited to the use of these resins.
[0034] It should also be noted that accurate die-cutting of the coated cloth to the desired shape prior to placing in the mold, and employing some type of fixturing hardware such as i.e. spring-loaded clips inside the mold which allow the molding machine operator to easily attach and accurately position the cloth in the mold cavity via corresponding holes or tabs die-cut into the cloth, would produce quality parts with a high yield.
[0035] Having described preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims. | A method for resin-based molding of electrical structures which possess desired properties of electrical conductivity, radio frequency (RF) energy reflectivity, and electromagnetic interference (EMI) shielding, while still retaining the basic physical and structural properties of the base (plastic) material. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of genetic engineering, more particularly to a method for enhancing N-acetylglucosamine (GlcNAc) production in genetically modified B. subtilis by microbial fermentation.
DESCRIPTION OF THE RELATED ART
[0002] GlcNAc is a pharmaceutically and nutraceutically useful compound, which was widely used for treatment of osteoarthritis and maintaining health of the joints. Biological production of GlcNAc via microbial fermentation by engineered B. subtilis emerged as a promising method to produce GlcNAc in a safe and sustainable approach. The phosphoenol-pyruvate (PEP)-sugar phosphotransferase system (PTS) is the main glucose transportation system in B. subtilis . Despite efficient glucose uptake by the phosphotransferase system (PTS), 1 mol of pyruvate will be produced for each mole of internalized glucose. Rather, pyruvate also can be produced by central metabolism. As a consequence, much glucose would be used to synthesize pyruvate, which leads to low GlcNAc titer and low yield for the conversion of glucose to GlcNAc. Noticeably, low GlcNAc titer of engineered B. subtilis restricted the application for industrial production. To move a step forward for microbial GlcNAc fermentation in industrial conditions, GlcNAc titer and yield should be improved.
SUMMARY OF THE INVENTION
[0003] In order to solve the above problems of the prior art, one object of the present application is to provide a method for improving GlcNAc production of recombinant Bacillus Subtilis.
[0004] For the above technical purpose and effects, the application utilizes the following technical solutions:
[0005] A method for improving GlcNAc production of recombinant Bacillus Subtilis , the method comprises steps of deletion of phosphoenolpyruvate carboxykinase pckA, deletion of pyruvate kinase pyk, as well as overexpression of pyruvate carboxylase pycA.
[0006] Preferably, the above recombinant Bacillus Subtilis is BSGNK which is obtained by overexpressing a glucosamine-6-phosphate synthase glms under the control of an inducible promoter PxylA and GlcN-6-phosphate N-acetyltransferase GNA1 under the control of a constitutive promoter P43 in the basis of deleting nagP, gamP, nagA, nagB, gamA and glck of Bacillus Subtilis 168. In a specific embodiment, the BSGNK is constructed by the method disclosed in the China Patent Application Ser. No. 201510394205.7.
[0007] In an embodiment, deletion of phosphoenolpyruvate carboxykinase encoding gene pckA comprises step of constructing a pckA disrupt cassette, the pckA disrupt cassette includes a pckA upstream homology sequence, a zeocin resistant gene expression cassette, and a pckA downstream homology sequence, from Bacillus Subtilis 168. Wherein DNA sequence of phosphoenolpyruvate carboxykinase encoding gene pckA is as shown in NCBI-Gene ID: 937235.
[0008] In some embodiments, the length of the pckA upstream homology sequence is 0.5-1.5 kb, preferably 0.5-1.0 kb, and more preferably 1.0 kb.
[0009] In some other embodiments, the length of the pckA downstream homology sequence is 0.5-1.5 kb, preferably 0.5-1.0 kb, and more preferably 1.0 kb.
[0010] In a specific embodiment, the DNA sequence of the pckA disrupt cassette is as shown in SEQ ID NO.1.
[0011] In an embodiment, deletion of pyruvate kinase encoding gene pyk comprises step of constructing a pyk disrupt cassette, the pyk disrupt cassette includes a pyk upstream homology sequence, a zeocin resistant gene expression cassette, and a pyk downstream homology sequence, from B. subtilis 168. Wherein the DNA sequence of pyruvate kinase encoding gene pyk is as shown in NCBI-Gene ID: 936596.
[0012] In some embodiments, the length of the pyk upstream homology sequence is 0.5-1.5 kb, preferably 0.5-1.0 kb, and more preferably 1.0 kb.
[0013] In some other embodiments, the length of the pyk downstream homology sequence is 0.5-1.5 kb, preferably 0.5-1.0 kb, and more preferably 1.0 kb.
[0014] In a specific embodiment, the DNA sequence of the pyk disrupt cassette is as shown in SEQ ID NO.2.
[0015] In an embodiment, the pyruvate carboxylase pycA is overexpressed under the control of a constitutive promoter P43 and replacing a start codon GTG with ATG. The DNA sequence of pyruvate carboxylase encoding gene pycA is shown in NCBI-Gene ID: 935920.
[0016] In another embodiment, overexpression of pyruvate carboxylase encoding gene pycA comprises step of constructing a pycA overexpressed cassette which includes a pycA upstream homology sequence, a zeocin resistant gene expression cassette, a P43 strong promoter, and a pycA sequence with replacing the start codon GTG with ATG, from B. subtilis 168.
[0017] In some embodiments the length of the pycA upstream homology sequence is 0.5-5 kb, preferably 0.5-1.0 kb, and more preferably 1.0 kb.
[0018] In a specific embodiment, the DNA sequence of the pycA overexpressed cassette is shown as SEQ ID NO.3.
[0019] In a preferable embodiment of the invention, the method comprises the following steps:
[0020] (1) deleting phosphoenolpyruvate carboxykinase encoding gene pckA of recombinant Bacillus Subtilis BSGNK to block the anaplerosis from PEP to oxaloacetate, to obtain a recombinant strain BPTS1;
[0021] (2) deleting pyruvate kinase encoding gene pyk of the recombinant strain BPTS1 to block the synthesis from PEP to pyruvate by glycolysis pathway, to obtain a recombinant strain BPTS2; and
[0022] (3) overexpressing pyruvate carboxylase encoding gene pycA of recombinant strain BPTS2 to facilitate cell growth, to obtain a recombinant strain BPTS3.
[0023] In a more preferable embodiment, the step (1) specifically comprises:
[0024] utilizing a primer pckA-F/pckA-R to amplify a pckA disrupt cassette which includes a pckA upstream homology sequence, a zeocin resistant gene expression cassette, and a pckA downstream homology sequence, from Bacillus Subtilis 168;
[0025] transforming the amplified pckA disrupt cassette into BSGNK, and selecting a positive transformant;
[0026] introducing a vector pTSC into the positive transformant to delete the resistance marker cassette; and
[0027] evicting the plasmid pTSC to obtain the recombinant strain BPTS1.
[0028] In a more preferable embodiment, the step (2) specifically comprises:
[0029] utilizing a primer pyk-F/pyk-R to amplify a pyk disrupt cassette which includes a pyk upstream homology sequence, a zeocin resistant gene expression cassette, and a pyk downstream homology sequence, from Bacillus Subtilis 168;
[0030] transforming the amplified pyk disrupt cassette into the recombinant strain BPTS1, and selecting a positive transformant;
[0031] introducing a vector pTSC into the positive transformant to delete the resistance marker cassette; and
[0032] evicting the plasmid pTSC to obtain the recombinant strain BPTS2.
[0033] In a still more preferable embodiment, the step (3) specifically comprises:
[0034] utilizing a primer pycA-F/pycA-R to amplify a pycA overexpressed cassette which includes a pycA upstream homology sequence, a zeocin resistant gene expression cassette, a P43 strong promoter, and a pycA sequence with replacing the start codon GTG with ATG, from Bacillus Subtilis 168;
[0035] transforming the amplified pycA overexpressed cassette into the recombinant strain BPTS2, and selecting a positive transformant;
[0036] introducing a vector pTSC into the positive transformant to delete the resistance marker cassette; and
[0037] evicting the plasmid pTSC to obtain the recombinant strain BPTS3.
[0038] Due to the above technical solutions, the embodiments of the present invention have the following advantages as compared with the prior art: the method disclosed in the specification is more effective for improving production of N-acetylglucosamine (GlcNAc). Specially, the GlcNAc production of the recombinant strain BPTS3 reached to 11.3 g/L, which was 1.84-fold of that of the starting strain BSGNK. Furthermore, the method also greatly increases the yield for the conversion of glucose to GlcNAc and the GlcNAc Productivity. So, this method can be used for improving cellular property of engineered B. subtilis for GlcNAc production, which can be further applied to industrial production of GlcNAc.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1 is a graph showing the comparison of cell growth of the strains BSGNK, BPTS1, BPTS2 and BPTS3 during fermentation;
[0040] FIG. 2 is a graph showing the comparison of GlcNAc titer of the strains BSGNK, BPTS1, BPTS2 and BPTS3 during fermentation;
[0041] FIG. 3 is a graph showing the comparison of the residual glucose concentration of the strains BSGNK, BPTS1, BPTS2 and BPTS3 during fermentation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] The invention will be further illustrated in more detail with reference to accompanying drawings. It is noted that, the following embodiments are intended for purposes of illustration only and are not intended to limit the scope of the invention.
[0043] The present invention provides a g method for improving GlcNAc production in engineered B. subtilis . Specifically, the method comprises the steps of deletion of phosphoenolpyruvate carboxykinase encoding gene pckA, deletion of pyruvate kinase encoding gene pyk and overexpression of pyruvate carboxylase encoding gene pycA in a recombinant Bacillus Subtilis . In a preferable embodiment, the starting strain is BSGNK-PxylA-glmS-P43-GNA1 (BSGNK), and the finally obtained strain with improved GlcNAc production and yield is BPTS3.
Embodiment 1
[0044] Deletion of Phosphoenolpyruvate Carboxykinase Encoding Gene pckA of the Strain BSGNK to Block the Anaplerosis from PEP to Oxaloacetate, to Obtain the Recombinant Strain BPTS1, Wherein BSGNK is Obtained by the Method Disclosed in China Patent Application Ser. No. 201510394205.7.
[0045] Deletion of phosphoenolpyruvate carboxykinase pckA was first performed to block the anaplerosis from PEP to oxaloacetate. Specifically, a primer pckA-F (ACGGACTTCACTTAGGCGGC)/pckA-R (GACGGATTTTTATATTTGCGCG) was used to amplify a pckA disrupt cassette, which included a pckA upstream homology sequence (1 kb), a zeocin resistant gene expression cassette, and a pckA downstream homology sequence (1 kb), from B. subtilis 168. DNA sequence of the pckA disrupt cassette is as shown in SEQ ID NO.1. The amplified pckA disrupt cassette was transformed into the strain BSGNK, and transformants were selected on LB plate with 30 μg/mL zeocin. Positive transformants with pckA gene deletion were further verified by colony PCR with primers pckA-F/pckA-R. The vector pTSC was introduced into the Positive transformants to promote the recombination between lox71 and lox66, thereby deleting the resistance marker cassette. Plasmid pTSC was then evicted by incubating at 50° C. for 12 h to obtain the strain without the selected marker and plasmid, naming BPTS1.
Embodiment 2
[0046] Deletion of Pyruvate Kinase Encoding Gene pyK in the Strain BPTS1 to Block the Synthesis from PEP to Pyruvate by Glycolysis Pathway.
[0047] Deletion of pyruvate kinase pyK was performed to block the synthesis from PEP to pyruvate by glycolysis pathway. Specifically, the primer pyK-F (ACGAATAGGGGTATTAACGAGCG)/pyK-R(CAGCTAACAGCAAAGCAATCAGC) was used to amplify a pyK disrupt cassette, which included a pyK upstream homology sequence (1 kb), a zeocin resistant gene expression cassette, and a pyK downstream homology sequence (1 kb), from B. subtilis 168. DNA sequence of the pyK disrupt cassette is as shown in SEQ ID NO.2. The amplified pyk disrupt cassette was transformed into the strain BPTS1, and transformants were selected for on LB plate with 30 μg/mL zeocin. Positive transformants with pyK gene deletion were further verified by colony PCR with primers pyK-F/pyK-R. The vector pTSC was introduced into the Positive transformants to promote the recombination between lox71 and lox66, thereby deleting the resistance marker cassette. Plasmid pTSC was then evicted by incubating at 50° C. for 12 h to obtain the strain without the selected marker and plasmid, naming BPTS2.
Embodiment 3
[0048] Overexpression of Pyruvate Carboxylase Encoding Gene pycA of the Strain BPTS2 to Facilitate Cell Growth.
[0049] Overexpression of pyruvate carboxylase encoding gene pycA was performed to facilitate cell growth. Specifically, a primer pycA-F (GCAGAGCTGGTTTAAAATCGG)/pycA-R(CCCAAGTTGAAAGCTTAACGAGA) was used to amplify a pycA overexpressed cassette, which included a pycA upstream homology sequence (1 Kb), a zeocin resistant gene expression cassette, a P43 strong promoter, a pycA sequence with replacing the start codon GTG with ATG, from B. subtilis 168. DNA sequence of pycA overexpressed cassette is as shown in SEQ ID NO.3. The amplified pycA overexpressed cassette was transformed into the strain BPTS2, and transformants were selected on LB plate with 30 μg/mL zeocin. Positive transformants with pycA gene overexpression were further verified by colony PCR with primers pycA-F/pycA-R. The vector pTSC was introduced into the positive transformants to promote the recombination between lox71 and lox66, thereby deleting the resistance marker cassette. Plasmid pTSC was then evicted by incubating at 50° C. for 12 h to obtain the strain without the selected marker and plasmid, naming BPTS3.
Shake-Flask Fermentation of the Strains BSGNK, BPTS1, BPTS2 and BPTS3.
[0050] The seed medium was Luria-Bertani broth or agar plates containing (g/L): tryptone 10, yeast extract 5, and NaCl 10. The fermentation medium contained (g/L): tryptone 6, yeast extract 12, (NH 4 )SO 4 6, K 2 HPO 4 .3H 2 O 12.5, KH 2 PO 4 2.5, MgSO 4 .7H2O 3, CaCO 3 5, glucose 60, and 15 ml of trace metal solution. The trace metal solution contained (per liter of 5M HCl) (g/L): FsSO 4 .7H 2 O 4.0, CaCl 2 4.0, MnSO 4 .5H 2 O 1.0, CoCl 2 .6H 2 O 0.4, NaMnO 4 .2H 2 O 0.2, ZnSO 4 .7H 2 O 0.2, AlCl 3 .6H 2 O 0.1, CuCl 2 .H2O 0.1, and H 3 BO 4 0.05. Seed culture was carried out in 250-mL shake flasks each containing 20 ml of seed medium with shaking at 200 rpm and 37° C. for 12 h. The seed culture (5 ml) was inoculated into 500-mL shake flasks containing 95 mL of fermentation medium. And then, fermentation was carried out at 220 rpm and 37° C. for 48 h on rotary shakers. When the optical density at 600 nm (OD600) reached 0.4, xylose was added to the medium to a final concentration of 5 g/L to induce gene expression under the control of the xylose-inducible P xyla promoter.
Embodiment 4
[0051] Effects of Deletion of Phosphoenolpyruvate Carboxykinase Encoding Gene pckA on Cell Growth and GlcNAc Production
[0052] To determine the effects of deletion of phosphoenolpyruvate carboxykinase encoding gene pckA on cell growth and GlcNAc production, the strain BPTS1 and BSGNK were inoculated with an inoculum size of 5% (v/v) into 500-mL shake flasks each containing 95 mL of fermentation medium. And then, fermentation was carried out at 220 rpm and 37° C. for 48 h on rotary shakers.
[0053] It can be seen from FIGS. 1-2 that the strain BPTS1 produced GlcNAc to a higher concentration than BSGNK by 7.14 g/L in the flask cultivation, which was 1.16-fold of that of BSGNK, and deletion of phosphoenolpyruvate carboxykinase encoding gene pckA had little influence on cell growth. The results indicate that deletion of phosphoenolpyruvate carboxykinase encoding gene pckA is benefit for the GlcNAc synthesis.
Embodiment 6
[0054] Effects of Deletion of Pyruvate Kinase Encoding Gene pyk on Cell Growth and GlcNAc Production
[0055] To determine the effects of deletion of pyruvate kinase encoding gene pyk on cell growth and GlcNAc production, the strains BPTS2 and BPTS1 were inoculated with an inoculum size of 5% (v/v) into 500-mL shake flasks each containing 95 mL of fermentation medium. And then, fermentation was carried out at 220 rpm and 37° C. for 48 h on rotary shakers.
[0056] It can be seen from FIG. 2 that the strain BSPT2 produced GlcNAc to a higher concentration than BPTS1 by 8.5 g/L in the flask cultivation, which was 1.18-fold of that of BPTS1. However, deletion of pyruvate kinase encoding gene pyk leaded to the low glucose consumption rate and decreased DCW. FIG. 3 shows the time profile of glucose consumption of BSGNK, BPTS1, BPTS2, BPTS3 in shake flask. The residual glucose concentration of BPTS2 was 12.2 g/L. This was thought to be the non-optimal TCA flux and reduced glycolytic flux.
Embodiment 7
[0057] Overexpression of Pyruvate Carboxylase Encoding Gene pycA to Facilitate Cell Growth
[0058] It is possible that the overexpression of pycA can lead more pyruvate to synthesize OAA and facilitates the glutamine synthesis. Finally, we tested the effects of overexpression of pyruvate carboxylase to cell growth and GlcNAc production. It can be seen from FIGS. 1-2 that the overexpression of pycA can facilitate cell growth, and the glucose consumption rate of BPTS3 was improved than that of BPTS2. Finally, the GlcNAc production of BPTS3 reached 11.3 g/L, which was 32.8% higher than that of BPTS2 and 1.84-fold of that of BSGNK.
[0059] FIGS. 1-3 show the effects of deletion of phosphoenolpyruvate carboxykinase encoding gene pckA and pyruvate kinase encoding gene pyk and overexpression of pyruvate carboxylase encoding gene pycA on cell growth, GlcNAc production and glucose consumption.
[0060] Table 1 shows the comparison of the maximum GlcNAc titer, the maximum DCW and the GlcNAc productivity of BSGNK, BPTS1, BPTS2, BPTS3 in shake flask fermentation system.
[0000]
TABLE 1
The maximum
The maximum
GlcNAc
GlcNAc titer
DCW
productivity
Strains
(g/L)
(g/L)
(g/L/h)
BSGNK
6.17
7.17
0.036
BPTS1
7.14
6.81
0.044
BPTS2
8.48
6.08
0.030
BPTS3
11.3
6.03
0.052
[0061] The above preferred embodiments are described for illustration only, and are not intended to limit the scope of the invention. It should be understood, for a person skilled in the art, that various improvements or variations can be made therein without departing from the spirit and scope of the invention, and these improvements or variations should be covered within the protecting scope of the invention. | The invention provides an effective method for improving N-acetylglucosamine (GlcNAc) production by engineered B. subtilis Deletion of phosphoenolpyruvate carboxykinase encoding gene pckA and encoding pyruvate kinase gene pyK in recombinant GlcNAc-producing strain BSGNK-PxylA-glmS-P43-GNA1 (BSGNK) is first performed to enhance GlcNAc production, followed by overexpression of pyruvate carboxylase encoding gene pycA for facilitating cell growth. Finally, the GlcNAc production of the recombinant strain BPTS3 reached to 11.3 g/L, which was 1.84-fold of BSGNK. This method can be used for improve cellular property of engineered B. subtilis for GlcNAc production, which can be further applied to industrial production of GlcNAc. | 2 |
BACKGROUND OF THE INVENTION
As currently popular used Hair Dryers or Hand Dryers are divers in body structures and various in types; however, they are limited for one purpose only, i.e., Hair Dryers are only for drying hairs, while the Hand Dryers are only for drying hands. In other words, when you want to dry your hairs or to dry your dress when it is wet, the Hand Dryer cannot help; similarly, when you want to dry your wet hands, nothing can be done by the Hair Dryer, too. Especially, the common Hand Dryers are not only large in volume and occupying more spaces, but also in practical use, must first press or turn a preset button or switch to operate. (The Hair Dryers are also necessary to preset with a switch.) Similarly, after using, the switch must be cut off to complete the operation. Hence, it lacks the functions of simplicity and rapidity for practical use.
The inventor of this Invention dealing with the manufacture of various electrical appliances for many years, in view of lacking a new structural design of dual purpose dryer for both hair and hand among the popularly used electrical appliances, tried hard in continuous experiments for research and renovation, and finally, by gathering the results from multiple experiments and research and accompanying with accumulated working experiences for so many years, invented a kind of Dual Purpose Dryer for Both Hair and Hand. Moreover, in operating for practical use, the hand drying can be performed by the automatic inductive control of the ultrared ray, being sanitary and safe, with high practical value.
SUMMARY OF THE INVENTION
This invention is a kind of structure of Dual Purpose Hair and Hand Dryer. The structure contains a small type removable high efficiency hair dryer hidden in the hanging box so that when in use, this invention can provide simultaneously the dual functions of drying hairs and hands. Moreover, in operating for use, the Dryer shall be performed by the automatic inductive control of the ultrared ray, unnecessary to touch any switch, being sanitary and safe, generally suitable for family and hotel uses.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. I--the three-dimentional outlook diagram of this invention
FIG. II--the analytical diagram of this invention
FIG. III--the schematic diagram of this invention
FIG. IV--the practical electric circuit diagram for this invention
DESCRIPTION OF THE PREFERRED EMBODIMENT
For providing a further understanding to the structure and functions of this invention, detailed descriptions matched to the attached drawings are given below:
Referring to the FIGS. I and II, the structure of this invention is consisted of a Base Body or front part (1) of the device for containing the accesories and a Hanging Box Body or base part (2). The Hanging Box Body has two Arms Braces (3) and (4) in the shape of "]" at its two terminal sides respectively; and a Bottom End Face (10) and a Top End Face (11). Two Concave Rabbets (6) and (61) are fixed separately in the inner flange at the top front ends of the Arm Braces (3) and (4); two Holes (7) and (71) are fitted at the bottom front ends of the Arm Braces (3) and (4) respectively; and a Hole Path (8) is fitted for passing the electric wire. The Base Body (1) also has two Arm Braces (9) and (91) at its two terminal sides respectively, and a Side Face (12). Between the Arm Braces (9) and (91), a Base Face is formed; and on one side of the Base Face (13), a Hole (14) is fitted for inserting the head of the dryer. Another two Holes (15) and (16) are fixed symmetrically in the inner side at the bottom ends of the Arm Braces (9) and (91). Two Pintle Retainers (5) and (51) are used to insert into the Pintle Holes (15) and (16) and (7) and (71) so that the Base Body (1) and Hanging Box Body (2) to lock up to become a combination which can slew freely on the pintle pivot. Besides, on the outer flange near the inside of the bottom ends of the two Arm Braces (9) and (91), separately fitted with a pair of Convex Wave Pattern Surfaces (17) and (18) and two elastic Caliper Tenon Hooks (19) and (20) for the convenience of hand holding. Again, in the central position of the Arm Brace (9) on the same side of the elastic Caliper Tenon Hook (19), a notch of Concave Groove (21) is opened for passing the electric wire connecting to the tail part of the dryer. There are several perpendicular side surface set on the bottom end of the Base Face (13), with a Microswitch (22) and a Time Controller (23) fixed on it. And, a Sensor Switch (25) is fixed on the Side Face (12) of the Base Body (1); under the control of this Sensor Switch, even when the dryer is taken out of the Base Body (1) and the Microswitch (22) is in the "ON" position, the dryer can be used for hair drying or other "blowing to dry" purposes, and when the cover-opened Dryer (24) is placed back on the Base Body (1), the Microswitch (22) will be pressed from the top to turn to the "OFF" position.
In regard to the practical condition in using this invention, please refer to the diagrams indicated in the attached drawings. When this invention is used for hand drying (as shown in Fig. I), once the hands reach to the Outlet (26), the Sensor Switch (25) will immediately be induced and automatically start to operate, thus push the hot wind to blow out from the Outlet (26). And, when the current is connected, the Time Controller (23) will control the time to be 90 seconds; after 90 seconds, the power source will be automatically cut off. The control of power source is shown by the Circuit Route Diagram given in FIG. IV. When this invention is used for hair drying or other drying purposes, just use your hands to press the Concave Wave Pattern Surfaces (17) and (18) on two end sides of the Base Body (1) so that the elastic Caliper Tenon Hooks (19) and (20) will be disengaged from the Concave Rabbets (6) and (61) on the Hanging Box Body (2), thus the Hanging Box Body (2) will slew downward, forming an angle of 60° opening so that the dryer can be removed from the whole body and individually used for hair drying and other drying purposes.
Therefore, it is understood that the primary objective of this invention is intended to provide a Dual Purpose Hair and Hand Dryer. Beyond its function of hand drying, the structure design of this invention enables the performance of its another function of hair drying by pressing open the Hanging Box Body to take out the dryer.
The subsidiary objective of this invention is that the performance of its hand drying function is controlled by fully automatic inductive ultrared ray, unnecessary to touch any switch, being sanitary and safe.
The another objective of this invention is to utilize its structure of small volume, light weight and being easily installed, hence suitable for family and hotel uses.
In recapitulation, it is apparent that the structure under this case has the aforesaid excellent characteristics, with unprecedented conventional functions improved in its operations and further giving it the practicality. It is really a very good design structure for products with practical values. Again, all the characteristics mentioned above are only those more easily applied practical examples of this invention, but they are not used to limit this invention; since it is possible for all people who are familiar with such techniques may make effectual changes from this invention to be adaptable for other applications, hence all such variations within the scope of this invention shall all be included within the range of the patent rights of this Invention. | A dual purpose hand and hair dryer, and a cabinet for mounting the hair dryer on a wall for use as a hand dryer. The cabinet has a swing-down front part which receives the hair dryer and which has electric circuitry for operating the hair dryer including a light-sensitive switch and a timer. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority under 35 USC §119(e) to Kremen's U.S. Provisional Application Ser. No. 60/853,050, filed Sep. 17, 2006, which is incorporated herein by reference. The present application is related to Kremen's concurrently filed applications entitled: 1) SYSTEMS, METHODS AND FINANCIAL INSTRUMENTS FOR RENEWABLE ENERGY CONSUMER PREMISES EQUIPMENT FINANCING; 2) METHODS FOR COST REDUCTION AND UNDERWRITING CONSIDERATIONS FOR FINANCING RENEWABLE ENERGY CONSUMER PREMISES EQUIPMENT (CPE); 3) METHOD FOR UNDERWRITING THE FINANCING OF SOLAR CONSUMER PREMISES EQUIPMENT; 4) SYSTEMS AND METHODS OF REDUCING FINANCING COSTS FOR RENEWABLE ENERGY CONSUMER PREMISES EQUIPMENT; 5) METHODS, SYSTEMS AND FINANCIAL INSTRUMENTS FOR FINANCING RENEWABLE ENERGY CONSUMER PREMISES EQUIPMENT, all incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
THE NAMES OF THE 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] The present invention relates to financing consumer equipment that generates power (electricity) from a renewable energy source and is located on a consumer's premises.
BRIEF DESCRIPTION OF THE INVENTION
[0006] Electricity or power (hereinafter used interchangeably unless otherwise noted) is an essential part of modern life. In residences, businesses, in institutions and in other locations, electricity is used in numerous ways by the consumer or end user (hereinafter “consumer”).
[0007] Power plants generate electricity that is delivered by utilities through a network of transmission and distribution lines. This network is hereinafter referred to as the “power transmission and distribution grid,” “the electric grid,” “the grid” or “power grid.” In general, a power system includes a power plant, power transmission and distribution grid (including appropriate transformers for stepping up and down the voltage as required) and the consumer's power (i.e., electricity) equipment residing on the consumers' premises (real property).
[0008] The demarcation line between the power grid and the consumer location is typically the electric meter, which is owned by the utility and the main circuit panel, which is owned or controlled by the consumer. FIG. 1 illustrates an example of a prior art power system.
[0009] As discussed, power plants generate the electricity and transmit and distribute it via the power grid. These power plants generate electricity based on different sources of energy. Such sources include, but are not limited to, fossil fuels (e.g., coal, natural gas or refined oil products), nuclear energy and renewable energy sources such as water (hydroelectric power), wind, biomass and solar energy (hereinafter “renewable energy sources”). Individual consumer power usage or consumption is measured with a power meter (or “meter”). The meter measures watts, which is a unit of energy or power. A watt is voltage multiplied by current. (While there are differences in the definitions of watts for both AC and DC power, the units of measure for both (watts) are treated similarly for purposes of this application.) A Kilowatt is 1,000 Watts. The meter also measures Kilowatt-hours (KWH), which is usage of power or energy over time or the kilowatts being used times the number of hours used. Most consumers pay electric rates based on KWH units.
[0010] The entities that purchase, sell or market power may vary. In general, these are referred to as utilities. In addition, these entities may be a not-for-profit municipal entity such as the Franklin Municipal Power and Light (electricity provider in the City of Franklin and parts of the City of Suffolk, Southampton and Isle of Wight, Va.) or Henderson Municipal Power & Light or HMP&L (owned by the City of Henderson, Ky.) an electric co-operative owned by its consumers such as Central Wisconsin Electric or Northern Virginia Electric Cooperative (NOVEC), a for-profit company owned by stockholders such as Pepco Holdings, Inc. or Dominion Virginia Power (often called an investor-owned utility).
[0011] However not all utilities own their own electrical generation equipment: distribution companies and retail services may sell power to consumers. Examples of power marketers include Green Mountain Energy or Duke Energy Marketing Corporation. Some federally owned or affiliated entities also purchase, sell, or market power. Examples of federally owned entities include Bonneville Power Administration (BPA) or the Tennessee Valley Authority (TVA). Other sources of electricity may include other utilities, power marketers and independent power producers (IPPs). IPPs, such as Calpine Corporation or certain members of the Independent Energy Producers (http://www.iepa.com) generate electricity and then sell their power in wholesale markets (such as California's PX). Any entity that purchases, sells or markets power to (or from) the consumer of power or has the primary relationship with that consumer is for the purpose of this application known as a utility.
[0012] The origin of the electricity use by the consumer may also vary. Utilities may generate, transmit and distribute all of their own electricity. Alternatively, utilities may purchase power on the wholesale market from other sources off the transmission lines. The wholesale market is a place in which power is bought and sold by entities that sell electricity to the consumer. Alternatively, the utilities can source (i.e., purchase) electricity from smaller residential, business industrial, commercial and institutional users of electricity that have the means to produce the electricity (for themselves) and sell any excess back (known as buyback) to their utility. Regulators regulate the price and terms of these buybacks transactions.
[0013] All electricity generation, transmission, distribution, purchases, trading, marketing and sales are generally regulated by two authorities: The Federal Energy Regulatory Commission (FERC) and the State Public Utility Commissions (PUCs). The Federal Power Act of 1934 as amended created FERC and has jurisdiction over interstate transactions and facilities as well as wholesale sales. The PUCs have jurisdiction over intrastate trade of electricity and regulate retail rates for consumers, approve sites for generation facilities, set buyback prices and terms from smaller, localized producers and issue relevant environmental regulations. Some States or their PUCs (to be used interchangeably in this application) allow deregulation of retail prices, the introduction of competition between utilities and the buying, marketing and selling of power within the State.
[0014] Pricing of electricity can also vary greatly depending on the regulatory authority that regulates the source of the power. A consumer's bill is based on many factors including, but not limited to the price per Kilowatt-hour and the amount of kilowatt-hours consumed or used by the consumer for a given time period that the bill covers. In addition to the kilowatt-hour charge, there are other extras included in an electricity bill such as state and local taxes, and other costs. Such other costs include, but are not limited to, equipment maintenance costs, deprecation of generation and distribution equipment, transmission costs, decommissioning costs for nuclear plants, retail and wholesale competition, weather, subsidies of varies types, etc. See Energy Information Administration www.eia.doe.gov for more details.
[0015] Daily demand for electricity is usually highest in the afternoon and early evening (on-peak). Consumers may pay different prices during different parts of the day (collectively known as “Time of Day usage pricing” or “Peak pricing”). Seasonal peaks are caused by regional weather and climatic conditions. The highest usage seasonal peak usually occurs in the summer when air-conditioning use is greatest. The price per Kilowatt-hour for electricity (power) may also change depending upon monthly (or other time period) cumulative usage (tiered pricing) as well as time of day considerations. In this way, pricing increases in “steps” as usage increases. In other words, the greater the electricity consumption, the greater the increase in price per kilowatt-hour charged to the consumer. The rise in price will increase beyond a baseline usage level. A baseline level is the minimum price charged for electricity for low usage levels. The baseline level, like many other issues involved in energy is set taking into account public policy issues and usage patterns.
[0016] Consumers face price increases for electricity over the long-term, net of any increases due to inflation. Electricity prices have steadily increased over the long-term (with decreases and increases in short-term periods). For example, residential electricity prices were predicted to increase by 10.2 percent in 2006 compared with 2005 because the costs of fuels for electricity generation have risen and retail electricity price caps have recently been loosened in some States, particularly in New England and the South Atlantic region, as a result of restructured electricity markets (http://www.eia.doe.gov/emeu/steo/pub/contents.html).
[0017] While an increase in an electric bill is unfortunate for consumers, an increase in the demand for electricity has a more disastrous consequence. The long-term demand for electricity is projected to increase. For one thing, the use of power consuming devices such as air-conditioners and computers has increased. Temperatures appear to be increasing globally. An increase in demand requires an increase in electricity production. The production often times places a strain on existing power plants. Building new power plants is expensive and subject to strict environmental review and widespread opposition. Consequently, there is a need for alternate sources of energy to supplement existing sources. Renewable power sources are one such source. In fact, renewable energy sources are quite desirable.
[0018] Specifically, renewable energy sources cause less environmental harm than non-renewable sources of power and are therefore socially and politically acceptable energy sources. There are large organizations and powerful figures that believe the exploration for and the pollutants produced by fossil fuels are destroying the environment. Nuclear electric power generation has opponents that are concerned about radioactive waste disposal as well as nuclear proliferation issues. Renewable electricity development is therefore a priority in many circles for these reasons alone. Some consumers will pay premium prices for electricity derived from renewable energy sources just on the basis of it helping the environment.
[0019] In addition, renewable, local energy generation is useful to generate power for back-up purposes in the event the utility sources are terminated (e.g., because of an outage or and arrangement with the utility. For example, under certain arrangements, the utility will terminate power supply to specific consumers during peak hours or cases of demand exceeding supply capacity. The consumer will receive discounted power rates for such concessions. This is called an interrupted power contract.
[0020] Smaller renewable energy sources are also advantageous because they generate energy locally (i.e. not at a centralized power plant). Local energy generation reduces strain on a utility power grid (in which are almost universally underinvested), and therefore increasingly unable to respond to demand. While new grid infrastructure is required to meet such demand, the reality is new infrastructure is expensive and hard to get approved. The general population resists the construction of this new infrastructure. The prospect of additional transmission lines and other electrical components adjacent home dwellings and office buildings poses real or perceived safety concerns.
[0021] Even with population approval, infrastructure will continue to face an uphill battle. To obtain proper approval, a request must endure a complicated and time consuming political process (e.g., passing through a maze of Federal, State and local government offices). For these reasons, local power generation is not only good public policy, but an effective means to avoid a political process in which additional power infrastructure projects are subject to endless investigative processes to determine the purpose, need and environmental impact statements. For a current example, see San Diego Sunrise Power Transmission Project (http://www.cpuc.ca.gov/static/hottopics/1energy/a512014.htm). Suffice it to say, renewable, localized energy sources are quite advantageous and desirable.
[0022] Local solar energy is one of the more desirable renewable sources of energy. For one thing, solar energy can essentially be harnessed in most developed country locations with solar access. For another, solar equipment consumes no fossil fuels and generates no air pollutants. The use of solar equipment is generally regarded as environmentally safe. In addition, there are direct financial motives for investing in solar energy for electricity production that complement any consumer personal or public policy considerations. Utilities in many States are required (or voluntarily do so) for public policy reasons to credit or actually buy excess solar electricity generated by the consumer. Specifically, some States require utilities to derive a portion of their sales from renewable energy sources. Consequently, if the utilities cannot satisfy this requirement, then they must purchase the electricity from other suppliers such as an IPP or from consumers with solar equipment.
[0023] In some States, consumers are paid for surplus power (electricity) generated (as opposed to credits that can only be applied for limited future use such as in California). Such payments are usually in the form of certificates or could be actual cash payments. For example, New Jersey has a Solar Renewable Energy Certificate program (“SREC”). See http://www.nicep.com/srec/index-primary.html. According to New Jersey's SREC program, the utility will issue a SREC for every 1,000 KWH that a grid tied solar system generates. The SREC can then be sold or traded independent of the power (typically via a broker or aggregator). New Jersey's SREC Program assists in the sale of SRECs to electric suppliers that are required to invest in solar energy purchase of SRECs. New Jersey's purchase requirement is expected to increase each year. It is projected that New Jersey's SRECs' equivalent will total 90 MW of solar electricity in 2009 (enough to power 8,000 homes). In sum, the specific terms of payments and credits (i.e., net metering or dual metering as described below, certificates etc.) vary from State to State and utility to utility.
[0024] In addition to the financial benefits described above, State, Federal or other jurisdictions offer financial incentives that reduce the costs associated with the purchase, installation and sometimes the operation of solar equipment. For example, Illinois State offers a 30% rebate (up to a maximum $10,000) for the purchase of solar equipment. The State of California offers a rebate of $2.30 per watt of new capacity purchased (amount of rebate to change over time subject to certain caps and other conditions). In general, the incentives vary by State. Federal law also offers certain tax credits for the purchase of solar equipment (See www.dsireusa.org for more details on State and Federal incentives for solar equipment). Note that solar energy is one type of renewal energy. That is, other renewable energy sources may be eligible for rebates, credits, subsidies and other favorable treatments (as discussed below). (This application applies to all other renewal energy (and non-renewable) sources.)
[0025] One problem with some of the rebates or credits is that they are not received at the same time the equipment is purchased. For example, the California solar credit is running up to six months behind certified installations.
[0026] In order to receive these benefits, solar equipment typically must be properly connected to (i.e., integrated) the power (electricity) grid of the local utility in accordance with utility rules. This is known as on-grid, grid-tied, utility-interactive (UI) or grid inter-tied solar equipment or systems. These systems generate solar power and route it to the power grid. The solar power (electricity) offsets consumer electrical consumption and, in some instances, even turns the electric meter backwards by routing unused power onto the grid to supply other consumers. In many States, the utility actually credits a homeowner's account for excess solar electricity produced. This amount sometimes can be applied to other time periods when the system produces less or in time periods when electrical consumption is greater (the electricity at times may be used as a credit or may be lost in a given time period as dictated by the States). This credit arrangement is called net metering or net billing which will be discussed in more detail below. The pricing for such credits might be the wholesale price of the electricity or some other pricing dictated by the individual States' PUCs. These credits can substantially reduce or eliminate an electricity bill.
[0027] While the Federal and State incentives described above are significant, the remaining costs for the purchase of solar equipment may be beyond the amount of cash a consumer has on hand or wishes to commit. For consumers that wish to displace 75% of the consumer's electricity consumption, for example, the cost for the purchase of solar system can actually reach as such as $60,000 or more. On average, residential yearly consumption ranges from 2,000-5,000 KWH. The price for the purchase of solar systems (photovoltaic cells, inverters and other auxiliary equipment) is estimated at $9 per Watt. Consequently, the total cost (on average) of such equipment ranges from $18,000-$45,000. In Illinois for example, a solar system designed to displace 75% of electricity consumption may cost about $30,000 ($45,000 less State rebates and grants). In San Diego, the purchase price of solar equipment is estimated to cost $20,160 ($37,800 less State rebates for 75% electricity displacement). These are only examples of the costs. The actual cost of the solar equipment or system may vary widely depending upon installation complexity, location, component availability, and the size of the installed system. Suffice it to say, the costs for purchase make solar equipment prohibitive for most consumers without financing. (A good analogy is the purchase of a new automobile. That is, most consumers would be prohibited from purchasing automobiles without financing options.)
[0028] There are several existing financing options for the purchase of solar equipment. These options are predominantly based on traditional financing products like a mortgage or deed of trust, as well as the less commonly used sale purchase contract or conditional sales purchase contract. While these financial instruments differ in legal structure, they are all methods for a lender to obtain a security interest (or lien) to secure their loan with the borrowers' real property. For the purposes of this application, these methods are collectively referred to as a mortgage, real property security interest or real property mortgage.
[0029] Real property mortgages are available in many flavors. For consumers that wish to purchase a new home or building there is the purchase money mortgage. For those consumers who renovate an existing home or building there is an option of an equity line of credit or second loan. Mortgages are also available for consumers that wish to refinance their existing properties. However, these mortgages are not advantageous for the purchase of solar equipment. For consumer's intending to buy a new home, it would be difficult logistically to buy the property and the CPE simultaneously.
[0030] For consumers wishing to purchase solar equipment for an existing home, the consumer would apply for a second mortgage (or refinance the first mortgage or obtain a line of credit) in which the successful loan recipient may receive a loan. Second mortgages, however, will likely have higher interest rates because they second in priority for collection security behind the first mortgage (from credit perspective). Lines of credit or home equity loans usually have commitment, annual, use or check issuance or cash advance or other service fees, some of which accrue whether or not the line of credit is used. In all cases (first mortgages, refinances, second mortgages or lines of credit), the entire subject property would be used as collateral for the loan.
[0031] There are other disadvantages to mortgages as a vehicle for solar equipment purchase. In order to obtain a mortgage for real property, the consumer must provide proper information and documentation supporting the application including financial background such as assets, bank accounts, salary, loans, credit card debt and other debt. For new property, a down payment will be required which ranges from 0-30% of the purchase price. The consumer's debit to income ratio, loan to home value ratio, the consumer's credit information including the consumer's credit score (known commonly as a credit or FICO score) and other underwriting criteria will ultimately determine whether the consumer is awarded the loan and the loan amount. From the loan applicant's viewpoint, the process is time consuming with limited success in obtaining the loan unless the applicant satisfies lender's detailed requirements.
[0032] In addition to those disadvantages, an applicant for a mortgage will typically be charged fees which are a subset of what is collectively known as closing costs. Examples of such closing costs may be found in Appendix A below. Even with advertised “no-fee” mortgages, the consumer/borrowers are charged the foregoing fees (in reality) in the form of a higher interest rate. All of these fees or charges are both considerable and economically impractical in view of the size of the loan request. There may be other costs including pre-payment penalties for loans that pay off existing loans.
[0033] There are other options for financing solar equipment. For example, a limited number of financial institutions or lenders offer another type of loan called an Energy Efficient Mortgage (EEM). The Environmental Protection Agency (EPA) offers a financing program with lenders to provide special financing for buyers of energy efficient homes. These financing options are similar to the mortgages described above, but such mortgages are offered to potential homeowners that wish to purchase a home or refinance a home that is energy efficient or will be energy efficient after energy saving equipment is installed. In some instances, an energy rating must be obtained to determine the cost-effectiveness of the improvements. See “The Borrower's Guide To Financing Solar Energy Systems, A Federal Overview,” Second Edition, U.S. Department of Energy, 1999. In these arrangements, the lenders require similar financial information from the potential homeowner as described above and will perform the same analysis to determine whether the potential homeowner is worthy of the loan. In addition, the potential homeowner must submit additional information that supports a claim of energy conservation for the property or the lender will provide an evaluation as part of the closing costs for the loan.
[0034] In summary, while these financing options (mortgages) may be adequate, they are not optimal from the perspective of both the lender and the consumer (residential) borrower. From the viewpoint of a borrower, secured loans such as real property mortgages (of any type including home equity, home line of credit, or EEM) are difficult to obtain without the proper financial background. Borrowers must adhere to lender requirements and guidelines or pay more. In addition, new home loan borrowers must put down a substantial down payment or pay more in interest costs. As part of the loan application costs, borrowers must also pay for costs such as appraisals, title insurance, inspection fees, closing costs and escrow accounts. In view of the size of the loans needed for the solar equipment (e.g., $50,000), these costs do not make economic sense for the consumer as their average cost to obtain is in the thousands of dollars.
[0035] Lenders find mortgages equally suboptimal for financing solar equipment. In the event the borrower defaults on the mortgage, the lender must institute costly and lengthy foreclosure proceedings on the subject property. The process is not only time consuming and expensive, but the lender becomes an unwilling owner/possessor of the real property. These disadvantages affect secured lenders of all types regardless of the collateralized property (e.g., residential, business, institutional or other). The prospect of these costs and administration are high compared with the size of a loan needed to finance solar equipment, which might be $50,000 or more or as little as $10,000 or less. Suffice it to say, traditional mortgage financing do not fully meet the needs for lending for the purchase of solar CPE.
[0036] There are other secured financing methods for the purchase of solar equipment. For example, personal property loans or personal property security interest (sometimes referred to as chattel mortgages or chattel loans) are a type of mortgage that is secured by personal property instead of real property. In another words, a personal property security interest is a lien that provides a lender a security interest in personal property, as opposed to real estate (land, buildings) pledged as collateral for repayment of a loan. Personal property can be any kind of movable property, such as automobiles, jewelry, etc. A personal property security interest is normally used in financing consumer goods, such as household appliances; the lien terminates when the obligation is paid. Personal property interests are usually evidenced by a UCC (Uniform Commercial Code) filing at the Secretary of State or other government office in the State in which the personal property is located.
[0037] For non-business consumers, personal property loans or interests are disadvantageous for the purchase of solar equipment. The interest payments for personal property loans are usually not tax deductible on a federal or state level. This deprives the consumer of a very important economic benefit. In addition, the interest rates for personal property loans are typically higher because the subject property is personal, not real. The personal property can be removed from the lender's reach or made less valuable. Consequently, the loan is a greater risk for the lender (than a real property mortgage). In general, banking regulators much prefer mortgages for real property.
[0038] Further, when it comes to solar equipment, lenders do not know how to characterize such property for credit and loan purposes. Because of the intrinsic nature of solar equipment and the mechanism used to attach it to the subject real property, lenders do not know whether solar equipment constitutes “real property” (i.e., a fixture under the law) or personal property under the law. The particular characterization for the solar equipment will dictate, among other things, the proper location for recording or filing (perfecting the security interest). Real estate is recorded in the county office in which the property is located. On the other hand, personal property is typically filed at the office of the Secretary of State in which the personal property is located. Because of this confusion, the lenders are apprehensive about such loans. Such apprehension usually translates into higher interest rates with stricter restrictions.
[0039] Unsecured personal loans are another type of financing option for a consumer. They are also not an optimal choice for lenders and borrowers. Unsecured loans are typically not available at affordable interest rates for the vast majority of consumers because they do have adequate financial background and the proper relationships with lenders to receive such a loan. Lenders are cautious about making unsecured loans because such loans are higher risk than secured loans.
[0040] There is another financing option available to the consumer. In this option, the installer of the solar equipment may float (or advance) a portion of the purchase price for a solar equipment. The purchase price might also include the cost of installation. This is not attractive to the installer because they must pay many of these costs upfront. In most cases, the installers have limited working capital for such an expenditure. For this reason, installers rarely offer their own direct financing. If they do decide to offer financing, installers only offer very short-term financing. Distributors, dealers and manufactures do not even offer financing (credit) for consumer solar equipment purchasing.
[0041] There is no financing program or product available that is advantageous to lenders that wish to offer loans and borrowers that wish to borrow money for the purchase of solar equipment. It would be desirable to provide a method and/or system that would overcome the disadvantages described above with respect to the financing options for solar equipment.
SUMMARY OF THE INVENTION
[0042] The present invention teaches a variety of systems and methods enabling renewable energy consumer premises equipment (CPE) such as dual metering techniques. The present invention contemplates, among other things, supporting, by increasing a likelihood of meeting financing obligations, a consumer purchasing, leasing, installing and/or maintaining renewable energy CPE for power generation at a consumer premises. The renewable energy CPE may be attached to a structure on the consumer premises, disposed free standing on the consumer premises, or utilized through any other suitable means on the consumer premises.
[0043] According to one embodiment, a method of increasing the likelihood of repayment of a loan provided by a lender for the purchase of renewable energy consumer premises equipment (CPE) by a customer is disclosed. The method couples the CPE to a power grid operable to receive at least a portion of the power generated by the CPE, measures power generated by the CPE and delivered onto the power grid, and processes receivables associated with the power generated to an entity at times corresponding to power measurement to fulfill the customer's obligation to repay the loan. The processing can be accomplished by any suitable means such as distributing and/or securing the receivables.
[0044] Another aspect of the present invention contemplates a business method for increasing a likelihood of repayment of a loan, lease or other financial instrument provided by a lender for purchase, lease, installation, and/or maintenance of renewable energy consumer premises equipment (CPE) by a consumer. This aspect contemplates measuring excess power incrementally over a period of time generated by the CPE and delivered onto a power grid, and processing receivables associated with the excess power generated to the lender at increments corresponding to increments that the excess power is measured. This enables the customer to fulfill the customer's obligation to repay the loan, lease or other financial instrument through an entity.
[0045] Yet another embodiment teaches various methods for billing by an entity for financing renewable energy consumer premises equipment (CPE) installed on a consumer premises. Here the CPE is capable of generating power, and at times at least a portion of the power is consumed by a consumer associated with the consumer premises. According to one aspect, the present invention contemplates coupling the CPE to a power grid maintained by a second entity, distributing at least some of the power generated by the CPE to the power grid, giving a monetary value to the at least some power generated by the CPE and distributed to the power grid, and the second party making payment directly to the first entity for the financing of the CPE.
[0046] An embodiment of the present invention teaches various methods of financing at a purchase price the purchase of consumer premises equipment (CPE) suitable for installation by a consumer and power generation or power use reduction at a consumer premises. Related embodiments identify whether at least one credit is associated with the purchase and/or operation of the CPE by the consumer at the consumer premises. Other embodiments take into consideration both subtracting any associated credits from the purchase price of the CPE and reselling of the CPE at a market rate, net any remarketing costs, in case of a default by the consumer.
[0047] Further embodiments teach billing and payment systems for financing purchase, lease, installation and/or maintenance of a renewable energy consumer premises equipment (CPE) suitable for installation by a consumer and power generation at a consumer premises. According to related embodiments, the billing and payment system includes a power grid, a power measuring device, and a billing mechanism.
[0048] The power grid is typically operable to distribute power to the consumer premises, the power grid further operable to receive power from the CPE. The power measuring device is operable to measure power delivered to the consumer premises via the power grid, the power measuring device further operable to measure power delivered onto the power grid by the CPE. The billing mechanism is operable to determine on a periodic basis any excess value of power generated via the CPE over power delivered to the consumer premises via the power grid. The billing mechanism may also credit any excess value generated by the CPE to an entity that financed the purchase, lease, installation and/or maintenance of the CPE up to an amount owed by the consumer to the entity during a relevant period.
[0049] Another embodiment of the present invention teaches a variety of systems for enabling purchase, lease, installation and/or maintenance of solar power generation consumer premises equipment (CPE) suitable for installation by a consumer and for power generation at a consumer premises. According to these embodiments, the system includes a financing mechanism, a power grid, a power measuring device and a billing mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] The accompanying drawings, which are incorporated herein and constitute a part of the specification, illustrate embodiments of the invention, and together with the general description given above and the detailed description of the embodiments including the Appendices A and B given below, serve to explain the principals of the invention.
[0051] FIG. 1 illustrates a diagram of a prior art power system.
[0052] FIG. 2 illustrates a block diagram of a power system incorporating consumer premises equipment (CPE) for a real property structure.
[0053] FIGS. 2A-B illustrates net and dual metering arrangements, respectively.
[0054] FIG. 3 illustrates a method of financing the purchase of CPE in accordance with an embodiment of the present invention.
[0055] FIG. 4 illustrates routine A shown in FIG. 3
[0056] FIG. 5 illustrates routine B shown in FIG. 3 .
[0057] FIG. 6 illustrates routine C shown in FIG. 3 .
[0058] FIG. 7 illustrates routine D shown in FIG. 3 .
[0059] FIG. 8 illustrates examples of a power proxy shown in FIG. 7 .
[0060] FIG. 9 illustrates examples of the attributes of power or CPE shown in FIG. 7 .
[0061] FIG. 10 illustrates routine E shown in FIG. 4 .
[0062] FIG. 11 illustrates routines F, G, H, I, J and K shown in FIG. 7 .
[0063] FIG. 12 is a flowchart of a method of financing the purchase of CPE in accordance with another embodiment of the present invention.
[0064] FIG. 13 is diagram of consumer power consumption.
[0065] FIG. 14 illustrates a pool of individual loans for a collateralized power obligation (CPO) in accordance with another embodiment of the present invention.
[0066] FIG. 15 illustrates a CPO in accordance with the embodiment of the present invention shown in FIG. 14 .
DETAILED DESCRIPTION OF THE INVENTION
[0067] FIG. 1 is described above in the Background of the Invention.
[0068] FIG. 2 illustrates consumer premises equipment 10 (also known or referred to as “CPE,” “renewable energy consumer premises equipment” and “renewable energy equipment”) that resides on a residential building, but may alternatively reside on a business, institution or other real property. According to the embodiment of FIG. 2 , CPE 10 incorporates renewable energy equipment that is used by the consumer for energy generation. In this embodiment, CPE 10 includes solar components as the renewable energy equipment (source). Alternatively, any renewable equipment may be used such as wind, biomass or water (hydroelectric) energy generation equipment as well as non-renewable energy sources. Many terms used herein and the definitions for such terms are set forth in Appendix B.
[0069] The solar components described herein are collectively known as photovoltaic (“PV” or “solar”) equipment (or system). In general, there are two types of PV systems: systems that interact with the utility power grid with no battery backup capability and systems that interact with the power grid and include battery backup. In addition, there are other systems that do not interact with the grid. In the embodiment shown in FIG. 2 , the PV system (equipment) interacts with the power grid 32 but does not include a battery backup. As a result, this system operates only when the utility is available. This PV system will typically provide the greatest amount of savings to a consumer per dollar of investment. However, the system will shut down during an outage, and will remain that way until utility power is restored. Note that the consumer is a homeowner or resident for this discussion, but may alternatively be a business, institution, entity or other user or purchaser of power (electricity).
[0070] CPE 10 comprises several components including a PV (photovoltaic) array 12 along with the appropriate mounting equipment. PV array 12 is made up of PV modules, which are an environmentally-sealed collections of PV cells. These cells convert the sunlight into electricity. One of the most common PV modules is 5-25 square feet in size. Usually four or more smaller modules are framed together by struts called a panel. A panel spanning 20-35 square feet in area may be used for more easily handling on a roof. CPE 10 includes mounting and wiring systems used to integrate the solar modules into the electrical systems of a residence or alternatively a business, institution or other consumer.
[0071] CPE 10 includes (as part of the wiring system) PV array circuit combiner 14 , ground fault protector 16 , DC fused switch 18 and DC/AC inverter 20 connected in series. PV array circuit combiner 14 is connected to PV array 12 . DC fused switch 18 is used as over-current protection for the solar (PV) modules. Ground fault protection 16 is a circuit breaker. Combiner 14 is used since PV array 12 (modules) requires fusing for each module source circuit. Some inverters alternatively include the fusing and combining function within the inverter housing. Inverter 20 is designed to take the DC power from PV array 12 and convert it into standard AC power used by devices that consumes standard AC power.
[0072] CPE 10 further includes AC fused switch 22 and utility switch 24 connected in series (and connected to DC/AC inverter 20 ). AC fused switch 22 is used as a disconnect (i.e., as an over-current protective device (OCPD)). Utility switch 24 is used by the utility to switch off PV array 12 . Most utilities require a visible-blade, lockable open switch or disconnect in the inverter's output circuit. The utility switch 24 is usually located within sight of the service-entrance meter for ease of locating by emergency response people. It should be noted that CPE 10 may include additional components or fewer components than described herein depending on power and installation requirements.
[0073] The components of CPE 10 are connected to original components including main service panel 26 , consumer loads or usage (or consumption) 28 , meter 30 and a local segment of the utility power grid 32 . Specifically, utility switch 24 is fused and is connected to main service panel 26 . The maintenance service panel 26 includes among other things the residential circuit breakers. Main panel 26 is coupled to the residential wiring and loads 28 .
[0074] Meter 30 is coupled between power grid 32 and main service panel 26 . Meter 30 is a device for measuring electricity consumption. In this instance, meter 30 is capable of net metering (or other alternative metering schemes discussed below). This is shown in FIG. 2A . CPE 10 is shown interconnected to power grid 32 to enable the consumer to feed any surplus or excess power (electricity) to grid 32 . Meter 30 will spin forward when power (electricity) flows from power grid 32 into the residence and backward when CPE 10 (solar components) produces surplus electricity that is not immediately used. (For purposes of this application, power consumed will have a negative value and power generated will have a positive value. This convention, however, may be switched.) Excess power (electricity) is “loaded” on power grid 32 .
[0075] Utilities may require an agreement for consumers to qualify for net-metering. This is known as net metering to those skilled in the state of the art. In alternative embodiments, there might be two separate meters as shown in FIG. 2B . Meter 36 is used as a measuring device for power consumed or used and meter 38 is used as a measuring device for power generated by the consumer's CPE. This “dual metering” convention may be desired by a consumer or required by a utility. This is because in some cases, the purchase price of power is different than the rate the utilities buy the power from the consumer.
[0076] The utilities may give credit or provide payment for excess electricity generated beyond power used by the consumer. In alternative embodiments, there may be two meters (as discussed above), one for forward measurement and one showing backward measurement. In this illustrative example, the consumer uses 1,000 KHW in the given time period. The consumer's CPE generates 1,600 KHW in the given time period. The price the consumer pays is $0.14 per KHW. The buyback price is $0.12 per KHW. Using net metering the consumer will receive a credit of $0.12/KHW*(1,000-1,600)=$72. Using dual metering the consumer will pay $0.14/KHW*1,000-$0.12* 1,600=$52. In other cases, the results will be different. The credit, payment or other quantifiable value for power generated by the CPE 10 is part of or known as “receivables” which will be described in more detail below.
[0077] Additional details of installation including factors effecting mounting, positioning, output and other related information are found in many power periodicals, papers and books including “A Guide to Photovoltaic (PV) System Design and Installation,” Edecon Engineering, Version 1, Jun. 14, 2001, the contents of this document being incorporated by reference herein.
[0078] The average cost for a solar system in the U.S. is approximately $30,000. Solar equipment cost may be calculated using commercial software such as the assessment tool marketed by Fat Spaniel Technologies. (See http://www.fatspaniel.com/solutions-eu-assess.html.) In addition, there are other web based tools available for calculations. An example of this is found at http://www.findsolar.com. A professional may also be used to determine the size and costs of solar equipment and installation. See “A Guide to Photovoltaic (PV) System Design and Installation,” Edecon Engineering, Version 1, Jun. 14, 2001 or other articles on this subject for more details. The solar components or equipment of CPE 10 that is subject to or may be borrowed against (may be secured) includes PV array 12 , circuit combiner 14 , ground fault protector 16 , DC switch 18 , DC/AC converter 20 and possibly other components including the mounting equipment. Note that these components may be considered fixtures depending on implementation and local laws.
[0079] FIG. 3 is a high level flow diagram of one method of financing CPE 10 in accordance with an embodiment of the present invention. At step 50 , a lender receives a loan or finance request from a consumer (borrower) for the financing of CPE 10 . The consumer may submit an application for such a loan much like a consumer does for other types of loans. However, such information submitted will be abbreviated to reduce the administrative mortgage costs which make CPE harder to finance. (In certain embodiments, the general lending underwriting standards are modified and costs associated with the same are reduced for the reasons discussed below). The financing application may be received in many ways including a letter, website, email, phone and fax. As part of the financing application, the consumer may be required to submit limited financial and other information (e.g., name, social security or tax ID number, location of real property, authorization for credit information, type of loan desired, etc.) for evaluation. CPE 10 (e.g., solar components) requirements and limitations will also be determined along with the costs for such CPE 10 .
[0080] Following step 50 , several steps are executed in parallel, as shown, or may be executed in any suitable manner. At step 52 , the monetary value of the estimated power generated by the CPE 10 over the life of the loan is determined. Details of step 52 are set forth in routine A shown in FIG. 4 . Suffice it to say, the power estimated may be excess power as measured by a net meter 30 from FIG. 2A or gross power generated and measured directly off of the meter 38 shown in FIG. 2B . At step 54 , the consumer's ability to repay the loan is assessed. The consumer's credit information including FICO score are obtained. This credit information will be evaluated to assess whether the consumer will pay back the loan independent of the value of any collateral or cash flows. In addition to this assessment, the actual value for the CPE 10 may be determined. The rebates, credits, subsidies and any other benefits for the purchase of CPE10 may be taken into consideration. In addition to step 54 , the effects of Federal, State and local laws as well as regulatory factors have on expected loan amount, loan term, interest rate and other terms and condition may be determined at step 56 .
[0081] Federal laws such as the U.S. Department and Urban Development (HUD) rules must be reviewed (particularly if the loan is used to purchase real property). For example, HUD rules require a cool-down period in which the consumer/borrower may terminate the agreement without penalty. State laws must also be reviewed. For example, State usury laws must be reviewed to determine the specific rules and restrictions on loans and interest rates. For example, California's usury and other laws regulate the loan of money and the interest rates employed. See Title IV-Loan, Ch. 3, Loan of Money, California Civil Code Section 1912-1916 and the California Finance Lenders Law of the California Financial Code. In addition, Federal, State and local anti-predatory lending laws that also protect the consumer/borrower for fraudulent, deceptive, discriminatory or unfavorable practices must be reviewed. The lender must also adhere to licensing laws for lending money to consumers.
[0082] Once steps 52 - 56 are completed, a loan or financing amount to be offered to the consumer is determined (calculated) along with the relevant interest rate, loan term and other conditions at step 58 . The amount, interest rate and other terms and conditions take into account market interest rates and conditions, as described in detail with respect to routine B in FIG. 5 . In addition, other factors relating to the CPE 10 are considered as described in detail with respect to routine C in FIG. 6 . Any down payment by the consumer will also be taken into consideration.
[0083] As part of this determination, applicant information is verified. As for the loan, the terms may be for a fixed monthly term or a variable term based on a payment amount the consumer prefers (and is supported by their credit information). Other terms and rates may be used including fixed or variable interest rates based on market conditions for a given credit information. Down payments may or may not be required based on the credit information and other factors. The loan application process may be done entirely through the web in real or near-real time. Execution then moves to step 60 wherein the lender approves the loan and offers the loan to the consumer at the terms determined (from steps 52 - 58 ). The consumer may be notified of such approval in many ways including a letter, email message, via website, print out or other efficient means. At this point, the consumer has the option to either accept or reject the loan at the given terms (steps 61 and 62 ). If the consumer rejects the loan, the process may return to step 58 wherein the loan terms are recalculated (if the lender desires). Assuming the consumer accepts the loan at the terms offered at step 62 , such acceptance shall be by execution which may include notarization. Execution may be in written or electronic/digital form.
[0084] Now, the lender wants to increase its chances that it will be repaid the full amount of the loan. To this end, the lender will secure the loan or financing at step 64 as described in routine D in detail ( FIG. 7 ). In brief, the lender may secure the loan against a power proxy, the CPE, rebates, credits and/or subsidies, a power purchase agreement, real property, and/or a conditional sales contract (or power contract). Additionally or alternatively, the lender may take or receive an assignment from the consumer for the receivables (as described below) it receives for future power generated by CPE 10 (excess or direct power off of the CPE). This is accomplished at step 66 . Alternatively or in addition, the lender may take an assignment in the other power proxy elements (besides the receivables as discussed below), power attributes and/or CPE attributes (discussed below), a power purchase agreement, power contract and/or a conditional sales contract.
[0085] Note that the method of FIG. 3 was described in terms of a loan for purchase. However, the present invention contemplates a variety of financing techniques for a variety of activities including purchase, lease, installation and maintenance of the CPE 10 .
[0086] With respect to the “receivables” described above, many utilities are required to either credit a consumer's account (back meter) or pay a consumer for electricity generated by CPE 10 and delivered onto the power grid. 32 . This payment may be in the form of a certificate, credit, money or other quantifiable value. For example, New Jersey offers SRECs for every 1,000 KWH of electricity. In March 2006, the cumulative weighted average price ($/MWH) for an SREC was $201.98 on the open market. See http://www.njcep.com/srec/trading-statistics.html. Therefore, the receivables include any valuable payment, instrument or other valuable consideration for the power generated by CPE 10 . The receivables may be provided by a utility or other entity for power (electricity) generated by CPE 10 (and delivered onto a power grid 32 ).
[0087] Referring to FIG. 4 , the value of power (excess or direct gross power of the CPE 10 ) generated at step 52 of FIG. 3 is broken down in detail in routine A. As will be appreciated, the method (steps) of FIG. 4 is only one suitable embodiment for accomplishing the estimation of step 52 . At step 52 a , power generated by CPE 10 is estimated (estimated power generated is referred to as “EPG”). Step 58 a may be accomplished through any suitable process such as by the steps in routine E shown in FIG. 10 .
[0088] Turning to FIG. 10 , seasonal factors affecting CPE 10 power generation are determined at step 58 a 1 . In brief, the seasonal strength of sunlight and length of sunlight hours affect estimated power generation by CPE 10 . These factors vary throughout the year (by season). Estimated power generation typically peaks during the summer and dips lowest during the winter. In some cases, this graphical function may be inverted (colder weather sometimes increases the power generation.). However, power generation depends on the angle (orientation discussed below) of the solar equipment (panels) as well as the weather conditions at the particular location.
[0089] Continuing with FIG. 10 , Execution moves to step 52 a 2 wherein the CPE 10 location based factors affecting seasonal power generation are determined. The longitude and latitude placement of the CPE structure are factors that will be considered (or alternatively the zip code that can be translated into longitude and latitude). At step 52 a 3 , the CPE 10 location based factors are used to determine weather based factors that affect power generation. That is, the specific placement of the CPE will affect power generation. For example, the CPE may generate greater power in the winter than in the summer depending on the particular placement (attachment) of the CPE 10 .
[0090] With further reference to FIG. 10 , at step 52 a 4 , the degradation of power (based on the components of CPE 10 ) is determined. In other words, the efficiency of CPE 10 over the life of the CPE 10 is determined. Typically, efficiency decreases over the economic lifetime of the CPE 10 . Many solar systems are warranted by their manufacture at their rated generation capability for 10-20 years (factory guaranteed output rating). With some CPE, the initial efficiency may be located above the manufacturer's rated capacity (100%). Average efficiency for CPE 10 will likely decrease linearly over time. There are also industry standards for degradation that may be considered in place of the manufacture's warranty. Also note that different system components may have different degradation rates and lives. These factors are also considered. Following step 52 a 4 , other factors affecting power generation are determined at step 52 a 5 . Such factors include panel type and the directional orientation of the CPE 10 (including degree of roof slope). The directional orientation includes the angle measure with respect to horizontal, vertical, or other reference plane such as ground or the surface on which the CPE is positioned. These factors also include sunlight concentration striking the CPE (due to water reflection, presence of concentrators or concentrating photovoltaics and/or coatings for example), sunlight blockage (e.g., a bush, tree, building, presence of residue of films of materials deposited from the air or from water and/or other element obstructing light from striking the CPE 10 ), expected sunlight at the CPE 10 over a given period of time and/or generation capacity of the CPE 10 . There are other considerations affecting power generation including temperature limits of the solar modules, dirt, dust and plant material accumulation, mismatch and wiring losses, and DC to AC conversion losses.
[0091] If the factors in 52 a 1 - 5 are taken into consideration, estimated power generation can be determined accurate enough for lending purposes. See “A Guide to Photovoltaic (PV) System Design and Installation,” Edecon Engineering, Version 1, Jun. 14, 2001 for additional factors and their effect on CPE generation. Of course, those skilled in the art will recognize that certain of these steps may not be included in the process, and/or may be performed optionally on a case by case basis.
[0092] Returning to FIG. 4 , following step 52 a , the market buy back price (sold back to the power grid) for estimated power generated (EPG) is estimated at step 58 b . In general, the buy back price will vary with the region, utility and market trading for power. In one example, market price may be maintained at a relatively high value for a given period of time and decreases to a low value. The price mildly increases following that decrease. In another example, market price may appear as a linear function over time wherein the market price steadily increases over time. See futures markets for power and discussion below. In sum, the buy back price may vary over time. The buy back price may be based on current market prices, scheduled PUC prices, future estimate market prices, wholesale prices, the amount of the power generated, timing of the power generated, and/or location of power generated.
[0093] Then, at step 52 c , the monetary estimated value of the EPG by CPE 10 is calculated over the life of the loan by multiplying the EPG by market buy back price. This calculation may be performed using an equation such as (or alternatively another similar equation):
[0000]
$
EPG
value
=
∫
0
t
EPG
t
×
PG
t
[0000] where “EPG” is the estimated power generated at a specified “t” time and “PG” is the buyback price of the power ($KWH) at a given time “t”. Following this calculation, execution moves to step 52 d wherein estimated power consumption (EPC) is determined. EPC varies constantly because demands vary constantly due to changing consumer usage. Current usage (or consumption) is affected by the number and type of devices used by the consumer. For purposes of calculation, estimated consumption may be a fixed average value or varying values based on historical usage, cost of living, by location or other factors.
[0094] At step 52 e , the market price (purchase from power grid) of power consumed is estimated. The market price of power will also vary and will depend on the geographical region, the entity selling the power, the arrangement (non-interruptible or interruptible contract) and time of day of use. Any given utility for example may set prices differently per season. In one example, the utility price for usage may remain constant over a period of time. Alternatively, the price may change based on a tiered (i.e., stepping) scheme over a given time period for a specific utility. California is an example of a State in which such a pricing scheme is used. In particular, usage price steps up incrementally after a certain amount of usage (over time).
[0095] In yet another example, utility price (daily) point maybe lower during off-peak periods. However, the price jumps to a higher level during peak periods of usage. Note that there might be more than one peak or non-peak rate. In yet another example, a different pricing scheme exists for consumers under “non-interruptible” and “interruptible” arrangements with a utility. In particular, the price per KWH is higher (for some real market prices) for consumers that do not accept interruptions in usage during peak usage periods. Alternatively, consumers that accept interruptions in power (due to peak usage, transmission congestion or other factors), the utility prices are substantially lower.
[0096] Rates are typically determined by the applicable regulatory agencies (PUCs) over a large period of time (e.g., 10 year or 20 years). The pricing component or gradient may be based on the consumer price index (CPI) for energy or may be derived from the futures commodity market for electricity proxies such Dow Jones electricity indexes (http://www.diindexes.com/mdsidx/?event=energyUSDaily) or natural gas futures market or other. In addition, any length of time may be used that is sufficient to enable the lender to determine long range pricing. (Price for power has historically increased 2-6% per year.) It is important for the lender to consider long-term pricing of power. While pricing is normally set by the PUCs, they will tend to mirror the projected long-term futures market for energy. Such information will help determine whether the customer can afford the repayments over the length of the loan. That is, the lender will determine whether there will actually be cash flow back to the lender over the long-term.
[0097] In sum, the consumer pricing scheme may be based on scheduled PUC prices, current market prices, future estimated market price, the presence or an absence of an interruption contract, the amount of power used, location of power used and/or the timing of the power used.
[0098] At step 52 f , estimated monetary value of consumption (EPC) is calculated over the life of the loan. This calculation may be accomplished using the equation (or alternatively a similar equation):
[0000]
$
EPC
value
=
∫
0
t
EPC
t
×
PC
t
[0000] where “EPC” is the estimated power consumption in dollars at a given time “t” and PC is the purchase price of power (from the utility or other entity that sells power) at a given time “t.”
[0099] Now, once the monetary values for EPG and EPC are calculated, the estimated net monetary value of power is calculated at step 52 g in FIG. 4 . This calculation is accomplished by the equation:
[0000] EPG−EPC =Net value for excess power.
This value will be used to determine the financing or loan amount awarded and other financing or loan terms.
[0100] As described above, the loan amount awarded, interest rate, etc. are determined at step 58 . As part of that determination, the routine B shown in FIG. 5 is performed to accomplish this task (along with information of steps 52 - 56 ). In particular, the lender shall continually review current market rates at step 58 a to determine the rate at which the lender may borrow money. Such information will be obtained from a database of current market rates. The rate at which the lender may borrow will ultimately allow the lender to determine the rate at which the lender may then lend money to a consumer. At step 58 b , the lender will determine the proper interest rate for the loan provided to the consumer based on the market interest rates for obtaining the money to loan the consumer.
[0101] Reference is now made to FIG. 6 wherein routine C is executed (as part of step 58 ). That is, the loan value (and terms) will take into an account any legal and other costs associated with collection should the consumer/borrower default on the financing or loan. These legal and other costs may include seizure costs and professional CPE service costs. In particular, at step 58 c , the gross salvage or liquidation value of CPE 10 will be estimated and factored into the loan determination at step 58 c . At step 58 d 1 , the net salvage value of the CPE 10 is determined. As part of this step 58 d , legal costs associated with the collected property will be subtracted from the gross salvage value. In addition, remarketing costs for CPE 10 resale will be subtracted from the gross salvage value of the CPE at substep 58 d 2 . These costs are factored into the loan equation at step 58 . In addition to these factors, there are costs for servicing the loan over the life thereof and other administrative overhead costs for processing the loan. These factors are determined at steps 58 e and 58 f.
[0102] At the same time as the steps of routines B and C are performed, or any other suitable time, to ultimately make a determination about loan terms, the consumer's application information shall be reviewed for fraud. In addition, the effective monetary value of CPE 10 is estimated. Rebates, credits, other subsidies and labor costs are determined and subtracted from the gross value of the CPE 10 . The gross costs of the CPE 10 are typically provided by a solar installation professional/contractor or may be obtained from a database from invoice information. The estimate provided by the professional will likely include actual costs for the equipment and the professional costs for installation. Rebates are based on the state in which the CPE will be positioned.
[0103] Returning to FIG. 3 , once step 58 is executed wherein the loan award amount is determined along with the terms thereof, the consumer's application is approved and the loan is offered to the consumer at step 60 . Execution then moves to step 62 wherein the consumer accepts the loan. Now, once the loan package (defined) is determined, offered and accepted by the consumer (steps 58 , 60 , 62 ), a financial instrument shall be created supporting the loan or financing for the CPE 10 . In an effort to increase the likelihood that the loan will be repaid, as part of the terms of the loan, the lender has the option to (1) secure the loan against personal and/or real property, at step 64 (routine D shown in FIG. 7 ) and/or (2) receive an assignment of the receivables at step 66 (alternatively or in addition take or receive an assignment in the other power proxy elements (besides the receivables), CPE attributes, a power purchase agreement, power contract and/or a conditional sales contract (all discussed below)). If the lender decides to secure the loan against personal and/or real property, a security interest(s) as discussed below shall be created as part of the financial instrument. If the lender chooses to receive an assignment of the receivables (unsecured loan), the lender will require that the consumer/borrower execute an agreement which, among other things, assigns the rights in the receivables to guarantee the loan. The same holds true for any assignment in other power proxy elements, power attributes, CPE attributes, a power purchase agreement, power contract and/or a conditional sales contract (all discussed below).
[0104] If the lender chooses to secure the loan against the personal property and/or real property as discussed below, the lender may follow the steps set forth in routine D in FIG. 7 . In particular, at step 64 a , the lender will take a security interest in the power proxy 80 as detailed in FIG. 8 . Details of securing the power proxy are described with reference to routine F in FIG. 11 . In addition to the security interest in the power proxy 80 , the lender may take a security interest in the CPE 10 at step 64 b (raw equipment as opposed to the attributes of the CPE 10 as described below) as well as in the real property on which CPE 10 is expected to be disposed at step 64 c . Details of securing the CPE 10 and real property are described in routines G and H, respectively, in FIG. 11 .
[0105] In addition or alternative to the security interests discussed thus far, the lender may take a security interest in the rebates, credits and any subsidies associated with the purchase of the CPE 10 and any power purchase agreement at steps 64 d and 64 e , respectively. The steps for securing the property in these steps are defined in routines I and J, respectively in FIG. 11 . Lastly, the lender will likely take a security interest in the attributes associated with the CPE 10 at step 64 f as defined in routine K in FIG. 11 . The lender may secure the loan for the CPE 10 by taking a security interest in one or more of the power proxy (elements in FIG. 8 ), CPE, real property, rebates, credits and subsidies, power purchase agreement, and CPE attributes as set forth in steps 64 a - f.
[0106] As stated above, the security interests discussed above (one or more) will be created as part of the financial instrument between the lender and the borrower/consumer. The financial instrument may include one note supporting the entire balance or a portion of the loan (financing) for the CPE 10 . Alternatively, the financial instrument may include a plurality of notes supporting a plurality of amounts of the loan (financing) for CPE 10 wherein the sum of the amounts equals the balance of the loan or alternatively is less than the balance of the loan. In the embodiment in which a plurality of notes are used, such plurality of notes may be cross-collateralized whereby a default by a consumer on one or more notes (of the plurality of notes) triggers a default by the consumer on any or all of the remaining notes. Alternatively, the plurality of notes may not be cross-collateralized whereby a default by the consumer on one note will not trigger a default by the consumer on the remaining notes (of the plurality of note under the financial instrument).
[0107] Reference is now made to FIG. 8 wherein examples of the power proxy 80 are shown. In particular, power proxy 80 includes receivables 82 , power 84 and housing 86 . Receivables 82 may be cash flows 82 a , certificates 82 b , and/or credits or other valuable consideration 82 c for the power generated by the CPE 10 . The receivables 82 may be provided by a utility or other entity that pays or reimburses a consumer for power generated by the CPE 10 . Power 84 may be defined as power attributes 84 a as set forth in FIG. 9 or naked power 84 b . Power attributes 84 a as defined in Appendix B are the characteristics of power that are transferable separate and apart from the actual naked power itself. Naked power is merely the electrons themselves. Housing 86 is used to segregate power (naked power) generated by the CPE 10 from power generated elsewhere (e.g., other consumer power or utility power). The housing 86 may be identified by warehouse receipts, bill of ladings, and/or other documents evidencing title to housing 86 including, without limitation, warranty registration and affixed serial numbers. Note that a security interest in the housing is also known as an administrative security interest.
[0108] Power proxy 80 also includes regulatory rights 88 in the power generated by the CPE 10 . For example, a regulatory entity such as a State PUC with control over a utility can change the amount billed to the consumer. These charges are similar to those third party charges that can be added to phone bills. The penalty for default would be loss of service and/or collection efforts. Such regulatory rights 88 are created by debiting a consumer's bill for power generated by the CPE 10 or alternatively by updating a consumer record. Power proxy 80 further includes rights in intervention 90 of the CPE 10 . That is, intervention rights is the ability (i.e., right) to interfere with the consumer's ability to use the CPE 10 to generate power. Such intervention may be by sending a person out to intervene or using a device (local or remote) to intervene.
[0109] Reference is now made to FIG. 9 wherein power attributes 84 a and CPE attributes 100 are shown. The attributes (power and CPE) shown in FIG. 9 may be associated with either power and/or the CPE 10 (i.e., indistinguishable from power or the CPE 10 ). Therefore, the attributes are shown in the same figure ( FIG. 9 ) as associated with both power 84 and the CPE 10 . Power attributes 84 a and/or CPE attributes 100 include emission reduction credits (ERC) 102 . ERCs 102 (certificates) are assets that can be used by its owner or sold to entities that need emission (e.g., ROC, NOx, PM (including PM 10 ), CO or Sox) offsets. An emission offset occurs when an entity compensates for an increase in emissions in one area by decreasing emissions in another area. ERCs 102 are only issued for reductions of actual emissions that are quantifiable, enforceable, permanent and surplus. Typically, there is no minimum or maximum limit on the amount of reductions that may be eligible for ERC (certificates). Once the ERC (certificate) is redeemed, the ERC is retired, and cannot be used again. State or county entities ultimately determine the rules by which ERCs 102 are issued and redeemed. Suffice it to say, the ERC system is both good for business and good for the air. ERCs 102 also means earning goodwill in the community.
[0110] Power attributes 84 a and/or CPE attributes 100 may also include tradable renewable credits (TRCs) 104 . TRCs 104 shall mean any and all awards, credits and/or other consideration representing the value for the attributes associated with power generated by a renewable energy (“green”) source. These attributes can be unbundled (i.e., separated) from the underlying power itself (naked power) and sold independently as one or more discrete, tradable instruments to entities that value “greenness.”
[0111] In detail, TRCs (green tags) are a market mechanism that represent the environmental benefits associated with generating power (electricity) from renewable energy sources. Rather than functioning as a tax on pollution-causing electricity generators, as traditional carbon emissions trading programs do, TRCs function as a non-governmental subsidy on pollution-free electricity generators. In states which have a TRC program, a TRC energy provider (such as a wind farm or a consumer with CPE) is credited with one TRC for every 1000 kWh of electricity it produces. A certifying agency gives each TRC a unique identification number to make sure it doesn't get double-counted. The TRC or green energy is fed into the electrical grid (by mandate), and then the accompanying TRC can be sold on the open market.
[0112] Power attributes 84 a and/or CPE attributes 100 also include independent power production (IPP) credits 106 and grid congestion credits 108 . IPP credits 106 shall mean the value in aggregating individual consumer power generation and selling aggregated power for more than the value of selling the components as un-aggregated power. In other words, IPP credits 106 may be aggregated or accumulated to attain the status of an IPP which afford that entity the opportunity to sell power at greater value than the value an entity may receive individually, for example, for selling power generated by CPE (e.g, below wholesale rates).
[0113] Grid congestion credits 108 are a mechanism that represents certain benefits associated with generating electricity from renewable energy sources and with relieving demand on the local power grid. Grid congestion continues to be a problem as the demand for power increases. Grid congestion credits 108 function as a credit or subsidy for a reprieve on local grid congestion.
[0114] Power attributes 84 a and/or CPE attributes 100 may also include royalty credits 110 . Royalty credits 110 means the cash flow associated with royalty interests. Royalty interests are payments made for the use of property such as the CPE 10 . The payment amount is usually a percentage of revenues obtained through the use of the property. Royalty credits 110 may also include an option to purchase some or all of the CPE, a divided or undivided interest in the CPE, a right to receive a certain amount of the output power from the CPE and/or royalty interest in the CPE (as indicated earlier). Power attributes 84 a and/or CPE attributes 100 also includes green tag credits 112 . Green tag credits 112 are the same as tradable renewable credits 104 . Power attributes 84 a and/or CPE attributes 100 may also include power production credits 114 (also known as power purchase agreement or credits). Power production credits accrue when power purchase agreements are accumulated.
[0115] The power attributes 84 a and/or CPE attributes 100 are credits that may include (identified by or associated with) federal tax credits, state tax credits, utility credits, third party credits, subsidies and/or rebates.
[0116] It should be note that a lender or consumer may sell the attributes (power attributes and/or CPE attributes) under different circumstances to reduce the amount financed.
[0117] In order to secure the loan as set forth in step 64 in FIG. 3 , the lender may take security interests as set forth in routine D of FIG. 7 .
[0118] Reference is now made to FIG. 11 wherein routines (F-K) for taking security interests in routine D ( FIG. 7 ) are described in detail. In particular, the lender shall take a security interest in the power proxy 80 (i.e., power proxy security interest). There are two steps in routine F to accomplish this. First, the lender must attach the security interest to the collateral (power proxy elements in FIG. 8 ) at step 64 a 1 . In other words, the security interest must be created by a financial instrument or other legal agreement document.
[0119] To create financial instrument or other legal agreement, the lender may require the consumer/borrower to execute such a financial instrument (UCC1 statement for personal property). The financial instrument will describe the collateral. In this case, the collateral includes one or more power proxy 80 elements shown in FIG. 8 (receivables 82 , power 84 , housing 86 , regulatory rights in power generated by the CPE 88 and the rights in intervention 90 ). In short, the financial instrument gives the lender the authority to foreclose or make a claim to the collateral. The financial instrument will also include other terms including payment terms, what constitutes a default, the rights of the lender/creditor upon default, maintenance of the solar equipment, insurance for the equipment and possibly other terms, including but not limited to the right to assign the financial instrument by the lender.
[0120] Second, the lender must perfect the security interest to ensure that the lender has priority over other creditors of the collateral. This is accomplished at step 64 a 2 . There may be different methods for perfecting different power proxy elements shown in FIG. 8 . The category or characterization of the elements (e.g., “receivables”) will ultimately dictate the method of perfection (in accordance with State law). One common method used for perfection of the power proxy security interest (if such elements are characterized as personal property under state law) is filing a financing statement (UCC1 filing for personal property). In short, the statement shall include the name of the consumer (borrower/debtor), the name of the secured party/lender and the property covered by the statement. There are, however, exceptions to filing. Possession of the collateral is one of them. For purpose of a security interest in “receivables” (e.g., cash flow security interest), the filing method for perfection would apply because “receivables” are likely characterized as personal property under relevant State law (UCC). On the other hand, “regulatory rights in the power generated by the CPE” may likely be characterized differently (see below for example).
[0121] In the event a filing is required, the lender shall follow the laws of the State to determine the proper office for filing. The most common office to file is the Secretary of State. In other situations, the recording office for filing is the county in which either the collateral or debtor is located. The location for filing varies by State and the type of collateral. For example, in California, the proper location for filing is the Secretary of State unless the security is a motor vehicle for which the proper location is the Department of Motor Vehicle. In Virginia, the proper location for filing is Virginia State Corporation Commission office of the Clerk. In Maryland, the proper location for filing is the Maryland Department of Assessments and Taxation. Article 9 of the UCC dictates the rules and requirements for taking security interests in personal property. All States have adopted Article 9 of the Uniform Commercial Code (UCC), but some have exceptions (e.g., filing). (Chattel mortgages may alternatively be used as a vehicle for security interests described herein if permitted by an individual State.).
[0122] An example of attachment and perfection is now described with respect to the regulatory rights in the power generated by the CPE (element of power proxy). In particular, attachment may take the form of a bill or invoice with the added charges representing the loan payments. Perfection in this case would be the possession of a copy of the bill or invoice which listed additional charges. The charges will be added to the balance or charged against any credit on the invoice. A copy of the bill with the additional charges in the possession of the lender shall give the lender superior rights over the consumer's payments against third parties.
[0123] Another example of attachment and perfection is described for a security interest in the housing 86 segregating power generated by the CPE from power generated elsewhere. Creating the security interest in the housing may include identifying the housing in the financial instrument by a warehouse receipt(s), bill of lading or other document evidencing title of the housing. Perfection may include possession of the warehouse receipts, bill of lading or other document evidencing title.
[0124] In addition to the security interest in the power proxy 80 , under the terms of the arrangement with the consumer, the lender shall also take a security interest in CPE 10 (CPE security interest) as set forth in step 64 b . To this end, a CPE security interest will be created by the financial instrument. In reality, the lender will do this because the lender wishes to ensure that (1) the CPE (as an asset) continues to generate power in order to garnish the benefits from the CPE and (2) the lender will be repaid upon the sale of the property in the event the consumer/borrower defaults. The security interest documents such as the financial instrument may permit the lender to place additional restrictions on the use, maintenance and insurance as well as restriction on the removal or sale of the CPE.
[0125] As for the process, the same UCC requirements equally apply to the CPE (provided that the CPE constitutes personal property as opposed to real property). CPE security interest must be attached (created) and perfected as set forth in steps 64 b 1 and 64 b 2 of routine G in FIG. 11 . Under the terms of the arrangement (financial instrument), the lender will be also be authorized to foreclose or make a claim to the collateral (CPE) described in the financial instrument. Similar to the power proxy security interest, the agreement will also include payment terms, default terms, lender/creditor terms upon default, CPE maintenance terms and insurance requirements. The agreement is likely to be State specific and take into consideration such elements as “one right of action” rules.
[0126] In addition to attachment, the lender must perfect the CPE security interest to ensure that the lender has priority over other creditors of the collateral. This is accomplished at step 64 b 2 . Perfection will likely be accomplished by filing a UCC1 statement (UCC1 filing for personal property). In short, the statement shall include the name of the borrower/debtor, the name of the secured party/lender and the property covered by the statement. In this case, the property is CPE. In the event a filing is required under applicable State law, the lender shall follow the State laws to determine the proper office for filing. As indicated above, the most common office to file is the Secretary of State. In other situations, the recording office for filing is the county in which either the collateral or debtor is located. The location for filing varies by State and the type of collateral.
[0127] Note that for security interests in personal property, the UCC filing is typically active for a period of five years unless continued for an additional five years at a time. The UCC filing will lapse at the expiration of the five-year period unless a continuation statement is filed, typically within six months prior to the date of lapse.
[0128] In addition to the security interests in the power proxy (e.g., receivables/power and CPE), the lender may secure the loan against the real property/estate on which the CPE will be attached. Much like the terms for the CPE, a security interest in the subject real property (real property security interest) will be attached and perfected (steps 64 c 1 and 64 c 2 of routine H in FIG. 11 ). The conventional real property/estate documents will be signed to attach (create) the interest to the real property. Such documents typically include the mortgage papers. Real property/estate papers (financial instrument) are typically separate from the documents (financial instrument) relating to the power proxy security interest and CPE security interest. However, all security interest documents may be evidenced by one universal financial instrument (provided such instrument abides by State law.)
[0129] If required, a deed will transfer to the lender or trustee and then be recorded along with the mortgage documents in the appropriate office for perfection. The real property documents are typically recorded in the county or local office in which the real property is located. The CPE will also be subject to and recorded as part of real property/estate. Once filing is performed, the transaction is secured against third parties. There is no need for further action on the part of the lender unless there is a default. The recorded documents remain of record until the lender is repaid the full amount of the loan. At this time, the mortgage documents will be returned to the consumer/borrower.
[0130] In the event a consumer has a conditional sales contract for the real property, the lender may take a security interest in the conditional sales contract (attachment and perfection).
[0131] Note that one real value to the consumer in securing the loan against the real property is the tax benefit. The consumer/borrower should receive tax deductibility treatment from the IRS and/or other taxing bodies for the interest on real property mortgage. As an alternative to a mortgage, a deed of trust may be used to secure the payment of the loan.
[0132] In accordance with the invention, the lender has now attached and perfected (i.e., filing) the CPE as personal property as well as part of the real property. There is a real advantage in following this process. The dual filings ensure that the public is placed on notice of the rights in the CPE against any third party interests. Since under State law there may exist some uncertainty whether CPE constitutes personal or real property, in accordance with the invention, the lender shall now record the CPE as personal property in the appropriate office of the Secretary of State (for example) and will record the CPE along with the real property in the appropriate county office. In this respect, the lender's interest in the CPE against any third party interests as well as bankruptcy or insolvency proceedings has been adequately protected. With respect to any type of property secured (described above), security interest documents may require a notary for creation of such documents.
[0133] In addition to the power proxy, CPE and real property security interests, the lender may secure the loan by taking a security interest in the rebates, credits and subsidies offered by the Federal, State and possibly local governmental entities for the CPE 10 at step 64 d (California Solar tax credits are one type of rebate/subsidy). Steps 64 d 1 and 64 d 2 of routine I ( FIG. 11 ) describe attachment and perfection of such rebates, credits and subsidies. The interest will be created by a financial instrument (agreement) which will describe the collateral (rebates, credits and subsidies) and authorized foreclosure or make a claim to the collateral. The financial instrument (agreement) will also include payment terms, default terms, lender/creditor terms upon default, CPE maintenance terms and insurance requirements. The financial instrument (agreement) is likely to be State specific and take into consideration such elements as “one right of action” rules.
[0134] In addition to attachment, the lender must perfect the security interest in the rebates, credits and subsidies to ensure that the lender has priority over other creditors of the collateral. Perfection will likely be accomplished by filing a financing statement (UCC1 filing for personal property) in the appropriate place or office dictated by State law. In short, the statement shall include the name of the borrower/debtor, the name of the secured party/lender and the property covered by the statement. State law will dictate the characterization of the subject property and the rules and requirements for attachment and perfection.
[0135] In addition the security interests described, the lender may take a security interest in a power purchase agreement (the actual agreement between the consumer and power provider to reimburse, credit or otherwise pay a consumer for power generated by the CPE). The security interest may be created by a financial instrument (alone or with other security interests described herein). Attachment and perfection are accomplished in steps such as steps 64 e 1 and 64 e 2 of routine K, respectively in FIG. 11 . State law will dictate the characterization of the subject property (i.e., power purchase agreement) rules and requirements for attachment and perfection. The lender may also take a security interest in any power contract between resident consumer and a utility.
[0136] In addition to the security interests above, the lender will likely secure the loan against the CPE attributes (similar to power attributes under power proxy shown in FIG. 8 ). Attachment and perfection are set forth in steps 64 f 1 and 64 f 2 , respectively. In particular, the security interest in CPE attributes will be created by a financial instrument and the security interest shall be perfected in accordance with State law. For the CPE attributes (like power attributes), such property may likely fall into the category of personal property and be perfected in accordance with the UCC (e.g., UCC1 filing).
[0137] In addition to the security interests above, the lender may take a security interest in (1) any assignment discussed above, including for example, the receivables or other power proxy elements and/or (2) any long term lease of the CPE and/or real property on which the CPE is disposed, and/or any chattel mortgage for the CPE. Attachment and perfection shall abide by State law for personal and real property.
[0138] In accordance with the present invention, the method for financing discussed above and the creation of these financial instruments may establish a market for creating and trading of such financial instruments. This market may include CPE installers which market services by introducing consumers to financing options through the plurality of financial instruments and brokers who facilitate the formation of the plurality of financial instruments.
[0139] Once all desired security interests are attached and perfected, execution of the method in FIG. 3 is complete. At this point, the lender may execute a check and forward it directly to the installer or other such suitable party. The check may be made for the entire amount or payment may be made incrementally. A first incremental payment may be made, for example, as a deposit for the materials. Another example may be an order or delivery of the materials/components that triggers a first incremental payment. Subsequent incremental payments could be made upon passing an inspection of the installation (at job site by any entity including a government entity, a private provider of traditional governmental service including power, sewage entities, or the consumer even). Under another financing scheme/model, payment alternatively could be made to a distributor, a dealer or a manufacturer of the components of the CPE. Payments to these entities in an incremental scheme will help reduce fraud and will also ensure that the money is actually used to purchase and install the CPE in accordance with the requirements set forth in the financing application process.
[0140] When the consumer/borrower defaults on his/her obligations to repay the loan, the lender as a secured party has the rights and remedies provided in the security agreement, provided by the State UCC and other laws as well as provided in the mortgage documents. In general, the lender may reduce his/her claim to judgment, foreclose or otherwise enforce the security interest(s) by any available judicial procedure. The rights and remedies may be cumulative. In the embodiment of the present invention, the lender, in case of a default, will focus attention on the secured collateral. In this case, the collateral is the one or more power proxy 80 elements ( FIG. 8 ), the CPE 10 , and the underlying real property on which the CPE is attached, rebates, credits and subsidies, power purchase agreement, CPE attributes (like power attributes as part of power proxy) and/or any other property secured. However, the real property is not required for collection. The lender has other vehicles to ensure loan repayment including, for example, the power proxy including the receivables, power and the CPE itself. Therefore, the process for foreclosure is greatly simplified. With a simpler, less costly foreclosure procedure the risk premium associated with these loans is minimized. The reduced process is discussed below in more detail.
[0141] Now, a loan for the purchase of CPE may be repaid using several different methods under the terms of an agreement with the consumer/borrower. Under a traditional loan terms, the consumer repays incrementally during the life of a loan much like any loan (e.g., mortgage). The payments are typically made in monthly increments. Payments may be initially applied toward interest with the remaining monies applied toward the principal of the loan if the loan is fully or partially amortized. The consumer may make prepayments to the lender to be applied toward the principal with and without penalties. While this traditional payment method has been adequate, there exists an improved repayment method that would increase the likelihood that the lender's loan will be repaid and/or increase the lender's profits and/or reduce the cost of the loan to the consumer/borrower.
[0142] By following the steps of the method set forth in FIG. 3 (including the routines in later Figs.) in accordance with an embodiment of the present invention), the entire lending underwriting standards (and process for such standards) have been simplified (modified) and the costs have been reduced for the consumer. The process is now more streamlined (reduced) than the typical process for obtaining a traditional mortgage for the subject real property. In the traditional process, the lender will undertake an appraisal evaluation, a title search and other administrative functions.
[0143] In accordance with an embodiment of the invention, limited/abbreviated or no appraisals, property inspections or title searches will be conducted. There is no need for these functions when the lender takes into consideration other factors to repay the loan such as the receivables, rebates, credits, and subsidies, value of the CPE itself (for example). Such factors considered are used to modify, for example, the income-to-debt ratio and the debt service coverage of the lending underwriting criteria. In addition, such factors may be taken into consideration to show an increase in appraisal value of the real property (if an appraisal is actually performed). In other words, sufficient security exists in the personal property and other non-real property being secured (e.g., receivables in the power proxy, CPE, CPE attributes, the rebates and credits, etc.) as well as through use of credit information and any fraud verification.
[0144] Because there is no need for such evaluations, title searches and other administrative functions, the lending process is simplified and the costs relating to financing are reduced. Escrow requirements have also changed in view of the considerations above (security interests discussed as an example). In sum, the mechanisms used for underwriting enabling and escrow enabling take into consideration many factors (described above) to modify the lending underwriting standards as well as the fees associated therewith.
[0145] Another aspect of the invention is now described. In this aspect, the lender shall receive payments directly from a utility for the power (excess or directly off of the CPE) generated by the CPE and delivered onto the power grid. In such an arrangement, the utility shall purchase the power and distribute payments (process receivables) to the lender directly. The payments processed shall correspond to power measured at set increments. The consumer/borrower will continue to pay the utility for power (electricity) consumed. FIG. 12 illustrates an implementation of this method in accordance with an embodiment of the invention. It is assumed that the consumer has applied for a loan, and the lender has completed the steps of the method shown in FIG. 3 . That is, the lender has offered and the consumer/borrower has accepted the loan at specified terms. At this point, the utility will measure or read the power consumed or generated by the consumer on a power measuring devices such as a meter (e.g., meter 30 shown in FIG. 12 at step 100 . These measurements or readings are performed incrementally over a period of time (periodic power measurements). Most utilities perform readings on a monthly basis. However, the meter may be read at other increments including, but not limited to, weekly, daily, hourly or other interval or period of time-based readings (limited only by the physical meter measurement constraints, regulatory constraints, and automatic meter measurement constraints).
[0146] Depending on the meter used, the power read may be the excess power generated by the CPE (power generated that exceeds the power used by the consumer) or gross power directly off of the CPE. Traditional dial meters are commonly employed today for reading power consumption. In many cases, the utility bills a consumer for the amount of power used since the previous meter reading. Many of these meters, however, are capable of net metering.
[0147] There are also bidirectional (or dual meters as discussed below) that can simultaneously keep track of power (electricity) consumed and power generated by the CPE. In some cases, dual meters are employed. One meter is used for measuring the flow of power (electricity) into the building from the utility and the other is used for measuring the flow of power out of the building (generated by the consumer). With dual metering only, the power generated is used as collateral. The consumer might pay the power company directly for the gross power they use from the utility. FIG. 13 illustrates an example of power consumed in a dual metering setting. P 1 -P N is the power read on the meter at T 1 -T N times, respectively. Note the different price values P 1 , P 2 , P 3 . . . P N for times T 1 , T 2 , T 3 . . . . T N .
[0148] Smart metering systems such automatic meter reading (AMR) systems enable the utility to measure a consumer's power consumption remotely as well as more frequently than manual readings at a lower cost. Smart metering systems allow the utility to communicate between a meter interface module and a central office via a communications system. Communication may take the form of a telephone, power line carrier, radio frequency, internet, cellular or cable television.
[0149] Returning to FIG. 12 , regardless of the method of meter reading (manually or remotely using smart systems), power measurements are taken incrementally over a period of time. The period may be any desired time interval, and power generated by the CPE is purchased by the utility or other entity at step 102 . The power may be the excess power or gross power directly measured from the CPE 10 as discussed above. In the event of net-metering (one meter), net power consumed at any increment of time (over a period of time) will have a negative value. Excess power generated measured at any given increment of time (over a period of time), however, will have positive values. The polarity of this convention may be switched.
[0150] As stated above, at step 102 , the power generated by the CPE and delivered onto the power grid is transferred to, converted and/or purchased by the utility. A billing mechanism may be used to determine on a periodic basis any value of the power generated by the CPE 10 (excess or directly off of the CPE 10 ). (There may also be a financing mechanism for identifying any rebates, credits and/or subsidies for the purchase of the CPE 10 .) The purchase may be in the form of credit, certificate (e.g., New Jersey), cash or security representing value for the power.
[0151] Following step 102 , the utility will distribute payments to the lender directly (or alternatively the consumer pays the lender directly as discussed below) to fulfill the consumer's obligation to repay the loan at step 104 . Specifically, the billing mechanism provides payments or credits the value for the power generated by the CPE to the lender or other entity for financing of the CPE (financing discussed herein is used to mean loan for CPE purchase but it may also mean purchase, lease, installation and/or maintenance of the CPE 10 ). Payments will be made at increments corresponding to meter reading increments. In the current situation, the increments are made on a monthly basis. However, the meter reading frequency (period or increments) may vary as desired (e.g., weekly, daily, by minute or other time). While it is possible to increase the frequency of meter reading using current manual methods, smart metering (or remote meter reading) can make this function more practical and economical.
[0152] In an alternative embodiment, the consumer may pay the lender directly or the consumer pays the lender or through a servicing agent. A servicing agent is a third party that collects money and interfaces with the consumer. In yet another alternative embodiment, the consumer may pay the lender directly until there are payment issues (i.e. the consumer is late with payments), and then the utility may step into the process and pays the lender directly.
[0153] In accordance with the present invention, the step of securing the loan against the receivables would effectively mean that the security interest would be a right in the receivables generated in accordance with the frequency readings (e.g., on a monthly, daily or other unit of time basis). Alternatively, in the event the lender chooses to be paid conventionally (paid by the consumer), the receivables may be garnished at the frequency rate of the meter readings (in the event of a default).
[0154] As indicated above, the method of FIG. 3 and related FIGS. 4-13 were described in terms of a loan for purchase. However, the present invention contemplates a variety of financing techniques for a variety of activities including purchase, lease, installation and/or maintenance of the CPE 10 . It is also noted that the method of FIG. 3 may be computer implemented, manually implemented or a combination of computer and manual implementation.
[0155] Reference is made to FIGS. 14 and 15 wherein another embodiment of the present invention is shown. The method employs a collateralized power obligation (CPO) for the cash flow from groups or pools of individual loans described above with respect to FIG. 3 . As an example, one group of pooled loans is shown in FIG. 14 (LOAN #1, LOAN #2, LOAN #3 . . . . LOAN #N). A CPO is similar but not identical to a CMO (collateralized mortgage obligation), CDO (collateralized debt obligations) or mortgage pass through security. In this embodiment, a security is backed by its ownership of the pool of the individual loans (offered in FIG. 3 ). This security or instrument is secured by the cash flow of the pool of individual loans as well as ownership in the underlying pool of individual loans.
[0156] In the CPO (in brief), the regular principal and interest payments made by borrowers (consumers) could be separated into different payment streams, creating several bonds that repay invested capital at different rates, with different terms. In short, the advantage of a CPO is that the original lender keeps the loans on their books only for a short time. The loans are resold at a profit to the equity or debt investors whom will pay more for tranches than the sum is worth. A tranche is a class of security or ownership interest in a CPO offering. In a CPO, the original lender may become what is known as a packager. The packager might only hold the individual loans temporarily. Similar to a warehouse line of credit, after a sufficient amount of loans are accumulated to create a CPO, the loans are conveyed to a trust or entity that owns the underlying loans for the benefit of investors that own an interest in various cash flows.
[0157] The consumer/borrower will likely pay the loan in installments composed of both interest and principal. Over the life of the loan, the interest component of payments, which typically comprises a majority of the payments in the early years, gradually declines as the principal component increases. To obtain funds to make more loans, original lenders or packagers either “pool” groups of loans with similar characteristics to create securities or sell the loans to issuers of securities. The securities created from pools of loans are essentially “pass-through securities.” Pass-through securities or bonds represent a direct ownership interest in a pool of loans or the trust or entity that holds these pools of loans. As the consumers whose loans are in the pool make their loan payments, the money is distributed on a pro rata basis to the holders of the securities.
[0158] In accordance with the present invention, CPOs offer investors a wider range of investment time frames and greater cash-flow certainty than had previously been available. As indicated above, the CPO issuer assembles a package of these pass-through securities or bonds and uses them as collateral for a multiclass security offering (as described above) such as tranches. The CPO structure enables the issuer to direct the principal and interest cash flow generated by the collateral to the different tranches in a prescribed manner, as defined in the offering's prospectus, to meet different investment objectives.
[0159] The cash flow from the CPO collateral may be allocated in a variety of ways. Usually, it is first allocated to meet the interest obligations on all tranches in the offering. Principal repayments, both scheduled and prepaid, are then distributed to the different classes of bondholders according to a predetermined priority schedule which is outlined in the CPO prospectus or offering circular. The tranche receiving principal repayment is referred to as “active” or “currently paying.” In more complex structures, more than one tranche can be paying principal at a time. In addition, there may be fees associated with tranches. Also, different tranches may have difference credit ratings based on risk assessed.
[0160] Each CPO tranche has an estimated first payment date, on which investors can expect to begin receiving principal payments, and an estimated last principal payment (or maturity) date, on which they can expect their final dollar of principal to be returned. The period before principal payments begin in the tranche, when investors receive interest-only payments, is known as the “lockout” period. The period during which principal repayments are expected to occur is called the “window.” Both first and last principal payment dates are estimates based on prepayment assumptions and can vary according to actual prepayments made on the underlying mortgage loans. These pass-through securities may typically appeal to investors with a certain investment horizon.
[0161] As seen in FIG. 14 , several payment streams with varying amounts, interest rates and other conditions are shown (Loan #1-Loan #N). FIG. 15 illustrates the CPO with several tranches (Tranches x ). In general, the CPO may have several arrangements including a fast-pay bond with a maturity much shorter than the total pool, a bond paying interest only for a period that may be fixed on some condition, and a bond paying variable interest based on an index such as LIBOR, the Prime Rate or an index based upon US Treasury bills, notes and bonds. Regardless of the bond arrangement, the CPO backed by the type of financial instruments discussed in this application will have lower risk of default than an individual loan. The bonds will be secured against or collateralized by the power proxy, CPE, credit, rebates and subsidies for CPE, CPE attributes and/or the real property on which the CPE is attached (as defined above).
[0162] The CPO described above may have two unique tranches in accordance with two different embodiments of the invention. In accordance with one embodiment, one tranche represents future power/CPE attributes including emission reduction credits or tradable renewal credits. As part of the contract with the consumer, consumers will assign to the lender any future carbon credits or renewal energy credits (for example). These credits may be sold in the future in any market that develops for them.
[0163] In accordance with the second embodiment, another tranche represents the value that might accrue because of the scale or size of the CPO allows the CPO to become a larger IPP. In this respect, the CPO may have the right to become a power marketer with the right sell power on the open market. Open market value is usually much higher than the prices offered by the utilities based on PUC dictated pricing. The two different embodiments of the tranche arise from assignable rights that the consumer will convey to the lenders.
[0164] While the embodiments of present invention described in this application are applied to property in the U.S., the methods may apply in any jurisdiction (US or foreign).
[0165] It should be noted that the lender described herein may be any entity including a bank, finance company, individual or other entity that is legally authorized to lend money or advance funds. It should also be noted that the embodiments of the method (of the present invention) above applies to solar energy. In alternative embodiments, however, any renewable energy source may be used that generates electricity (that can be valued). Many utilities will purchase electricity from a number of sources including wind, biomass and hydroelectric (in addition to solar). The sources of energy can be either renewable or non-renewable.
[0166] In summary, the embodiments of the methods described herein offer opportunities for financing the purchase of CPE and other financial rewards that are either not offered by or do not suffer from the disadvantages of the prior art.
[0167] The foregoing description of the embodiments 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 and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiments were chosen and described in order to explain the principles of the invention and its practical application to enable one skilled in the art to 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 and their equivalents.
[0000]
APPENDIX A
% of
institutions
2003
2003
charging
2003
2001
Definition
Highest
Lowest
(2003)
Average
Average
LENDER/BROKER
FEES
Administration fee
This is a fee charged by
$600
$325
14%
$336
$413
other lenders to cover some
of their expenses. It can
range from zero to several
hundred dollars.
Application fee
The fee charged by the
$350
$200
18%
$205
$266
lender to the borrower for
applying for a loan. A fee
usually paid at the time an
application is given to a
lender for helping to
complete and review an
application. Payment of this
fee does not guarantee that a
loan will be approved.
Commitment fee
Any fee paid by a potential
$660
$295
2%
$498
$268
borrower to a lender for the
lender's guarantee to lend
money at a specified rate
and within a specified time
period.
Document
This is a separate fee that
$400
$25
34%
$194
$162
preparation fee
some lenders or title
companies charge to cover
their costs of preparation of
final legal papers, such as
mortgage, deed of trust, note
or deed.
Funding fee
A fee paid for a loan, used
$375
$200
14%
$228
$126
to identify the fee paid to
the VA for issuing their
guarantee. Also may be
applied to an additional fee
paid for funding a
conventional loan, typically
a commercial loan, at
closing.
Mortgage broker
A charge, usually measured
$1,161
$150
46%
$839
$344
or lender fee
by points, made by the
mortgage broker for
originating the loan.
Included in closing costs.
Same as loan origination fee
for a bank.
Processing fee
Processing involves
$595
$37
45%
$320
$303
validating customer
information and
coordinating third-party
findings so that an
underwriter can make a
decision to approve the
application. Once approved,
loan documents can be
drawn and the closing can
be scheduled.
Tax Service fee
A search of the Registry of
$100
$60
82%
$73
$72
Deeds for the county in
which the property lies is
conducted to confirm that
taxes on the property are
paid in full and up to date.
Any unpaid property taxes
are a liability to the lender.
Underwriting fee
Underwriting covers the
$749
$100
40%
$269
$280
costs of assessing an
applicant's qualifications for
a mortgage loan.
Wire transfer fee
When your loan funds, it is
$45
$15
50%
$31
$55
a common practice for a
lender to wire the funds to
the settlement provider
(escrow holder, title
company, or attorney). This
is a fast and efficient way to
transfer funds in a
transaction where time is
crucial. The receiving a
Subtotal
$5,035
$1,407
$2,993
$2,290
THIRD-PARTY
FEES
Appraisal fee
This charge covers an
$600
$250
83%
$327
$269
appraisal report made by an
appraiser.
Settlement:
This fee pays for the
$1,423
$50
93%
$445
$374
Escrow/Attorney
services of the escrow or
settlement agent who
handles all the financial
transfers, plus payments
associated with the
transaction. In some states,
an attorney performs the
functions of an escrow
agent, in which case this fee
is in pl
Credit report fee
This fee covers the cost
$55
$8.50
81%
$29
$37
your lender incurs in
obtaining a copy of your
credit report. Your credit
report shows your credit
history, and the lender uses
this information to help
decide whether or not to
approve your loan and how
much money to lend you.
Flood certification
This fee covers the cost
$25
$10
95%
$17
$22
fee
(normally $10–$30) of a
report to determine if the
property is in a flood-risk
area as determined by The
Federal Emergency
Management Agency
(FEMA). If your home is
located in one of these flood
zones, you will be required
to secure insurance.
Pest & other
Termite and residence
$200
$30
8%
$68
$86
inspection fees
inspection.
Postage/courier fee
A charge for the costs of
$100
$25
81%
$45
$45
sending documents to
various parties using
couriers or express mail
services. These costs are
generally based on actual
usage and will generally be
higher when the process is
rushed, but some lenders
may use a fixed charge.
Survey fee
fee charged for an expert
$400
$50
28%
$174
$227
examination of the property
you are considering buying,
aimed at discovering any
structural flaws or repairs
needed which you may have
failed to notice yourself.
Title insurance fee
Insurance which protects the
$2,075
$50
83%
$605
$460
lender (lender's policy) or
the buyer (owner's policy)
against loss due to disputes
over ownership of a
property.
Title work
Title search, plat drawing,
$625
$25
29%
$200
$220
name search.
Subtotal
$5,503
$499
$1,910
$1,740
GOVERNMENT
FEES
Recording fee
A non-tax fee for the cost
$220
$23
99%
$76
$72
of actually recording a
mortgage loan.
City/county/state
A tax which some localities
$6,750
$22.50
33%
$1,339
$558
tax
collect when a mortgage
stamps/intangible
loan is recorded. It can be
tax fee
significant and is set by state
and/or local governments.
Subtotal
$6,970
$46
$1,415.00
$630
OTHER FEES
Reconveyance fees
A recorded document that
$45
shows a previous loan has
been paid in full.
Notary fees
This fee covers the cost of
having a person who is
licensed as a notary public
swear to the fact that the
persons named in the
documents did, in fact, sign
them.
Total
$17,508
$1,951
$6,318
$4,659
All the estimates
were based on a
$180,000 loan to
an applicant with
good credit who
makes a down
payment of at least
20 percent on the
purchase of a
single-family
residence.
http://www.bankrate.com/brm/news/
mortgages/20031106b1.asp and
http://www.bankrate.com/brm/news/
mtg/20010621b.asp
APPENDIX B
Terms and Definitions
[0168] “administration fee” shall mean the fee charged by lenders to cover some of their expenses. The fee can range from zero to several hundred dollars or more.
[0169] “administrative security interest” shall mean a security interest in the housing containing power. This security interest is created by administrative means, not specified by the Universal Commercial Code (UCC). This may include administratively segregating all the power generated over a specific time so that any one lender has a unique claim or security interest in a set amount of power.
[0170] “amount of power generated” shall mean the quantity of power produced by a consumer's CPE. The amount of power generated is typically qualified over a specific time period.
[0171] “amount of power used” shall mean the quantity of power used or consumed by a consumer. This is the same as the amount of power consumed.
[0172] “application fee” shall mean a fee charged by the lender to the borrower for applying for a loan. The application fee is usually paid at the time an application is given to a lender for helping to complete and review an application. Payment of this fee does not guarantee that a loan will be approved.
[0173] “appraisal fee” shall mean the charge covering an appraisal report made by a third-party appraiser.
[0174] “appraisal value” shall mean a monetary assessment or valuation of the property appraised.
[0175] “appraisal” shall mean the act of estimating or judging the value of something including, without limitation, personal property, real property, CPE or other property.
[0176] “assignment” shall mean a transfer of any right, interest and/or title in something of present or future value including, without limitation, receivables, cash flow and payment streams.
[0177] “attributes” shall mean the power attributes and/or the CPE attributes.
[0178] “automatic meter reading” shall mean the technology of automatically collecting data from energy meters and transferring that data to a central database for billing and/or analyzing.
[0179] “balance of the loan” shall mean the amount of unpaid principal on a specific note or notes.
[0180] “bill of lading” shall mean any legal document between a shipper of a particular good and the carrier detailing the type, quantity and destination of the good being carried. The bill of lading also serves as a receipt of shipment when the good is delivered to the predetermined destination. This document must accompany the shipped goods, no matter the form of transportation, and must be signed by an authorized representative from the carrier, shipper and receiver. In the context of this application, a bill of lading is any document evidencing the transmission of power from the consumer's CPE to the utility.
[0181] “bonds” shall mean a financial instrument with which the investor (lender) loans money to an entity that borrows the funds for a period of time at a specified interest rate. The indebted entity issues investors a certificate, or bond, that states the interest rate (coupon rate) that will be paid and when the loaned funds are to be returned (maturity date).
[0182] “cash flow” shall mean a revenue or payment stream that changes a cash account over a given period. Cash flow can also be defined as the monetary value of the power generated by the CPE over a specified period of time.
[0183] “cash flow security interest” shall mean a security interest in cash flow.
[0184] “chattel mortgage” shall mean a loan to buy some personal item or good, the item or good being used as security for the loan.
[0185] “city/county/state tax stamps/intangible tax fee” shall mean the tax which some localities collect when a mortgage loan is recorded. It can be significant and is set by state and/or local governments.
[0186] “collateral” shall mean any property or asset pledged by a borrower to secure a loan or other credit, and subject it to seizure in the event of default. Collateral shall include any real or personal property including, without limitation, receivables.
[0187] “collateralized power obligation” (also known as “CPO”) shall mean a financial instrument or security that is secured by its ownership of a pool of individual loans for the purchase of CPE. This security or instrument is secured by the cash flow of the pool of such individual loans as well as ownership in the underlying pool of individual loans.
[0188] “commitment fee” shall mean any fee paid by a potential borrower to a lender for the lender's guarantee to lend money at a specified rate and within a specified time period
[0189] “computer implementation” shall mean the execution of any or all process steps by computer.
[0190] “conditional sales contract” shall mean a contract for the sale of a property or an asset where the buyer has possession and use, but the seller retains title until the conditions of the contract have been fulfilled.
[0191] “consumer” shall mean a user or purchaser of power (electricity).
[0192] “consumer lending laws” shall mean any and all state and federal law enacted to protect the consumer from certain illegal lending practices. Usury laws and predatory lending laws are examples of consumer lending laws.
[0193] “consumer premises equipment” (also known or referred to as “CPE,” “renewable energy consumer premises equipment,” and “renewable energy CPE”) shall mean any thing or characteristic of the consumer premises equipment (CPE) including, without limitation, CPE attributes and the physical assets of the CPE (i.e., naked CPE). CPE shall include any and all renewable energy equipment (as the physical assets or naked CPE) purchased or owned by a consumer that resides or is disposed on or near a residential building or business, institution or other real property. CPE also includes any and all mounting equipment. CPE may also be referred to as Consumer Power Equipment or Consumer Premises Owned Equipment.
[0194] “CPE attributes” shall mean attributes or characteristics of the CPE that are transferable separate and apart from the actual physical assets of the CPE. CPE attributes may also be referred to as attributes.
[0195] “CPE security interest” (also referred to as a “CPE physical asset security interest” or “consumer premises security interest”) shall mean a security interest in the CPE.
[0196] “consumer protection laws” shall mean any and all state and the federal enacted laws to protect the consumer (the retail purchasers of goods and services) from inferior, adulterated, hazardous and deceptively advertised products, and deceptive or fraudulent sales practices. Consumer lending laws are a subset of consumer protection laws.
[0197] “consumer risk of default” shall mean the risk that a consumer will fail to make payments on a loan.
[0198] “consumer's credit information” (also referred to as “consumer credit information”) shall mean any information relating to the credit granted to a consumer permitting the use or ownership of goods or services during a term of payment. In the context of this application, this means information that underwrites the granting of a consumer a loan to purchase CPE. Credit information includes, but is not limited to, a consumer's FICO score.
[0199] “CPE factory guaranteed output ratings” shall mean the guaranteed ratings of CPE performance power generation by the manufacture of the CPE over the period of the warranty for the CPE.
[0200] “credit report fee” shall mean the cost that a lender incurs in obtaining a copy of a credit report. The credit report shows credit history, and the lender uses this information to help decide whether or not to approve a loan and how much money to lend.
[0201] “credits” shall mean any money or other valuable consideration offered to an entity for certain defined acts. Credit is based on the character of the borrower, the cash flow of the borrower and the collateral pledged (if any) by the borrower.
[0202] “cross-collateralized” shall mean a situation in which one or all notes supporting a loan are considered in default merely if one of the notes is in default.
[0203] “current market price” shall mean the last reported sale price of a financial instrument, security or other tradable commodity or the current bid and ask prices of the security or other tradable commodity.
[0204] “dealer” shall mean an entity who sells CPE from a distributor to an installer or directly to the consumer.
[0205] “debt-service-coverage ratio” is a ratio used by lenders in underwriting how much money to loan to a consumer. This ratio should ideally be over 1, which would mean that the consumer is generating enough income (net of expenses) to pay its debt obligations. The debt-service-coverage ratio is calculated by dividing the net operating income by total debt service. For purposes of this application, income is income net of expenses such as payments for utilities.
[0206] “deed of trust” shall mean a document which pledges real property to secure a loan by a consumer. The property is deeded by a title holder (trustor) to a trustee (often a title or escrow company), which holds the title in trust for the beneficiary (the lender of the money). When the loan is fully paid, the trustor requests the trustee to return the title by reconveyance. If the loan becomes delinquent or is in default, the beneficiary can file a notice of default and, if the loan is not brought current, the trustee can demand that the trustee begin foreclosure on the property so that the beneficiary may either be paid or obtain title.
[0207] “default” shall mean the failure to make a payment when due, which can lead to a notice of default and the start of foreclosure proceedings if the debt is secured by real or personal property.
[0208] “degradation as estimated by industry standards” shall mean an estimate of the gradual failing or loss of power generation of the CPE based on industry standard relationships of power generated over time.
[0209] “degradation as implied by the warranty” shall mean an estimate of the gradual failing of the CPE (loss of power generated) as implied by the warranty of the CPE.
[0210] “degradation of the CPE” shall mean the gradual failing or loss of power generated from the CPE over time.
[0211] “divided interest” shall mean an ownership interest in only a part of a property. The interest in the selected part may be total or partial.
[0212] “distributor” shall mean an entity who sells CPE to an installer or a dealer.
[0213] “document preparation fee” shall mean a separate fee that some lenders or title companies charge to borrowers cover their costs of preparation of final legal papers, such as mortgage, deed of trust, note or deed.
[0214] “dual metering” shall mean the use of two power measuring meters, one meter being used for measuring power consumption by the consumer and the other being used for measuring power generation by the CPE.
[0215] “emission reduction credits” (also known as “ERC”) shall mean any award, grant or “credit” that is provided to an entity for the reduction of emissions or pollutants into the air by implementing more stringent controls than required by a permit or an applicable regulation.
[0216] “entity” shall mean any person, group of persons, company, division, agency, partnership or other entity (private or government). Entity includes, without limitation, an installer, dealer, manufacture and distributor of the CPE.
[0217] “escrow” shall mean any documents, real property/estate, money, or securities deposited with a neutral third party (the escrow agent) to be delivered upon fulfillment of certain conditions, as established in a written agreement.
[0218] “excess power” shall mean the power generated by the CPE that exceeds the power consumed by the consumer. Excess power is also referred to as “net power.”
[0219] “expected net present value of net cash flows” shall mean the expected sum of the present values of the cash flows associated with a CPE and a consumer.
[0220] “expected sunlight” (at the CPE) shall mean the sunlight that is predicted to shine upon the CPE at a given period of time.
[0221] “federal tax credits” shall mean any credits offered by a Federal entity to a consumer to offset any income tax due.
[0222] “FICO score” (Fair Isaac Company score) shall mean the mathematical model that is used as a tool by lenders to evaluate the risk associated with lending to an entity money.
[0223] “financial instrument” shall mean any real or virtual document representing a legal agreement involving some sort of monetary value. Such financial instrument can be classified as equity based, representing ownership of the asset, or debt based, representing a loan made by an investor to the owner of the asset. Financial instruments shall include “notes.” Financial instruments are also known as securities.
[0224] “flood certification fee” shall mean the fee to cover the cost (normally $10-$30) of a report to determine if the property is in a flood-risk area as determined by The Federal Emergency Management Agency (FEMA).
[0225] “funding fee” shall mean a fee paid for a loan. The fee is used to identify the fee paid to the VA for issuing their guarantee. Also may be applied to an additional fee paid for funding a conventional loan, typically a commercial loan, at closing
[0226] “future estimated market price” shall mean an estimation of the market price of a commodity for example in the future. For the purposes of this application, it is the price that the consumer can sell (or buy) a certain amount of power at a certain point in time.
[0227] “future net cash flows” shall mean costs to maintain, and cash flows produced by power generated by the CPE.
[0228] “general obligation bond” shall mean a common type of municipal bond in the United States that is secured by a state or local government's pledge to use legally available resources, including tax revenues, to repay bond holders.
[0229] “generation capacity (CPE)” shall mean the maximum power a CPE can generate in a given period of time.
[0230] “green tag credits” (also known as renewable energy credits (RECs)) shall mean tradable renewable credits or certificates (TRCs)).
[0231] “grid congestion credits” are a mechanism that represents certain benefits associated with generating electricity from renewable energy sources. Grid congestion credits function as a credit or subsidy for a reprieve on local grid congestion.
[0232] “housing” shall mean any protective cover designed to contain or support something tangible including, without limitation, electricity. The housing segregates the electricity (for example) contained in the housing from other electricity.
[0233] “housing security interest” shall mean a security interest in a housing.
[0234] “income-to-debt-ratios” is a calculation of a person's monthly payments (minimum credit card payment, student loans, car loan, and in some circumstances, rent/mortgage) in proportion to your gross monthly income. For the purpose of this application, utility bills are monthly payments.
[0235] “independent power producer” shall mean any entity that generates electricity and then sells the power in wholesale markets (e.g., California's PX)
[0236] “independent power production credits” shall mean the value in aggregating individual consumer power generation and selling it for more than the value of selling it as un-aggregated power.
[0237] “installer” shall mean any party that installs CPE for a consumer.
[0238] “interest” shall mean the fee that is charged by a lender to a borrower for the use of borrowed money, usually expressed as an annual percentage of the principal.
[0239] “intervention” means the ability (i.e., the right) to interfere with a consumer's ability to use the CPE to generate power.
[0240] “intervention security interest” means a security interest in the rights in intervention in the CPE
[0241] “investors” shall mean any entity that commits money to investment products, financial instrument or security with the expectation of financial returns.
[0242] “late fees” shall mean any money assessed for failing to pay an amount due by a specified period of time.
[0243] “latitude” shall mean the angular distance North or South from the Earth's equator measured in degrees on the meridian of a point.
[0244] “lending underwriting criteria” shall mean any and all credit information (1) furnished by the borrower (consumer) including employment history, salary and financial statements, (2) publicly available information including the borrower's credit history, which is detailed in a credit report, (3) the lender's evaluation of the borrower's credit needs and ability to pay and the consumer's credit score.
[0245] “lending underwriting standards” shall mean the principles by which the lending underwriting criteria shall be judged in connection with the repayment of a loan.
[0246] “lending underwriting” shall mean or refer to the detailed rules and credit analysis preceding the granting of a loan. Such analysis includes a thorough review of lending underwriting criteria.
[0247] “loan amount” shall mean the amount of money offered to a consumer for the purchase of property including, without limitation, the CPE.
[0248] “loan” shall mean an arrangement in which a lender gives money to a borrower (the consumer), and the borrower agrees to return the property or repay the money, usually along with interest, at some future point(s) in time. Generally the lender has to bear the risk that the borrower may not repay a loan. A loan is evidenced by a specific financial instrument (or financial instruments).
[0249] “longitudinal (longitude)” shall mean the angular distance between a point on any meridian and the prime meridian at Greenwich.
[0250] “long-term lease” shall mean a lease whose term is enough time from initial signing until the date of expiration or renewal option that is qualifies for tax deductibility.
[0251] “manually implementation” shall mean the performance of any method or steps of a method by manual means (human).
[0252] “manufacturer” shall mean any entity that builds and/or assembles a product. For the purpose of this application, a manufacture is the producer of some or all of the CPE.
[0253] “market interest rates” shall mean the rate of interest paid on deposits and other investments, determined by the interaction of the supply of and demand for funds in the money market.
[0254] “mixed manually and computer implementation” shall mean the performance of a method or one or more steps thereof by both manual (human) interaction and computer execution.
[0255] “mortgage broker or lender fee” shall mean a charge, usually measured by points, made by the mortgage broker for originating the loan. The fee is included in closing costs. The fee is the same as a loan origination fee for a bank.
[0256] “mortgages” shall mean a debt financial instrument by which the borrower (mortgagor or consumer) gives the lender (mortgagee) a lien on property as security for the repayment of a loan.
[0257] “naked power” shall mean electricity (i.e., electrons) separate and apart from the power attributes associated with the power. Naked power is measured in units such as Watts or Kilowatts.
[0258] “negative excess power” shall mean power generated exceeding the power consumed.
[0259] “negative consumed power” shall mean power used by a consumer in excess of the power generated by the CPE.
[0260] “net metering” shall mean a mechanism that is used as a utility resource usage and payment scheme in which a consumer who generates their own power is compensated monetarily for the excess of the power generated by the CPE over the power used by the consumer.
[0261] “net cash flow” shall mean the cash flows experienced by a consumer including the initial investment in a CPE, costs to maintain, and cash flows produced by power generated by the CPE.
[0262] “notary fees” shall mean the fee covering the cost of having a person who is licensed as a notary public swear to the fact that the persons named in the documents did, in fact, sign them.
[0263] “note” shall mean a financial instrument or debt security that matures on a date set forth in the note. A loan might consist of or be supported by one or more notes.
[0264] “orientation” shall mean the latitude and longitudinal coordinates of the CPE.
[0265] “ownership interest” shall mean any interest in a business as a shareholder in a company that carries on the business or partner in a partnership that carries on the business or the sole proprietor of the business, including interest held indirectly through one or more intervening companies, partnerships or trusts.
[0266] “payment streams” shall mean cash flow associated with a CPE.
[0267] “perfecting” is a means by which a lender establishes superior rights in collateral against any third parties.
[0268] “personal property” shall mean property of any kind except real property. Personal property may be tangible, having physical existence, or intangible, having no physical existence, such as financial instruments. Personal property shall include, without limitation, CPE, CPE attributes, rebates, credits subsidies, receivables and cash flow.
[0269] “personal property security interest” shall mean a security interest in personal property.
[0270] “pest & other inspection fees” shall mean the cost of termite and residence inspection.
[0271] “physical meter readings” shall mean meter readings performed manually.
[0272] “postage/courier fee” shall mean the charge for the costs of sending documents to various parties using couriers or express mail services. These costs are generally based on actual usage and will generally be higher when the process is rushed, but some lenders may use a fixed charge.
[0273] “pool of individual loans” shall mean a grouping of individual loans. The individual loans may consist of one or more notes. For the purposes of this application, the purpose of the loans is for the purchase of CPE.
[0274] “power” (also known or referred to as “electricity” or “energy”) shall mean any thing or characteristic relating to power, including, without limitation, power attributes and naked power.
[0275] “power attributes” shall mean the attributes or characteristics of power that are transferable separate and apart from the actual naked power itself. Power attributes are also referred to as attributes.
[0276] “power attribute security interest” shall mean a security interest in a power attribute.
[0277] “power contracts” shall mean a contract between the producer of power and a resident consumer of power.
[0278] “power grid” (also known as the “power transmission and distribution grid,”
[0279] “electric grid” or “grid”) shall mean the network of transmission and distribution lines (and the step-up and step-down transformers) that is used to deliver electricity to consumers.
[0280] “power interruption contract” is a contract between a power generator and a consumer that allows the provider to interrupt power to the consumer during peak periods of demand in exchange for better electricity rates.
[0281] “power proxy” shall mean a representative of the monetary value of power generated (over a set time period). Power proxy shall include, without limitation, receivables, cash flow, power, regulatory rights in power generated by the CPE and intervention rights in the CPE.
[0282] “power proxy security interest” is a security interest in a power proxy.
[0283] “power purchase agreement” shall mean an agreement between a power provider and a consumer in which the power provider (e.g., utility) agrees to, among other things, reimburse, credit or otherwise pay a consumer for power generated by the consumer's CPE. Power purchase agreements typically involve a business consumer and extend for a long period of time.
[0284] “power security interest” shall mean a security interest in power.
[0285] “power usage or power consumed” shall mean power used or consumed over a period of time. Its units are Kilowatt-hours.
[0286] “principal” shall mean the amount of a debt on which interest is calculated.
[0287] “private activity bond” shall mean a bond for which more than 10% of bond proceeds are to be used directly or indirectly in a trade or business carried on by persons other than governmental units, and for which more than 10% of the debt service on the bonds is directly or indirectly secured by a private business.
[0288] “processing fee” shall mean fees involving validating customer information and coordinating third-party findings so that an underwriter can make a decision to approve the application.
[0289] “progress payments” shall mean payment made as work progresses or purchases are made under a contract.
[0290] “public utility commission” (also known as a PUC) is a regulatory body in every state in the U.S. that governs public utilities within its jurisdiction such as electricity, gas, oil, sewer, water, transportation and telephone service. Some states call it the Public Service Commission (PSC).
[0291] “real property” shall mean the land as well as any permanent fixtures on it including buildings, trees and other fixtures.
[0292] “real property security interest” shall mean a security interest in real property, including without limitation, consumer premises.
[0293] “rebates” shall mean a deduction from the amount due or a return of part of an amount given in payment.
[0294] “receivables” shall mean any payment, instrument or other valuable consideration owed to a consumer (or other entity) for the power generated by the CPE, whether or not such payment, instrument or other valuable consideration is currently due. The receivables may be provided by a utility or other entity. Receivables shall include, without limitation, any credit, money certificate or other quantifiable value for power generated by a CPE.
[0295] “receivables security interest” shall mean a security interest in receivables.
[0296] “reconveyance fee” shall mean fees for recording a document that shows a previous loan has been paid in full.
[0297] “recording fee” shall mean the non-tax fee for the cost of actually recording a mortgage loan.
[0298] “regulatory constraints” shall mean the constraints or rules imposed by a governmental entity.
[0299] “regulatory rights” shall mean any rights provided by a regulatory entity.
[0300] “regulatory security interest” shall mean any enforceable claim against a consumer that is created by debiting a consumer's bill.
[0301] “remarketing costs” shall mean the expenses incurred in the process of reselling foreclosed upon CPE.
[0302] “renewable energy” shall mean power supplied by energy sources that are naturally and continually replenished such as wind, solar power, geothermal, hydropower, and various forms of biomass.
[0303] “renewable energy source” shall mean sources of renewable energy such as water (hydroelectric power), wind, biomass and solar energy.
[0304] “resale of CPE” shall mean the act of selling the CPE again.
[0305] “revenue bond” shall mean bonds whose principal and interest are payable exclusively from earnings of a public enterprise.
[0306] “royalty credits” shall mean the cash flow associated with a royalty interest.
[0307] “royalty interests” shall mean a payment made for the use of property. The payment amount is usually a percentage of revenues obtained through its use.
[0308] “salvage value” shall mean the market value of a depreciable asset (e.g., CPE) at the time it is sold or removed.
[0309] “scheduled PUC prices” shall mean the prices planned by a PUC at specified times.
[0310] “securing” shall mean the step or steps of taking a security interest in collateral.
[0311] “securities” shall mean financial instruments.
[0312] “security interest” shall mean any interest in a property that secures the payment of an obligation. The property subject to a security interest is often times called collateral. Security interests shall include attaching the security interest in the collateral and perfecting the security interest.
[0313] “settlement: escrow/attorney fees” shall mean the fee that pays for the services of the escrow or settlement agent who handles all the financial transfers, plus payments associated with the transaction. In some states, an attorney performs the functions of an escrow agent.
[0314] “state recordation agency” shall mean the governmental entity of a State in which a record or other required document should be filed.
[0315] “state tax credits” are credits offered by a State to a consumer to offset any income tax due.
[0316] “subsidies” shall mean a monetary grant given by government to lower the price of a good such as CPE, generally because they are considered to be in the public interest.
[0317] “supporting a loan” shall mean character of a borrower, the collateral and associated cash flow.
[0318] “survey fee” shall mean the fee charged for an expert examination of the property, aimed at discovering any structural flaws or repairs needed.
[0319] “tax service fee” shall mean fees for a search of the Registry of Deeds for the county in which the property lies is conducted to confirm that taxes on the property are paid in full and up to date. Any unpaid property taxes are a liability to the lender.
[0320] “third party credits” shall mean credits provided to consumers by third parties.
[0321] “timing of power generated” shall mean the time at which power is generated by CPE.
[0322] “timing of power used” shall mean the time at which power is used or consumed by a consumer.
[0323] “title insurance fee” shall mean the fee for insurance which protects the lender (lender's policy) or the buyer (owner's policy) against loss due to disputes over ownership of a property.
[0324] “title insurance” shall mean the insurance that protects both the lender and the homeowner (borrower) against loss resulting from any defects in the title or claims against a property that were not uncovered in the title search and that are not specifically listed as exemptions to the coverage on the title insurance policy.
[0325] “title search” shall mean the process of examining all relevant records to confirm that the seller of a property is the legal owner of that property and that there are no liens or other claims outstanding.
[0326] “title work fee” shall mean the fees involving title search, plat drawing, name search and the like.
[0327] “tradable renewable credits” (also known as TRCs, renewable energy credits, RECs, renewable tradable certificates, green tags, green tag credits and green tickets) shall mean any and all awards, credits and/or other consideration representing the value for the attributes associated with power generated by a renewable energy (“green”) source. These attributes can be unbundled (i.e., separated) from the underlying power itself (naked power) and sold independently as a discrete, tradable instrument to entities that value “greenness.”
[0328] “traditional escrow requirements” shall mean any customary or conventional escrow requirements associated with a transaction involving real property.
[0329] “tranche” shall mean a class of security or ownership interest in a CPO offering.
[0330] “UCC1 filing” shall mean a UCC1 statement that is filed with the secretary of state or other designated public official under the Uniform Commercial Code (UCC). The document is time stamped, the filing date is noted, and a file number is assigned, securing the lender's claim to the assigned collateral.
[0331] “UCC1 statement” (also known as a financing statement) is a standard document under the Uniform Commercial Code, and this document is an agreement between a lender and borrower detailing, among other things, property taken as collateral from the borrower.
[0332] “underwriting fee” shall mean fees for underwriting. This covers the costs of assessing an applicant's qualifications for a mortgage loan.
[0333] “undivided interest” shall mean a complete or partial ownership of all parts of a whole. For example, an undivided interest in a pool of loans means the ownership or rights to a certain percent of each and every loan in the pool.
[0334] “usury laws” shall mean laws or regulations that prohibits a rate of interest on a debt that is exorbitant and in excess of the percentage allowed by law.
[0335] “utility” shall mean any entity that purchases, sells or markets power to (or from) the consumer of power or has the primary relationship with that consumer.
[0336] “utility credits” shall mean any credit offered by a utility, usually for public policy reasons.
[0337] “value of attributes of power generated” shall mean the monetary quantity assigned to the attributes of power generated by CPE.
[0338] “value of power attributes” shall mean the monetary quantity assigned to the power attributes of power generated by CPE.
[0339] “warehouse receipts” shall mean any document guaranteeing the existence and availability of a given quantity and quality of a commodity in storage for safekeeping.
[0340] “water reflection” shall mean the image of something as reflected by water. The image includes sunlight.
[0341] “wire transfer fee” shall mean the fee when a loan funds. It is a common practice for a lender to wire the funds to the settlement provider (escrow holder, title company, or attorney). This is a fast and efficient way to transfer funds in a transaction where time is crucial. | The present invention teaches a variety of systems and methods enabling renewable energy consumer premises equipment (CPE) such as dual metering techniques. The present invention contemplates, among other things, supporting, by increasing a likelihood of meeting financing obligations, a consumer purchasing, leasing, installing and/or maintaining renewable energy CPE for power generation at a consumer premises. The renewable energy CPE may be attached to a structure on the consumer premises, disposed free standing on the consumer premises, or utilized through any other suitable means on the consumer premises. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to a communication technique used in a wireless communication system and, more particularly, to a receiver for processing a received signal from a base station.
BACKGROUND OF THE INVENTION
[0002] A communication system is formed, at a minimum, of a base station and a mobile station, which are interconnected by way of a communication channel. Information to be communicated by the base station (also referred to as cell site) to the mobile station is transmitted via the communication channel to the mobile station. A wide variety of different types of communication systems have been developed and are regularly utilized to effectuate communication of information between base stations and mobile stations.
[0003] A wireless communication system, is an example of a communication system, which has been made possible due to advancements in communication technologies. Various standards have been promulgated relating to various types of wireless communication systems, and various types of wireless, as well as other, communication systems have been constructed, corresponding to such standards. The IS-95 and IS-2000 interim standards, promulgated by the EIA/TIA, are exemplary of standards which pertain to a wireless communication system, utilizing code division multiple access (CDMA) communication techniques.
[0004] Enhanced 3 rd Generation CDMA systems are currently being developed to address high speed Internet packet data services. Examples of such systems, which are the result of an evolution of IS-95 and IS2000, are 1XEV-DO (TIA/EIA/IS-856) and 1XEV-DV standards. These systems utilize both CDMA and some type of time division multiplexing communication techniques.
[0005] In an effort to port the Internet to the wireless communication system, 1 XEV-DO and 1 XEV-DV systems use a fat data pipe concept, which is shared among a number of users (mobile stations). The fat pipe, called the shared supplemental channel, is de-multiplexed into several code channels according to the usual CDMA access techniques. In the current proposal for 1XEV-DV, for example, the pipe is actually transmitted on 14 or 15 Walsh codes of length 16.
[0006] In high data rate systems, it is assumed that low mobility prevails and the use of soft handoff is not needed. Also, use of soft handoff would reduce the data rate capacity of the system. Therefore, a fast cell site selection is performed in the network, aided by measurements made at the mobile station. However, the mobile station can only assist the BS by sending information on the reverse link. Because of impairments on the reverse link, the BS may actually select a less then preferred cell site. instead of the preferred target cell site
[0007] In the high data rate, the shared supplemental channel is shared among a number of mobile stations in accordance with CDMA and TDMA communication techniques. The base station has an admission control algorithm such that the base station decides 1) when to transmit data packets to a particular mobile station; 2) the modulation type and coding rate; 3) the Walsh codes (among the 14 or 15 available) that will be assigned; and 4) the cell site that will transmit the data packets.
[0008] The BS simultaneously transmits the data packet, intended for the mobile station, on the supplemental channel and a signaling frame on the dedicated channel. This signaling frame provides the mobile station information such as 1) whether a data packet was sent to that MS; 2) the modulation type and coding rate used; 3) the Walsh codes; and 4) which cell site is transmitting on shared supplemental channel. Upon reception of a signaling frame, the mobile station decodes the dedicated channel and determines if there was a data packet for it on the shared supplemental channel. Thus, the mobile station is expected to buffer the received shared supplemental channel information in order to be able, after the fact, demodulate and decode the share supplemental channel. Generally, the dedicated channel and all the supplemental channels are de-spread to retrieve necessary information and all the expanded information is stored is a buffer. Generally, the buffer size required depends on the number of fingers needed, the number of Walsh channels, the sampling rate, etc. Since the mobile station must de-spread all the Walsh channels to determine if a data packet is transmitted for that MS, a large buffer size is needed, even if only one Walsh channel may apply.
[0009] Therefore, it would be useful if method and apparatus was provided to manage the buffering and processing of signals that would require less storage space and processing time.
SUMMARY OF THE INVENTION
[0010] The present invention, accordingly, advantageously, provides apparatus, and an associated method by which received communication signals are first stored in RAM and then processed.
[0011] The present invention encompasses a receiver having a buffer storing a received signal and replaying the received signal to process only a necessary portion of the signal. The buffer may comprise a plurality of buffers, wherein a received signal for a current frame is stored in a first buffer and a second buffer is used to process the signal received in a previous frame. According to an aspect of the invention, the received signal is stored in buffer prior to de-spreading the signal, thereby, advantageously requiring less storage space for the buffer. Once the signal is stored for a frame, during the next frame the signal may be evaluated to determine is any data for the mobile station has been transmitted on a shared supplemental channel. The signal is further processed only if data packets for that mobile station have been transmitted on the shared supplemental channel. Otherwise, advantageously, no further processing is performed on the signal to find data.
[0012] A more complete appreciation of the invention and to the scope thereof can be obtained from the accompanying drawings, the detailed description of the presently preferred embodiments of the invention, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 illustrates a block diagram of an exemplary receiver used in a wireless communication system;
[0014] [0014]FIG. 2 illustates a flowchart for a method of operating a reciever;
[0015] [0015]FIG. 3 illustrates a block diagram of a second embodiment of a receiver used in a wireless communication system; and
[0016] [0016]FIG. 4 illustates a flowchart for method of operating a receiver according to a second embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0017] [0017]FIG. 1 illustrates an exemplary wireless communication system 100 . The communication system 100 provides for radio communication between two communication stations, such as a base station 102 and a mobile station 104 , by way of radio links formed therebetween. The mobile station 104 is configured to receive and transmit signals to communicate with plurality of base stations, including base station 102 . In the exemplary embodiment shown in the figure, the communication system 100 operates according to the specification proposed for 1XEV-DO (approved version IS-856/TSG-C C.S0024 ver 2.0, published 10/2000) and 1XEV-DV (current proposal # C05-20010611-007 MNTIPA — 1 XEV-DV L1 Framework) communication system, which utilizes CDMA communication techniques. It should be understood that operation of the embodiment of the present invention is similarly also possible in other types of radio, and other, communication systems. Therefore, while the following description shall describe operation of an embodiment of the present invention with respect to the 1XEV-DO or 1XEV-DV systems, operation of an embodiment of the present invention can analogously be described with respect to any of various other types of communication systems.
[0018] The base station 102 , is coupled to a base station controller (BSC) 140 . And, the base station 102 is, in turn, coupled to a mobile switching center (MSC) 142 . The MSC is coupled to a network backbone, here a PSTN (public switched telephonic network) 144 , and correspondent node (CN) 146 is coupled to the PSTN 144 . A communication path is formable between the correspondent node 146 and the mobile station 104 by way of the PSTN 144 , the MSC 142 , the BSC 140 and base station 102 , and a radio link formed between the base station and the mobile station. Thereby, the communications, of both voice data and non-voice data, are effectual between the CN 146 and the mobile station 104 . In the exemplary implementation as shown in the figures, the base station defines a cell, and numerous cell sites are positioned at spaced-apart location throughout a geographical area to define a plurality of cells within any of which the mobile station 104 is capable of radio communication with an associated base station to communication therewith.
[0019] In the operation of the communication systems 100 according to 1XEV-DO and 1XEV-DV systems, the base station 102 transmits spread spectrum signals to mobile station 104 on what is generally known as the forward link. In general, the forward link transmission comprises a plurality of frames defined by the proposed system specification. In the exemplary communication system, the signals are received substantially during the reception a frame on plurality of channels (forward link channels), generally comprising signals for a pilot channel, control channels, supplemental channels and dedicated channels. The supplemental channels comprise interleaved and spread data signals. The dedicated channel comprise signaling information about the data transmitted on the supplemental channels.
[0020] The base station 102 broadcasts on the forward link channels, for example, on a pilot channel, a paging channel, a control channel, a dedicated channel and a plurality of supplemental channels. Generally, all the supplemental channels are spread using a Walsh Code in a process known as Walsh covering. Additionally, all the channels are modulated using a modulation-coding scheme (MCS) having a modulation type and coding rate. The modulation schemes are defined by the type of system, such as 1-XEVDO or 1XEV-DV, wherein each mobile station, in communication with one or more base stations, provides information, such as Carrier to Interference ratios (C/I) or Signal to Noise Ratio (SNR), to assist base stations in determining modulation type and coding rate.
[0021] In the exemplary communication systems, the supplemental channels are shared among a plurality of mobile stations (MS), including mobile station 104 . The base station 102 operates according to an admission control algorithm which determines, when to transmit data packets to a particular mobile station, what modulation type and coding rate is used, which Walsh codes will be assigned to the mobile station, and which base station of the system will transmit. In the exemplary communication system according to 1XEV-DV, the supplemental channels typically comprise up to 16 channels (Walsh channels), wherein any one of the channels may contain a packet of data for a particular mobile station. Each of the Walsh channels is spread using a different Walsh covering.
[0022] In the exemplary communication systems, the base station simultaneously transmits a packet of data and signaling information. The signaling information indicates to the mobile station 104 that the packet of data is sent to the mobile station 104 . The signaling information to determine the processing of supplemental channels, wherein the signaling information comprises the modulation type and the code rate, the Walsh codes that are utilized, and which base station is transmitting on the supplemental channels.
[0023] The mobile station 104 , operable in 1XEV-DO and 1XEV-DV systems, comprises an antenna 106 , a front end filter 108 , an analog to digital (A/D) converter 110 , a Random Access Memory (RAM) 112 , a Rake receiver 118 , an Interpolator 128 , a Master controller 130 and a decoder 132 . The antenna 106 receives radio frequency (RF) signals (forward link) from the base station 102 and from other base stations in the vicinity. The received RF signals are converted to electrical signals by the antenna 106 and provided to the front end 108 . The front end 108 filters the signals and provides conversion to baseband signals. The baseband signals are provided to the AD converter 110 , which converts the baseband signals to digital signals for further processing.
[0024] In accordance with the an embodiment of the invention, the received signal (also referred to as current frame signal) is stored in Random Access Memory (RAM) 112 prior to any de-spreading of the signal. The RAM 212 comprises first and second buffers 114 and 116 . In an exemplary embodiment, the first buffer 114 may be used to store a current frame signal and the second buffer 116 may be used to store a previous frame signal. The master controller 130 , coupled to the RAM 114 , comprises logic to toggle the use between first buffer 114 and second buffer 116 . Because the signal is stored before de-spreading the signal, the memory size requirement is significantly less then if the signal was stored after de-spreading the signal. Since, the converted signal is stored in the buffer 114 or buffer 116 prior to de-spreading, advantageously system time tick 2 samples per chip may be used. Therefore, for example, the buffer size of first and second buffers, 114 and 116 , may be 98304 bits or 12.3 kbytes, generally calculated using 6144 (chips)×2 samples×4 bits×2 (I and Q) equaling to approximately 98304 bits. It should be noted that size of the RAM 112 , the first and second buffers, 114 and 116 , might vary based on the manufacturers desired sampling rate and other factors.
[0025] The Rake receiver 118 is a conventional receiver comprising a sample selector 120 , a correlator 122 , a Walsh de-spreader 124 and a symbol combiner 126 . The Rake receiver 118 processes the signal received on the dedicated channel to determine signaling information and sends the signaling information to a master controller 130 . Using well-know techniques, the Rake receiver 118 , extracts all the information necessary for master controller 130 to efficiently evaluate the supplemental channel data stored in RAM 112 . The signaling information generally comprises an indication that a packet data for a particular mobile station is on the supplemental channel. The signaling information further comprises the Walsh codes, the number of supplemental channel, modulation type and coding rate used by the BS. Additionally, the signaling information may comprise a system time counter, pseudo-random noise states and Long code states.
[0026] The master controller 130 comprises logic to control the operations of all the components of the receiver. The master controller 130 includes a clock 131 . The clock controls timing of the mobile station 104 . The master controller 130 is coupled to the other elements of the mobile station 104 and such interconnections are not shown so as to not unduly complicate the drawing figure.
[0027] In an operation of an embodiment of the present invention, for every frame, the conventional rake receiver 118 of the receiver 104 , processes the dedicated channel of the received signal. The rake receiver 118 extracts the signaling information for the current frame and sends the signaling information to the master controller 130 via the decoder 132 . Simultaneously, the signal, which contains all channels, including the supplemental channels, is stored in RAM 112 . The master controller 130 determines which one of the buffers, first buffer 114 or second buffer 116 , to use. Generally, one buffer is used to store current frame signal and the other buffer is used to store previous frame data. Simultaneously, the master controller 130 having soft information from the previous frame, replays the previous frame data stored in RAM 112 to process the data using the soft information. The master controller 130 only replays the stored data, if the soft information indicates that a packet data for mobile station 104 is in the signal received on the supplemental channel. The master controller 130 determines which buffer to use for storing the current frame signal.
[0028] The master controller 130 comprises logic to decode the signaling information comprising the modulation type, coding rate, the Walsh codes assigned to the mobile station and the base station that transmitted the data. Using the Walsh code assignment extracted from the soft information, the master controller 130 processes the control channel and thereafter despreads the supplement channels to extract the data packets as defined in the 1XEV-DO and 1XEV-DV specification. The master controller 130 also comprises logic to control the operation of the interpolator 128 for generating the best sampling instant for the correlator 122 . The master controller 130 uses the signaling information from Rake receiver to program the interpolator 128 .
[0029] An interpolator 128 may be single hardware unit, used in a time divisional method (i.e. time shared). The interpolator 128 according to invention, controlled by a master controller 130 , for generating best sampling instances.
[0030] [0030]FIG. 2 illustrates flowcharts of tasks, generally shown as 200 , 250 and 270 , which are executed simultaneously during each frame. In the preferred embodiment of the invention the master controller 130 simultaneously executes tasks, 200 and 250 , and the Rake receiver 118 executes task 270 . Task 200 handles the reception of the communication signal during the current frame 201 and task 250 handles the processing of the stored signal. Task 270 handles the extraction of signaling information from the signal received during the current frame.
[0031] The signal reception task 200 is initiated for every frame upon the raw signal being converted to a digital signal. At block 202 , the digitally converted signal is received. At block 204 , the received signal is stored in RAM 212 prior to the de-spreading of the signal. When storing the signal in RAM 212 , the master controller uses the first buffer 114 and the second buffer 116 . In the preferred embodiment, for every frame, master controller 130 toggles the use between the first buffer 114 and the second buffer 116 when storing the received signal. For example, in any given frame the master controller 130 may read from the first buffer 114 and write in the second buffer 116 , then toggle for the next frame such that master controller 130 is now reading from the second frame 116 and writing in the first frame 114 .
[0032] The signal-processing task 250 is initiated for every frame upon start of each frame. At block 252 , the master controller 130 replays the signal stored in the previous frame (also referred to as, previous frame signal) and processes the stored signal using the signaling information received from the conventional rake receiver 118 . At block 256 , using the signaling information, the master controller 130 determines if there is a data packet for this mobile station on any of the shared supplemental channels. If yes, then at block 258 , the master controller 130 de-spreads the stored signal using signaling information, such as the Walsh codes and other information. Thereafter, the master controller 130 processes the control channel, the supplemental channel and decodes the data using the signaling information.
[0033] The signaling information extraction tasks 270 is initiated for every frame upon the raw signal being converted to a digital signal. At block 272 , the rake receiver 118 , using well-known techniques, generally defined in the standards, extracts the signaling information from the dedicated channel of the current frame signal. At block 274 , the rake receiver provides the signaling information to the master controller 130 .
[0034] [0034]FIG. 3 shows a mobile station 300 according to a second embodiment of the present invention. In this Figure, components, which are similar to those described with reference to FIG. 1, have been numbered with like reference numerals. In addition to the components described in the mobile station 104 , the mobile station 300 according the second embodiment, further comprises a control channel decoder 302 . The control channel decoder is coupled to the analog to digital (A2D) converter 110 and master controller 330 . In an operation according to the second embodiment, the A2D converter 110 sends the converted signal to the control channel decoder 302 , the Rake receiver 118 and stores the signal in RAM 112 . The control channel 302 processes the control channel of the received signal and provides the information to master controller 330 to use during next frame processing. Simultaneously, the Rake receiver 118 processes the received signal to extract signaling information of the current frame. In the second embodiment, the master controller 330 , uses the signaling information from Rake receiver 118 to determine is the there is any data packets for this mobile station.
[0035] The operations of the master controller 330 are similar to that described for master controller 130 , except for the following. Since master controller 330 receives the control channel information from the control channel decoder 302 , the master controller 330 does not process the control channel. At the start of the frame the master controller 330 replays signal and de-spreads the supplement channels to extract the data packets. The data packets are processed according to proposed standards. This embodiment offers an advantage of faster data packet processing, since the control channel decoder 302 processes the control channel information in the previous frame which is used by the master controller 330 .
[0036] [0036]FIG. 4 illustrates flowcharts of tasks according to the second embodiment, generally shown as 200 , 270 , 450 and 480 , which are executed simultaneously during each frame. In this Figure, tasks, which are similar to those described with reference to FIG. 2, have been numbered with like reference numerals (for example tasks 200 and 270 ).
[0037] In the second embodiment of the invention the master controller 130 simultaneously executes tasks, 200 and 450 . The Rake receiver 118 executes task 270 and the control channel decoder 302 executes task 480 . As described in FIG. 2, task 200 handles the reception of the communication signal during the current frame 201 and task 270 handles the extraction of signaling information from the signal received during the current frame. Task 450 handles the processing of the stored signal and task 480 handles the processing of the control channel.
[0038] The signal-processing task 450 is initiated for every frame upon start of each frame. At block 452 , the master controller 130 replays the signal stored in the previous frame and processes the stored signal using the signaling information received from the conventional rake receiver 118 . At block 456 , using the signaling information, the master controller 330 determines if there is a data packet for this mobile station on any of the shared supplemental channels. If yes, then at block 458 , the master controller 330 de-spreads the stored signal using signaling information, such as the Walsh codes and other information. Thereafter, the master controller 330 processes the supplemental channel and decodes the data using the signaling information.
[0039] The control channel-decoding task 480 is initiated for every frame upon the raw signal being converted to a digital signal. At block 482 , the control channel decoder 302 , decodes the received signal of the current frame to process the control channel information. At block 484 , the control channel information is sent to the master controller 330 .
[0040] While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. That is, other modifications and variations to the invention will be apparent to those skilled in the art from the foregoing disclosure and teachings. Thus, while only certain embodiments of the invention have been specifically described herein, it will be apparent that numerous modifications may be made thereto without departing from the spirit and scope of the invention. | The present invention encompasses an electronic device operated in a communication system (for example 1XEV-DO, 1XEV-DV, CDMA, etc). The electronic device receiving a signal from a base station, the signal containing signaling information and data packets. The electronic device processing portion of the signal during the current frame and simultaneously storing the received signal prior to de-spreading, for further processing during the following frame. The electronic device further processing previously stored signal, during current frame. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to information processing systems and methods for transferring to, and updating information on, information handling systems such as spreadsheets, word processors, and the like, with information from web pages, other unstructured flat files, structured data sources such a databases, and other sources.
[0003] 2. Description of Related Art
[0004] Computer users have a need to take data from web pages, databases, or other data sources, and incorporate specific data items in an information handling system such as a spreadsheet, word processing document, etc. The displayed information can be organized in rows and columns or other dimensional formats. A columnar presentation is the natural presentation for a spreadsheet program. The foregoing presentation may include a word processing document that contains a table, a presentation graphics file with a table, a word processing bookmark, or a database organized into fields and records.
[0005] Referring to the prior art method of FIG. 1, a user can employ an ordinary browser 1 to operate over the Internet 2 and designate an Internet data source 3 by specifying a URL (Uniform Resource Locator), address, or file name. By formulating an appropriate web query 4 , the user can retrieve the data into an Internet browser (operation 5 ) or other similar software program.
[0006] Next, using the Windows® clipboard, or a similar program, a user can extract (copy) the required information from the browser as shown in operation 6 . The user would then paste the data into a separate document that can be used by, for example, spreadsheet application 7 . If the structure of the data on the web page, or other similar document does not match the organization of the end document, multiple copy and paste operations would be required.
[0007] More sophisticated users might import the entire web page into a spreadsheet and then provide “links” to the required areas of the document. The term “links” refers to a memory-addressing scheme that allows an item in one document to be tied to another item so that when one item changes, the item linked to it also changes. While minimizing the copy and paste method, this approach still requires the user to enter a web address, copy and paste the data into a spreadsheet, and manually insert “links” for each data item required. This is still a very labor intensive operation. Many documents may require multiple web pages imported for a single update.
[0008] In commercially available spreadsheet programs (e.g., the Excel™ spreadsheet program) one can create web queries that allow one to fetch data over the World Wide Web and automatically load this data into a spreadsheet. To use this feature one must be skilled in writing statements in HTML (hyper text markup language). This requires a specialized skill that many users will not have the time or desire to acquire.
[0009] Commercially available programs can be modified with “add-ins.” For example, objects are available for the Excel™ spreadsheet to assist a software designer who wishes to create such an add-in. Existing development tools can create add-ins for other applications. At a more fundamental level, a component object model (COM) has been developed, which defines a standard for software objects that can be used as components in software from third parties unrelated to the object developer. This COM standard has been applied across many platforms and forms the basis for more sophisticated techniques for establishing communications or a server-client relationship between different software programs. These various techniques offer tools that are understood by sophisticated software programmers and do not form a basis for allowing ordinary users of applications to extend the capability of those applications.
[0010] In U.S. Pat. No. 5,437,006 an Excel™ spreadsheet program allows user-defined macros to call DLLs, which are then able to call back to the spreadsheet program to change its state or use its various functions or commands. This reference shows general-purpose tools and is not arranged to enable a non-specialist to fetch and display data in a running application in a simple fashion.
[0011] In U.S. Pat. No. 6,078,924 applications such as Word™, Excel™, or PowerPoint™ can be extended with menus and buttons enabling a user to gain access to a database maintained by a catalog server and information server. The user can request that the catalog server obtain information from the World Wide Web and store the collected information in the database. This system can parse the information obtained over the Internet. The catalog server acts as an intermediary and retrieves data over the Internet according to its own search schedule. Operation of this system requires the deployment of a large scale, specialized database and is not designed to easily allow a single user to directly handle information currently available from the Internet and other sources without an intermediary.
[0012] In U.S. Pat. No. 5,983,268 a user can access a specialized web server over the Internet using a conventional browser. The user can identify certain web pages, which are then presented to the user who can then mark the data of interest. The web server will record marker information around the selected data so just the selected data can be parsed and retrieved later. The selected data can be later presented to the user in a spreadsheet format so the user can perform calculations based on various cells in the usual manner. Again, this system requires the deployment of a sophisticated server and is not designed to allow the user to directly handle information currently available from the Internet and other sources without an intermediary.
[0013] In U.S. Pat. No. 5,319,777 a number of personal computers are connected through a LAN to one or more table servers. Each of the PCS can run a conventional spreadsheet program. This system is designed to fetch existing tables and does not consider rearranging information to accommodate a user's preferences for display in a spreadsheet program or other application.
[0014] In U.S. Pat. No. 5,893,079 users at various workstations can send queries to a database over a network that can use TCP/IP. The user has a spreadsheet interface and can export the fetched data to a conventional spreadsheet program, such as the Excel™ program. This is a cumbersome approach requiring the user to switch from the downloading application to a spreadsheet application. Once the spreadsheet program is launched, the user is then faced with rearranging the downloaded data to meet personal preferences.
[0015] See also U.S. Pat. Nos. 5,819,271 and 5,864,871 (users access word processing documents or spreadsheet files over the Internet using a conventional browser; U.S. Pat. No. 5,381,470 (database created by accessing a computerized auto-dialer, and creating reports using conventional spreadsheet packages); U.S. Pat. No. 5,361,393 (accounting data is entered into a conventional spreadsheet program before being uploaded into a central database); U.S. Pat. No. 5,937,155 (planning software with spreadsheet-like interface); U.S. Pat. No. 5,293,615 (integration of a database and spreadsheet program). U.S. Pat. No. 5,784,545 (a spreadsheet program); U.S. Pat. No. 6,061,695 (a Windows® desktop is produced from a hypertext page); U.S. Pat. Nos. 5,778,357 and 5,414,838 (a query language for a database); and U.S. Pat. No. 5,297,032 (trading data is delivered to workstations on the trading floor).
SUMMARY OF THE INVENTION
[0016] In accordance with the illustrative embodiments demonstrating features and advantages of the present invention, there is provided an object for enhancing an application. The enhanced application permits a user to enter or retrieve at least one ordinary expression for processing and display. The object is capable of accessing a data source and has a query generator, a composer, and an interface. The query generator can (a) read the ordinary expression, and (b) request information from the data source based on the ordinary expression. The composer can receive requested information from the data source in response to the query generator and transfer the requested information to the application for processing and display alongside the ordinary expression. The interface can allow the user to adjust where the application will display the requested information.
[0017] In accordance with another aspect of the invention, there is provided a method for enhancing an application. The enhanced application permits a user to enter or retrieve at least one ordinary expression for processing and display. The method is performed with a data source and includes the step of electronically reading the ordinary expression. Another step is requesting information from the data source based on the ordinary expression. The method also includes the step of receiving requested information from the data source. Another step is automatically transferring the requested information to the application for processing and display alongside the ordinary expression. The method also includes the step of allowing the user to specify in advance of a request, where the application will display the requested information.
[0018] By employing objects and methods of the foregoing type an enhanced system can be achieved for updating tabular forms, or documents (FIG. 2, item 8 ), including the ability to automate and simplify the method of collecting, organizing, and posting information. The information may originate from a variety of sources including the Internet, databases, text files or other data sources. The preferred system presents a graphical user interface 8 A (FIG. 2) for the user to control the data retrieval process, and select document format options. This includes options for the user to select data from the document or file, query the underlying data source 9 , select data items returned from the data source, and determine the relative placement of these data items in the underlying document or file.
[0019] In a preferred embodiment of the present invention a software program (referred to herein as an object) will run concurrently with the underlying information handling program (referred to herein as an “application”), such as a spreadsheet, word processor, database software, etc. The preferred software object typically runs as a background program, and is conventionally referred to as an “add-in,” which may be called as needed by the user. Once invoked, this software object will present a graphical user interface that allows the user to control the retrieval and posting of data to the underlying document or file.
[0020] The document or file to be updated may be organized into a dimensional structure such as a spreadsheet containing rows and columns. The preferred graphical user interface provides a means to identify data from within the document or file for querying the data source. For instance, a specific range from a spreadsheet may be specified which contains items that can be indexed to the underlying data source. The interface also provides the ability to select items from the data source that are associated with this index. This includes the means to select any number of these items, (in any sequence and order). Additionally, the interface provides the ability to specify the relative placement of the returned items in the document.
[0021] Preferably, the software object provides a means to automatically connect to the underlying data source and the ability to query the source based on the data specified in the underlying document or file associated with the running application. For instance, in the case of the Internet as a data source, the software has the ability to download a web page and parse and search the retrieved page for requested information. In the case of a database, the software has the ability to connect to the database and return data based on specific queries. It is highly desirable however, for the data source to be indexed on a specific item, and information associated with the items are returned based on this index. Once data is collected from the data source, it is posted in the document or file as specified by settings made in the user interface.
[0022] Other preferred features include the storage and recall of system settings associated with a particular document or file; the ability to undo changes made thereto; the choice of the originating data source; and other formatting options. The system is non-invasive and does not require the user to alter the underlying document or file in any way, and offers other significant automation advances when compared to the prior art.
[0023] The invention may be embodied in a software object that consists of all or part of the following elements:
[0024] 1. An interface component for identifying the first data record to be updated and whether data for that record are to be organized in rows or columns. All additional data records are referenced relative to the first record. This first row or column already contains information to create the request for information to the data source. The data source will then return the additional data record items required by the document or file. For example, this process may consist of a dialog that allows the user to “point to” or reference the first symbol in a table. In a spreadsheet, this would be a cell reference, such as “D3”. Another dialog box or software element may be used to specify row or column orientation.
[0025] 2. A series of dialogs or other interface components for the user to select the data items to be retrieved and their sequence. For instance, in the case of data associated with a stock symbol, the user could choose to retrieve the last price and volume out of a list of ten data items. Multiple lists are provided to allow the user to select any item in any order.
[0026] 3. A dialog or other interface component that allows an offset to be specified for all data items relative to the first data item. This allows the items to be arranged in a non-sequential order as needed by the user. This offset option can be set positive or negative, relative to the first data item.
[0027] 4. Software used to capture the data from the data source. In the case of a web page, this may be the components of a web browser, a socket or other software to retrieve the required data directly into the underlying document or file. It also may be a program that retrieves data from a database or other structured or non-structured data source.
[0028] 5. Software that can parse a retrieved web page and update the document or file based on the data requested through the user dialogs.
[0029] 6. A series of dialogs or other interface components that allows the user to store and recall settings for multiple documents rather than always requiring manual recreation of these settings.
[0030] The present invention may also offer the following desirable features in order to enhance performance, power, and flexibility:
[0031] 1. Select whether the program will add formatting or rely upon the user formatting in the underlying document or file.
[0032] 2. Specify the source of the data. Specifically, a single interface may be used to interface with multiple data sources.
[0033] 3. Refresh the data by re-executing the query.
[0034] 4. Execute elements that link (or undo) the underlying document or file back to the data source to retrieve data that may exist in other formats or related data. In the case of a stock symbol, the user could “point” to a symbol and then by selecting this function, retrieve a web page that displays company news for this symbol.
[0035] 5. Use a “command bar,” “toolbar,” or other software element that groups these additional functions in a convenient format for the user.
[0036] 6. Automatically generate the data request and subsequent document updating at specified intervals. For example, one could update the specified document or file at intervals of 5 seconds without the user having to take any further action.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] The above brief description as well as other objects, features and advantages of the present invention will be more fully appreciated by reference to the following detailed description of presently preferred but nonetheless illustrative embodiments in accordance with the present invention when taken in conjunction with the accompanying drawings, wherein:
[0038] [0038]FIG. 1 is a graphical illustration of a process that can be conducted using techniques conventional in the prior art;
[0039] [0039]FIG. 2 is a high-level diagram of an application enhanced with a software object and capable of implementing a method in accordance with principles of the present invention;
[0040] [0040]FIG. 3 is a block diagram of equipment capable of implementing the enhanced application of FIG. 2;
[0041] [0041]FIG. 4 is a more detailed diagram of the system architecture of the enhanced application of FIG. 2;
[0042] [0042]FIG. 5 is a diagram of the graphics associated with the interface of FIG. 4;
[0043] [0043]FIG. 6 is a flowchart associated with the software of FIG. 4; and
[0044] [0044]FIG. 7 is a detail of the menu and toolbar of the enhanced application of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0045] Referring to FIG. 3, a user's computer 40 is shown with conventional input/output devices; namely, monitor 42 , keyboard 44 , and pointing device (mouse) 46 . The computer 40 has its own non-volatile memory 40 A; for example, a hard drive. Memory 40 A can contain one or more of a variety of applications, such as, spreadsheet programs, word processing programs, database programs, etc. Memory 40 A can also contain a variety of files that may represent word processing documents, spreadsheets, or database files. The various items in memory 40 A can be opened by a central processing unit in computer 40 in the conventional manner.
[0046] Computer 40 is shown connected in a network along network cable 48 , which connects to other networked computers as indicated by phantom lines 50 . Network cable 48 can also connect through router 52 to other networks. A server 54 is shown connected to network line 48 to supply various services to computers on the network. Server 54 can act as a file server and also as a database server for permitting access to database 56 .
[0047] The network is also shown connecting to another server 58 , which acts as a router and provides a gateway and firewall between network cable 48 and the Internet 60 . Accordingly, computer 40 can access the Internet 60 through server 58 to obtain information in the usual way. A web server 62 is shown being accessible over Internet 60 . Web server 62 makes available a database 64 . In this embodiment database 64 contains financial information correlated to stock symbols, although other classes of data may be offered by different web servers established for different purposes.
[0048] In other embodiments, computer 40 may be a personal computer (PC) that is not part of a network. This PC may in some instances gain access to a global communications network, such as the Internet, through an individual DSL line, cable access, high-speed T 1 line, or dial up connection.
[0049] In the present, exemplary embodiment, computer 40 may run a spreadsheet program, which processes and displays information in the form of a number of spreadsheet cells identified by coordinates (for example, A 1 for the cell at the intersection of first row and first column).
[0050] This spreadsheet program is enhanced by an add-in. This add-in can be loaded by selecting it from a drop-down menu in the interface of the spreadsheet program itself, or by pre-configuring the spreadsheet program (or by using a platform registry) so that the add-in is automatically loaded whenever the spreadsheet program is launched. Alternatively, a separate, freestanding program can be launched that may (a) link to and obtain service from a spreadsheet program using, for example, an OLE protocol; or (b) permit two-way communications with a spreadsheet program using, for example, a DDE protocol or other protocol permitting communications and providing spreadsheet services. In still other embodiments the spreadsheet program can provide a “hook” that allows an independent program written in a native programming language to temporarily gain control of a process before returning control back to the original application.
[0051] Referring to FIG. 4, a system architectural diagram is given of an object that enhances a spreadsheet program, which spreadsheet is schematically indicated herein as table 66 . The software object is composed of several modules offering various services and functions. A service access module 68 is shown with a query generator 70 coupled to a data source 72 in order to fetch information therefrom.
[0052] In instances where information is obtained over the Internet, query generator 70 will produce a URL annotated with user input information designed to elicit specific information from a web-based data source 72 (e.g., web server 62 of FIG. 3). In other instances, query generator 70 can produce a database query using, for example, a SQL command. In the latter case the data source 72 may be a database accessible through a database server over a network (e.g., database server 54 of FIG. 3), or a database file that is available on the hard drive of a user's PC (e.g., database file in hard drive 40 A of FIG. 3).
[0053] Information returning from the data source 72 is delivered to a composer. 74 / 76 . This composer is shown receiving information from data source 72 into a formatter/parser 74 , which feeds its output to a data writer 76 . Component 74 can parse information to isolate the requested information from other information that is returned by the data source 72 . In the situation where the data source is providing web pages fetched over the Internet, parsing is performed by pre-programming component 74 with information about the layout of the web page being returned. For example, component 74 may extract a data block appearing after a specific keyword; or may extract data strictly based on its position in a specific string. After parsing and extraction, component 74 can also format the extracted information, that is, establish a font, an alignment, etc.
[0054] The composer's data writer 76 is shown communicating with the spreadsheet table 66 . As described further hereinafter, cells in the spreadsheet will be populated with data obtained from the service access module 68 .
[0055] A graphical user interface 78 is shown communicating with the query generator 70 and data writer 76 . Interface 78 is shown with a data items selector 20 , which enables a user to designate up to n data items representing different data types. As explained further hereinafter, these data types can correspond to categories of financial information about stocks or other securities; for example: price of last trade, change in share price, percentage change in share price, etc. It will be appreciated that other classes of information can be specified for interfaces designed to fetch a different category of information.
[0056] Interface 78 provides a number of components that the user can selectively operate. With component 10 the user can identify a “first symbol” position. As shown in table 66 the first column is a list of symbols, the first (Fl) being “IBM.” The user can identify this first symbol Fl either by pointing to it with a mouse or by explicitly entering its coordinates.
[0057] With component 12 the user can specify whether the previously mentioned symbols are arranged in a row or column. In the example given for table 66 , the symbols are arranged in a column and are ordinary expressions (i.e., they are not programming code and are ordinary terms in the relevant field; here, securities trading). Other options are provided as generally indicated by component 11 , which will be explained in further detail presently.
[0058] Previously mentioned data items selector 20 has associated therewith components for setting a spatial offset for the n data items. As explained further hereinafter, the cells in table 66 need not be populated by writing in sequence into the cells next to the symbols (in the example of table 66 , the symbols are in the column of symbols that starts with first symbol Fl). Instead, components 16 can be used to specify an offset value indicating the number of cells to skip before writing the data for the associated data type.
[0059] A number of features are provided by component 24 . The upper block shows a document selector that enables a user to save and recall various settings that were entered through components 10 , 11 , 12 , 16 , and 20 . This feature allows the user to store in memory settings for multiple documents. The lower block indicates an undo feature that allows the user to reverse the most recent changes to the settings of components 10 , 11 , 12 , 16 , and 20 . Basically, the interface stores previous settings in a data cache and restores them when requested by the undo function.
[0060] This system is described within the context of an example application, consisting of a portfolio of individual securities, updated from a web page or pages. The foregoing assumes the following are available:
[0061] 1. Web pages or other data sources. In each case the data source 72 will deliver the requested data in response to a query or other request from the user. For instance, in the case of a stock symbol Fl used as a query term, a web page can be fetched that shows items such as last price, high, low, volume, etc. In general, the structure of the data from the underlying data source is transformed to match the structure of the data required in the end user's document or file.
[0062] 2. A document or file prearranged into a dimensioned or structured format (such as rows and columns) and requiring information from the underlying data source. In one example, this may be a stock portfolio presented in a spreadsheet that requires the price data so that its total value would reflect the latest data.
[0063] 3. A predetermined row or column in the document or file, which will be used to index the row/column data items to the data source. For example, the stock symbols in the first column can be used to create a query to the data source for High, Low, Close, etc.
[0064] Referring to FIG. 5, the graphical presentation is given for the interface (interface 78 of FIG. 4). The graphical features corresponding to software components previously illustrated in FIG. 4, will bear the same reference numeral where appropriate. The interface offers the following components and features:
First Symbol Location
[0065] The user enters in data entry box 10 the coordinates of a cell, such as a column/row reference from a spreadsheet or the column/row cell references defined in a table in a word processing document. The symbols entered in a cell may represent securities listed on the various exchanges for stocks, bonds, futures, etc.
Symbol List
[0066] Symbols may be listed in either a column or row format. The user indicates a preference in one of these two orientations by checking the appropriate radio button 12 A or 12 B. The returned data will then be presented using the column or row format if button 12 A or 12 B is checked, respectively.
Quote Data Field(s) Location
[0067] The software data writer has the ability to place retrieved data in specified fields relative to the selected first symbol location placed in box 10 . Specifically, by checking button 14 A, the returned data will be placed in the nearest cell location relative to the first symbol location specified in box 10 , proceeding along a row or a column, depending on whether button 12 A or 12 B is checked. For example, if the user's array of query data are arranged in a column of stock symbols, and specified as such by button 12 A, then the returned data will be laid out perpendicular to the column, i.e., in a row. In other examples the roles of the column and row can be interchanged if button 12 B is selected. In any event, the present software will overwrite any existing data that may be in one of the receiving cells if button 14 A is selected.
[0068] If button 14 B is selected instead, the returned data will be written in the nearest blank cell relative to the first symbol location specified in box 10 , proceeding along a row or column, depending on whether button 12 A or 12 B is checked.
[0069] If button 14 C is selected instead, ten additional data field entry boxes are deployed, as indicated by the boxes 16 , shown in phantom. These boxes 16 will switch from inactive and hidden to active and visible when button 14 C is checked. This mode offers an offset feature that allows the user to place the retrieved data somewhere other than a default location. The offset value will be entered in the data field entry box 16 as a numeric integer value, signed negative numeric values being permitted.
Data Fields
[0070] The user has the ability to select up to ten data fields for retrieval, although a different number may be available in other embodiments. Here ten drop-down selection boxes 20 are provided, marked with the numeric indicia 1 through 10 . By clicking the drop-down button on the right end of the box 20 , a list of data types will be displayed. For this embodiment, which concerns securities data, the possible types of data include: (a) last trade, (b) change, (c) percent change, (d) bid, (e) ask, (f) open, (g) previous close, (h) today's high, (i) today's low, (j) 52-week high, (k) 52-week low, (l) volume, (m) average volume, (n) market capitalization (millions), (o) price/earnings ratio, (p) annual dividends per share, (q) ex-dividend date, (r) dividend yield, (s) market (exchange), (t) date of last sale, (u) time of last sale, and (v) source of displayed data.
[0071] Some embodiments may offer a shorter list that includes a subset of the foregoing list, possibly supplemented with other data types. Other embodiments will offer a longer list that may include supplementary or substitute data types. The supplementary or substitute data types may include: (a) size of last sale, (b) volatility, (c) earnings, (d) shares outstanding, (e) earnings per share, (f) dividend amount, (g) dividend frequency, etc. In some embodiments, different ones of the selection boxes 20 may have a different drop-down list. In other embodiments unconcerned with securities, a completely different list of data types will be offered.
[0072] The order in which the data is displayed is based on the sequence of fields selected with the selection boxes 20 (with exception noted below). Thus, in the example of FIG. 2 the returned data types will be displayed in the following sequence: “last trade,” “change,” and “% change,” in that order. The sequence can be overridden when the data field location offset is selected (button 14 C). In that case blank fields 16 appear adjacent to the ten main data selection boxes 20 . The user manually enters the desired numeric values for the offset (including possible negative offsets), which then controls the location of the displayed output without regard to its position in the sequence of selection boxes 20 .
Headings
[0073] The user can select either one of the two yes/no buttons 18 to indicate a preference for column (row) headings for displaying the names of the data fields selected by boxes 20 .
Format
[0074] The user selects one of the two yes/no buttons 22 to indicate a preference for the presentation of data. The data can be displayed in either free form (“no” button 22 ), or formatted to significant decimal positions (“yes” button 22 ).
Session Commands
[0075] The foregoing selections can be saved so they can be recalled for use as a template in new projects or for reuse in a previously configured document or file that was already setup in an earlier session. The following session commands are available to the user for such purposes:
[0076] The Select button 24 A will pop up a dialog box to allow the user to select a stored configuration. The Save button 24 B will pop up a dialog box so the user can store the selection criteria of the current session. This dialog box will prompt the use for a name under which the configuration will be saved.
[0077] The Default button 24 C allows the user to store the current configuration as the default values that will be used in new sessions, until changed by the user in that session. The application comes with several input and output settings stored as default values, but those values can be overridden with this feature. The user can select the most common usage of the session commands and save it as a default command with this feature. This enables the user to restore those favorite without remembering the name of the store.
[0078] The Delete button 24 D will pop up a dialog box to allow the user to select a stored configuration and delete this stored session command. The Save As button 24 E will pop up a dialog box to allow the user to save a previously stored configuration under a new name.
[0079] The Undo button 24 F reverses the most recent changes to the settings of FIG. 5 and restores the prior settings.
Operation
[0080] To facilitate an understanding of the principles associated with the foregoing apparatus, its operation will be briefly described in connection with the operations of FIG. 6. The sequence of FIG. 6 is not a simple flowchart, but a hybrid showing a specific sequence of operations that the user may actually choose to exercise when taking advantage of the interface of FIG. 5. In step S 1 the interface of FIG. 5 is popped up either by selecting a menu item (from menu bar MN of FIG. 7) or by clicking icon 82 on the toolbar TB of the spreadsheet program. The user can obtain help on using the interface by clicking on button 26 (FIG. 5). Alternatively, the user can cancel the interface by clicking on button 28 .
[0081] In step S 3 of FIG. 6 the user may restore previously saved sessions by operating select button 24 A (FIG. 5). A dialog box will pop-up and display session commands previously saved under names chosen by the user.
[0082] Assuming the user has not restored (or is not satisfied with) previously saved session commands through button 24 A, the user may now select a first symbol location, as indicated in step S 5 . Specifically, the user may type in box 10 (FIG. 5) the coordinates of a specific spreadsheet cell (e.g., the coordinates of cell Fl of FIG. 4).
[0083] Alternatively, the user may click on selection box 10 A. In response, the dialog box of FIG. 5 will collapse to a narrow box to make the underlying spreadsheet cells visible. Also, the cursor will change to a special symbol; for example, a large “X”. The user may click the special cursor on the first symbol (for example symbol Fl of FIG. 4). The symbol becomes highlighted and the user may now click the collapsed, narrow dialog box to restore it to full-size.
[0084] In step S 7 of FIG. 6 the user can select one of the radio buttons 12 A or 12 B (FIG. 5) to indicate whether the symbols are listed in a column or row, respectively. In the example of FIG. 4, the symbols are listed in a column.
[0085] In step S 9 of FIG. 6 a user can specify certain writing options by selecting one of the radio buttons 14 A through 14 C (FIG. 5). Overwriting will occur with button 14 A, but with button 14 B cells will be skipped to avoid overwriting cells containing data. If button 14 C is selected, boxes 16 are deployed so that the user can specify a cell offset.
[0086] In step S 11 of FIG. 6 a user can specify whether the information displayed through this program will be formatted (predetermined fonts, alignment, etc.) by using radio buttons 22 (FIG. 5). Also, the user can specify whether this program will automatically provide headings for each of the columns (or rows) of data returned to the spreadsheet program by using radio buttons 18 (FIG. 5).
[0087] In step S 13 of FIG. 6 the user can specify what data source will supply the requested data. A dialog box (not shown) can pop-up and offer a number of data sources. For example, the user can select any one of a number of displayed web sites. Also, the user can select whether data will be obtained over the Internet, over a network from a local or remote database server, from a database file contained on the user's computer, etc. As needed, the user can supply a URL, domain name, network address, gateway, password, etc. The user can also be given the ability to add the identity of data sources that have not been pre-programmed into this software.
[0088] In step S 15 the user will operate the data fields selection boxes 20 (FIG. 5). By clicking the drop-down button to the right of each of the individual boxes 20 , the user will be offered a drop-down menu listing data types as specified above. By highlighting one of the data types the user can add that data type to the user's selection. The user will make as many selections as needed. In this embodiment ten selections are possible (although the software can be operated multiple times to display more than ten data types in a single spreadsheet). In other embodiments a different total number of selections may be offered.
[0089] In step S 17 user may save the session by clicking on button 24 B (FIG. 5). This will save to the previously opened session file, or if none was opened, pop-up a dialog box that allows the user to select the name under which the session will be saved. If the user wishes, a previously opened session file can be saved under another name by clicking on button 24 E.
[0090] Once the various commands are established using the foregoing steps (or by relying on default settings, or on recalled sessions) the user may click on button 30 of FIG. 4 to operate the service access module 68 of FIG. 6, thereby invoking step S 19 . In the following step S 21 the query generator (generator 70 of FIG. 4) will read the symbols found in the symbol column, starting with symbol Fl of table 66 (FIG. 4).
[0091] Assuming data source 72 is a web site, query generator 70 will compose a URL that will include input data corresponding to the previously mentioned symbols. In the embodiment of FIG. 3 the request will be sent along network cable 48 to server 58 , which will transmit the request to Internet 60 . In this instance the URL points to web server 62 , which receives the query and examines the input data transmitted with the request. Server 62 will fetch appropriate data from financial database 64 .
[0092] In this embodiment, web server 62 will compose a web page using a markup language such as HTML, XML, or other languages. This web page will be composed primarily for display on a web browser. Thus, this web page will have much extraneous information. In particular, the web page may return every data type that the site offers, even though the user may only wish to review a subset of these data types. Also, this web page may present its data in columns, whereas the user wishes to view the information in rows. Moreover, the web page may present information concerning several stock symbols and this information may be presented in a consolidated table or in separate tables that are not arranged in a fashion desired by the user.
[0093] Accordingly, the parser/formattter 74 (FIG. 4) is executed in step S 23 of FIG. 6. Component 74 is pre-programmed with information about the layout of this web page. For example, component 74 may expect this web page to start one of its lines with a stock symbol followed by a predetermined sequence of data types concerning that stock symbol. Alternatively, a line of stock symbols may be followed by successive lines, each containing just one data type in the same sequence as the stock symbols.
[0094] In any event, the present program may store the requested information in arrays for use later during the writing process. The data may be formatted at this time. For example, certain information may be presented in a currency format and the type point size may be reduced for numbers having a large number of digits. If data is unavailable, an appropriate warning may be supplied for this item. Otherwise, the information will be formatted in the default format or the format specified by the user (font type, alignment, etc.).
[0095] In the following step S 25 data is written to the spreadsheet table 66 (FIG. 4) so that the user can review the output in step S 27 . The table 66 of FIG. 4 is a simple presentation where the user does not provide any of the displayed information except for that appearing in the symbol column containing first position Fl. Thus, the four following columns including their headings are provided by the present software object.
[0096] In some instances, the user will wish to provide additional information, such as the number of shares owned by the user for each of the stock symbols. Accordingly, Table 1 shows a situation where the user has prepared the first two columns: (1) the stock symbols (IBM, GE, XOM), and (2) the number of shares owned (250, 100, 300), including the heading for the second column, “No. Shares.” The user also supplied the banner heading, “John User's Stock Portfolio.”
TABLE 1 JOHN USER'S STOCK PORTFOLIO No.Shares Last Trade Value Change % Change Open IBM 250 89.100 22275.00 0.020 0.02 89.120 GE 100 37.700 3770.00 −1.300 −3.33 38.750 XOM 300 77.700 23310.00 −2.110 −2.64 79.750 49355.00
[0097] In this example, the user has also created a fourth column having the heading “Value.” The three illustrated cells under this heading (referred to herein as a derived sites) each contain a formula to obtain the product of the numbers in the two cells to the left in that row (those two cells referred to herein as source sites). For example, the number of shares of GE (100) is multiplied by the price at the last trade (37.7) to calculate the displayed value of 3770.00.
[0098] The user has also placed a formula at the foot of the fourth (“Value”) column. Specifically, this formula calculates the sum of the three numbers immediately above. Accordingly, the user will see the value of each share, the value of the user's holdings for each company, and the total value of all holdings. Using vector notation, if the numbers of the second and third columns are considered vectors, their scalar product (dot product) would equal the total value appearing at the bottom of the fourth column.
[0099] To avoid overwriting the user's input, the present program should not write information indiscriminately to the right of the first column. Using normal procedures, the user will identify the first symbol position as that cell containing the stock symbol “IBM.” Then, the user can select button 14 B (FIG. 5) so that information will not be written over the second column entitled, “No. Shares.” Instead, the software will skip the second column and begin writing information in the third column. The software will also notice that formulas appear in the fourth column and will skip that column as well. Therefore, the software will next write in columns 5-7.
[0100] Alternatively, the user can select button 14 C of FIG. 5 in order to specify specific offsets. Consequently, the offset entry boxes 16 will appear. The user will insert “2” in the first box so that the first data type will be offset two columns and be written therefore in the third column. Next, the user can specify an offset of “4” for the second data type. The offset for the third data type will be “5,” and so forth.
[0101] For the example given in Table 2 the user has specified that the symbols are listed in a row. In this instance the user will identify the first symbol location as that spreadsheet cell containing the symbol “UST.” If this first symbol is considered being in a first row, the second row is shown containing information entered by the user, namely, the number of shares owned by the user for each of the stock symbols. The fourth row has formulas. As before, this fourth row calculates the product of the two numbers immediately above to determine the value of the holdings of the company identified by the stock symbol. Also as before, the user can use the options offered by buttons 14 B or 14 C so that none of the numbers or formulas entered by the user will be overwritten. In this example the user also calculates the total value of all holdings by summing the values contained in the fourth row entitled “Value.” In order to make a more compact presentation, this total value appears in a formula located below the main body of the spreadsheet.
[0102] It will be noticed that the numbers and headings have been automatically formatted by the present software. In particular, the headings have been boldened and left justified while numbers have been right justified. The numbers in the penultimate row have distinct formatting that was applied by the present software. Specifically, the first two entries have a relatively small point size, and the last entry has a greater point size, but one that is still smaller than the other numbers in the other rows.
TABLE 2 MARY TRADER'S STOCKS Stock Symbol UST CIT SUN No. Shares 250 100 300 Last Trade 27,230 29,300 30,720 Value 6807.50 2930.00 9216.00 Change −0,430 −0,200 −1,760 % Change −1.55 −0.68 −5.42 Open 27,660 29,550 32,200 52-wk High 32,700 31,810 37,000 52-wk Low 13,870 13,310 23,750 Volume 933,800 2,544,700 620,500 Mkt Cap (mil) $1,212,470.00 $6,856,110.00 $729,590.00 Annual div/Shr 4436.50 7673.90 2604.87 Total Value $18,953.50
[0103] After one of the foregoing tables have been created it can be stored using the files save commands provided by the underlying (unenhanced) spreadsheet program. Thereafter, the user can recall the spreadsheet file to display all of the information previously obtained. After the user highlights the first symbol cell (for example, the cell containing the stock symbol UST in Table 2) the user can quickly update the table (update mode) by clicking the appropriate icon (item 80 of FIG. 7) on toolbar TB. Since all the configuration commands selected in the previous session have been restored with this file, the present program will immediately begin to update the spreadsheet display by fetching more recent information from the data source. If for some reason this updated information is not desired, the user can reverse the updating (undo mode) by clicking the undo icon (item 84 in toolbar TB of FIG. 7).
[0104] The user may also link to web sites having general information about the companies listed in this spreadsheet by highlighting one of the stock symbols. Next, the user can click the drop-down button 86 A of icon 86 and select one of the information sources displayed thereby. After selecting one of these sources the present program will automatically launch the default browser and the user can view the relevant information on web pages from this web source.
[0105] If the user wishes to change the configuration settings, the user can click icon 82 of toolbar TB to pop up the graphical interface of FIG. 5. The user can then change the complement of data fields previously selected or change other settings. Thereafter, the user can save these new sessions settings by clicking button 24 B.
[0106] The foregoing operations demonstrates many of the advantages of the present system. The updating of a document is done automatically without copy and paste operations by the user. The user is given the ability to create data requests without understanding programming or other structured requests or queries to the data source. The technique is also non-invasive. It does not require the user to import data or modify the underlying document with links.
[0107] The technique does not require the user to organize the document or file in an inflexible sequential order. In the foregoing examples, the user can insert a row or column that contains a formula showing the total amount of a stock position. The technique does not require the user to reorganize the document in any way to anticipate and accept the structure of the underlying web data source. Data can easily be arranged in any sequence within a row or column organization.
[0108] The technique provides a method to update multiple documents, each with a unique reorganization, without having to manually reprogram the software.
[0109] The user is able to query the data source by entering familiar, non-programming expressions in the underlying document or file. Such simple entries then enable the user to import data in a sophisticated way into a set spreadsheet, or other document. Also, the user can (a) choose the order and sequence of the retrieved data; (b) format and place the retrieved data in prescribed positions; (c) store user defined data format options for future use; (d) automatically refresh or undo changes from previous requests; and (e) link to and retrieve other pertinent information related to a document.
[0110] The system eliminates arduous collection methods that require users to navigate to select web sites in order to download data. The technique does not require the user to copy and paste data, insert links, or modify the document in the way required by the prior art.
Using the Invention in Other Document Types
[0111] This type of software object and method of updating tables can be used in applications other than spreadsheets. Tables in a word processing document or presentation program that have a column and row orientation may be updated just as described for the spreadsheet application.
[0112] Additionally, the foregoing may be used on one-dimensional arrays. Within a word processor document an item called a “bookmark” is used to locate a specific line and character position. All the bookmarks in a document can be organized into an array to form an index that lists all the bookmarks in a document in sequential order from beginning to end. This array can then be used by a software object such as an add-in program that runs concurrently with the word processor to insert text from a data source into the document.
[0113] One example of this would be an add-in program designed to insert data from a legal case history database into a word processing document. The database for this example is indexed by the name or citation of the case. Data items for each case may include such data as case history, other cases citing this case with treatment (approval/disapproval), summary, court, date of specified actions, parties' names, attorneys' names, prosecutor's name, judge's name, judgment, etc.
[0114] The add-in program would allow the user to define the bookmark where the name (or citation) of the case is to be inserted. A series of drop-down dialogs would then be used by the user to select the additional data items to be brought into the document. With each data item, the user would be able to select an offset number. This number would define the number of bookmarks between the “case name” bookmark and the bookmark for the data item.
[0115] As a specific example, consider a document organized into 10 bookmarks listed in order as (Bookmark 1 . . . Bookmark 10 ). The user would specify that Bookmark 3 is the location to find the case name (or citation). An additional data item could then be selected (such as the date of the case) by using a drop-down dialog box. Further a negative offset of −2 may be specified with the selected data item. This would insert the date of the case into Bookmark 1 .
[0116] In practice, given a limited number of bookmarks within a document, an alternative method of inserting data may be used. This alternative method would address the bookmark's absolute name rather than its relative position. As before, a series of drop-downs would be used to select the items from an organized data source that are to be inserted into the text document. Instead of an “offset.” an additional drop-down list could be presented for each data item listing all the bookmarks within the document. Each data item would then have a unique bookmark associated with it to identify where in the document it should be inserted.
[0117] It is appreciated that various modifications may be implemented with respect to the above described, preferred embodiment.
[0118] In some embodiments the software object may be structured as a plug-in that is used in a web browser such as Netscape Communicator™ or Internet Explorer™. This plug-in can be pre-programmed with information about the layout of certain web pages. The plug-in can parse the desired information identified by the user and display it in a fashion similar to that described above. In other embodiments the information obtained over the Internet can be organized using XML (extended markup language) so that the data source provider can identify the information of interest so that the user need not have detailed advance knowledge of the layout of a web page. In this situation the web browser may be enhanced to handle the specially tagged information with a plug-in. Alternatively, another application, such as a spreadsheet or database program, may be enhanced with the ability to fetch information over the Internet and process it appropriately using the XML tags.
[0119] In still other embodiments the present software object may be adapted to enhance any one a variety of applications, such as financial accounting software, communications software, personal database managers, email programs, graphics editing programs, etc. In other embodiments some of the features described above may be eliminated, and other features may be offered, such as automatic adjustment of column widths, alarms when a holding passes through a user-defined threshold, tips on trading securities (or some other topic), a selection of prototype spreadsheets (or database files, or word processing documents), etc. When using a prototype the user need not supply the symbols (such as the symbol Fl of FIG. 4); or prototype symbols may be offered as examples that the user will modify. Also, the present software object can respond to a single request by simultaneously retrieving and displaying information from different sources (for example, two Internet sources and a database maintained by the user).
[0120] There is no restriction on the types of data that can be requested and displayed. In some embodiments the user will be offered selections, so that the present software object will seek information of an alternate type; for example, sports statistics, movie theater showings and times, cultural events, election statistics, shopping information including comparative prices, etc.
[0121] In addition, the present software object can be run on a simple PC, a workstation, a terminal of a larger computer, etc. Furthermore, an application enhanced with the present software object needed not reside on the user's computer or terminal, but may run on a server accessible over a private network or over the Internet.
[0122] Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | A software object and method is arranged to enhance an application. The enhanced application permits a user to enter (or retrieve) for processing and display at least one ordinary expression, such as a stock symbol. The software object is capable of accessing a data source and employs a query generator, a composer, and an interface. The query generator can implement the processes of (a) electronically reading the ordinary expression, and (b) requesting information from the data source based on the ordinary expression. The composer can implement the processes of (a) receiving requested information from the data source in response to the query generator, and (b) automatically transferring the requested information to the application for processing and display alongside the ordinary expression. The interface can allow the user to adjust in advance where the application will display the requested information. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The subject patent application is a divisional application of U.S. patent application Ser. No. 10/818,961, filed on Apr. 6, 2004.
BACKGROUND OF THE INVENTION
[0002] 1) Field of the Invention
[0003] The subject invention generally relates to a lignocellulosic composite material and a method for preparing the lignocellulosic composite material. The subject invention also generally relates to a binder resin having at least one of an insecticide and a fungicide therein for forming the composite material.
[0004] 2) Description of Related Art
[0005] Composite materials, such as oriented strand board (OSB), medium density fiberboard (MDF), agrifiber board, particle board, flakeboard, and laminated strand board (LVL) are known in the art. Generally, these types of boards are produced by blending or spraying lignocellulosic particles or materials with a binder resin while the lignocellulosic particles are tumbled or agitated in a blender or like apparatus. Lignocellulosic particles generally refer to wood particles as appreciated by those skilled in the art. After blending sufficiently to form a uniform mixture, the particles are formed into a loose mat, which is compressed between heated platens or plates, or by steam injection between the two platens to cure the binder and bond the flakes, strands, strips, pieces, etc., together in densified form. Conventional processes are generally carried out at temperatures of from about 120 to 225° C. in the presence of varying amounts of steam, either purposefully injected into or generated by liberation of entrained moisture from the wood or lignocellulosic particles. These processes also generally require that the moisture content of the lignocellulosic particles be between about 1 and about 20% by weight, before it is blended with the binder resin to produce adequate physical properties of the composite material.
[0006] The lignocellulosic particles can be in the form of chips, shavings, strands, wafers, fibers, sawdust, bagasse, straw, wood wool, bamboo and the like, depending upon the type of composite material desired to be formed. When the particles are larger, the boards produced by the process are known in the art under the general term of engineered wood. These engineered woods include panels, plywood, laminated strand lumber, OSB, parallel strand lumber, and laminated veneer lumber. When the lignocellulosic particles are smaller, the boards are known in the art as particleboard and fiber board.
[0007] The engineered wood products were developed due to the increasing scarcity of suitably sized tree trunks for cutting lumber. Such products can have advantageous physical properties such as strength and stability. Another advantage of the engineered wood and particle boards is that they can be made from the waste material generated by processing other wood and lignocellulosic materials. This leads to efficiencies and energy savings from recycling processes, and saves landfill space.
[0008] Binder resin compositions that have been used in making such composite wood products include phenol formaldehyde resins, urea formaldehyde resins, melamine urea formaldehyde, and isocyanates resins. Isocyanate binders are commercially desirable because they have low water absorption, high adhesive and cohesive strength, flexibility in formulation, versatility with respect to cure temperature and rate, excellent structural properties, the ability to bond with lignocellulosic materials having high water contents, and no additional formaldehyde emissions from resin. The disadvantages associated with the use of isocyanates include difficulty in processing due to their high reactivity, too much adhesion to platens, lack of cold tack, high cost and the need for special storage.
[0009] It is known to treat lignocellulosic materials with polymeric diphenylmethane diisocyanate (polymeric MDI or PMDI) to improve the strength of the composite material. Typically, such treatment involves applying the isocyanate to the material and allowing the isocyanate to cure, either by application of heat and pressure or at room temperature. While it is possible to allow the polymeric MDI to cure under ambient conditions, residual isocyanate groups remain on the treated products for weeks or even months in some instances. It is also known, but generally less acceptable from an environmental standpoint, to utilize toluene diisocyanate for such purposes. Isocyanate prepolymers are among the preferred isocyanate materials that have been used in binder compositions to solve various processing problems, particularly adhesion to press platens and high reactivity.
[0010] In the past, various solvents have been added to binder resin with the aim of achieving a lower viscosity and better handling properties. After application, the solvent evaporates during the molding process, leaving the bound particles behind. One major disadvantage of prior art solvents is that they cause a reduction in the physical properties of the formed board including a reduction in the internal bond strength of the formed board.
[0011] Separately from the formulation of improved lignocellulosic composite materials, it is desirable to prevent insects from damaging the composite materials over time and during normal use. Those skilled in the art of insecticides have developed numerous insecticides that are capable of killing or intoxicating various insects once they are exposed to the insecticide.
[0012] While these insecticides have been very commercially successful in the agricultural applications, typical applications have encountered difficulty in applying them in lignocellulosic composite materials. Various methods have been employed to incorporate these insecticides into the wooden structures discussed above and any other wooden article. For example, various prior art methods dissolve an insecticide in a solvent, such as water, and spray the solution onto the wooden structure. The solvent then absorbs into the wood and prevents the insects from damaging the wooden structure. However, one drawback with spraying the solution on wood that is already formed is that over time, the insects will eat away at the wood and eventually get beyond the point where the solution has absorbed. At this point, the wooden structure is vulnerable to subsequent attacks by insects. Another drawback to this method is that any additional water added during formation of the composite material reduces the physical properties of the final composite material. During the pressing stage, steam pressure from any water present in the composite material tends to reduce the physical properties. Therefore, adding additional water would increase the steam pressure and further reduce the physical properties. Additionally, it is typical to dry the wood strands to lower moisture content at the beginning to minimize this effect, but this additional drying costs energy and time.
[0013] Other methods, especially used in the formation of plywood, include incorporating a powder insecticide directly into a glue or an adhesive. Plywood, or laminated veneer, is prepared by applying glue to an already formed layer of wood and compressing it together with another layer of wood. The glue, having the insecticide therein, is applied between the layers of the wood and is compressed to form the plywood. However, the insecticide is not present, i.e., dispersed, throughout the wood, since it is only located in the glue between the layers. Therefore, it is possible to have an initial infestation of insects eat through the glue layer exposing the unprotected wood underneath. Subsequent infestations of insects are then able to cause substantial damage because the insecticide has been removed. In this method, the plywood has not been made insect resistant, only the glue is insect resistant.
[0014] Still other methods have incorporated the insecticide by encapsulating the insecticide in a polyurethane. It is known that the dispersibility and dissolvability of certain insecticides, such as fipronil, is difficult to achieve in certain substances, such as water. Therefore, encapsulating the insecticide in polyurethane improves the dispersibility of the insecticide. However, the encapsulation restricts the direct contact of the insecticide with the insect and requires the insect, in addition to eating the wood, to eat through the polyurethane prior to reaching the insecticide. Therefore, encapsulating the insecticide is not desirable. Further, the additional steps required to encapsulate the insecticide increase the time and cost of production, which are commercially unacceptable.
[0015] Fungicides have also been used to treat lignocellulosic composite materials. Fungicides are substances possessing the power of killing or preventing the growth of fungus. Therefore, the fungicides reduce the likelihood that the composite material will decay as a result of fungus over time. However, the application of the fungicide has been limited in similar circumstances as the insecticides discussed above.
[0016] Accordingly, it would be advantageous to provide a lignocellulosic composite material that is insect and fungus resistant and that is capable of withstanding insect attacks over a longer period of time to prevent insect damage to the composite material. The related art methods that only apply the insecticide to the surface of the wood or in the adhesive layers between the wood are subject to subsequent insect attacks after the insecticide layer has been breached. Therefore, it is desirable to produce a lignocellulosic composite material that has the insecticide present in a low dosage and dispersed throughout the composite material for preventing insect attacks.
BRIEF SUMMARY OF THE INVENTION
[0017] The subject invention provides a lignocellulosic composite material formed from lignocellulosic particles and a binder resin. The lignocellulosic particles are used in an amount of from about 75 to 99.5 parts by dry weight based on 100 parts by weight of the composite material and the binder resin is used in an amount of from 0.5 to 25 parts by weight based on 100 parts by weight of the composite material. The binder resin comprises a polyisocyanate and at least one of an insecticide and a fungicide. The insecticide and the fungicide are dispersed throughout the polyisocyanate, which is then dispersed throughout the lignocellulosic particles. Since the insecticide and the fungicide are dispersed throughout the composite material, the composite material is insect resistant and/or fungus resistant to withstand a subsequent insect attacks and prevent fungus growth and decay.
[0018] The binder resin more specifically includes the polyisocyanate, a polar solvent, and the insecticide that is dissolved in the polar solvent to form an insecticide solution. The polar solvent is capable of dissolving at least 10 grams of the insecticide per one liter of the polar solvent. The insecticide solution is dispersed throughout the polyisocyanate to form the binder resin. Next, a lignocellulosic mixture is formed that comprises the lignocellulosic particles and the binder resin. The lignocellulosic composite material is formed by compressing the lignocellulosic mixture at an elevated temperature and under pressure.
[0019] The subject invention provides a lignocellulosic composite material having at least one of the insecticide and the fungicide dispersed throughout the composite material. The resultant composite material is insect and/or fungus resistant. The composite material is able to repel insect attacks and fungus decay throughout the life of the composite material. Since the insecticide is dispersed throughout, an initial infestation of insects is not able to breach an insecticide layer and any subsequent infestations of insects will suffer the same fate as that of the first. Therefore, the lignocellulosic composite material of the present invention enjoys a longer period of life because it is insect resistant.
DETAILED DESCRIPTION OF THE INVENTION
[0020] A lignocellulosic composite material and a method for preparing the lignocellulosic composite material are disclosed. The composite material includes lignocellulosic particles and a binder resin. Throughout the present specification and claims, the terms compression molded, compressed, or pressed are intended to refer to the same process whereby the material is formed by either compression molding the material in a mold or by using compression as between a pair of plates from a press. In both procedures, pressure and heat are used to form the material and to set the binder resin.
[0021] The lignocellulosic particles can be derived from a variety of sources. They can be derived from wood and from other products such as bagasse, straw, flax residue, nut shells, cereal grain hulls, and mixtures thereof. Non-lignocellulosic materials in flake, fibrous or other particulate form, such as glass fiber, mica, asbestos, rubber, plastics and the like, can be mixed with the lignocellulosic material. The lignocellulosic particles can come from the process of comminuting small logs, industrial wood residue, branches, or rough pulpwood into particles in the form of sawdust, chips, flakes, wafer, strands, medium density fibers (MDF), and the like. They can be prepared from various species of hardwoods and softwoods. The lignocellulosic particles may have a moisture content of from 1 to 15 weight percent. In a further preferred embodiment, the water content is from 3 to 12 weight percent, and most preferably from 4 to 10 weight percent. The water assists in the curing or setting of the binder resin, which is described further below. Even when the lignocellulosic particles are dried, they typically still have a moisture content of from 2 to 15 weight percent.
[0022] The lignocellulosic particles can be produced by various conventional techniques. For example, pulpwood grade logs can be converted into flakes in one operation with a conventional roundwood flaker. Alternatively, logs and logging residue can be cut into fingerlings on the order of about 0.5 to 3.5 inches long with a conventional apparatus, and the fingerlings flaked in a conventional ring type flaker. The logs are preferably debarked before flaking.
[0023] The dimensions of the lignocellulosic particles are not particularly critical. Flakes commonly have an average length of about 2 to 6 inches, and average width of about 0.25 to 3 inches, and an average thickness of about 0.005 to about 0.05 inches. Strands which are about 1.5 inches wide and 12 inches long can be used to make laminated strand lumber, while strands about 0.12 inches thick and 9.8 inches long can be used to make parallel strand lumber. The lignocellulosic particles can be further milled prior to use in the process of the invention, if such is desired to produce a size more suitable for producing the desired article. For example, hammer, wing beater, and toothed disk mills may be used.
[0024] In the subject invention, the lignocellulosic particles are present in an amount of from about 75 to 99.5 parts by dry weight based on 100 parts by weight of the composite material, preferably from about 80 to 99.5 parts by dry weight based on 100 parts by weight of the composite material, and most preferably 85 to 99.5 parts by dry weight based on 100 parts by weight of the composite material.
[0025] The binder resin includes a polyisocyanate and at least one of an insecticide and a fungicide. The binder resin is present in an amount of from 0.5 to 25 parts by weight based on 100 parts by weight of the composite material, whereby the remainder is the lignocellulosic particles. However, it is to be appreciated that other additives may be added, such as wax, flame retardant, and the like. In a preferred embodiment, the binder resin is present in an amount of from 0.5 to 20, and more preferably from 1 to 20 parts by weight based on 100 parts by weight of the composite material, and most preferably from 2 to 15 parts by weight based on 100 parts by weight of composite material.
[0026] The polyisocyanate that may be used in forming the binder resin includes aliphatic, alicyclic and aromatic polyisocyanates characterized by containing two or more isocyanate groups. Such polyisocyanates include the diisocyanates and higher functionality isocyanates, particularly the aromatic polyisocyanates. Mixtures of polyisocyanates which may be used include, crude mixtures of di- and higher functionality polyisocyanates produced by phosgenation of aniline-formaldehyde condensates or as prepared by the thermal decomposition of the corresponding carbamates dissolved in a suitable solvent, as described in U.S. Pat. No. 3,962,302 and U.S. Pat. No. 3,919,279, the disclosures of which are incorporated herein by reference, both known as crude diphenylmethane diisocyanate (MDI) or polymeric MDI (PMDI). The polyisocyanate may be an isocyanate-terminated prepolymer made by reacting, under standard conditions, an excess of a polyisocyanate with a polyol which, on a polyisocyanate to polyol basis, may range from about 20:1 to 2:1. The polyols include, for example, polyethylene glycol, polypropylene glycol, diethylene glycol monobutyl ether, ethylene glycol monoethyl ether, triethylene glycol, etc., as well as glycols or polyglycols partially esterified with carboxylic acids including polyester polyols and polyether polyols.
[0027] The polyisocyanates or isocyanate-terminated prepolymers may also be used in the form of an aqueous emulsion by mixing such materials with water in the presence of an emulsifying agent. The isocyanate compound may also be a modified isocyanate, such as, carbodiimides, allophanates, isocyanurates, and biurets.
[0028] Also illustrative of the di- or polyisocyanates which may be employed are, for example: toluene-2,4- and 2,6-diisocyanates or mixtures thereof; diphenylmethane-4,4′-diisocyanate and diphenylmethane-2,4′-diisocyanate or mixtures of the same, the mixtures preferably containing about 10 parts by weight 2,4′-or higher, making them liquid at room temperature; polymethylene polyphenyl isocyanates; naphthalene-1,5-diisocyanate; 3,3′-dimethyl diphenylmethane-4,4′-diisocyanate; triphenyl-methane triisocyanate; hexamethylene diisocyanate; 3,3′-ditolylene-4,4-diisocyanate; butylene 1,4-diisocyanate; octylene-1,8-diisocyanate; 4-chloro-1,3-phenylene diisocyanate; 1,4-, 1,3-, and 1,2-cyclohexylene diisocyanates; and, in general, the polyisocyanates disclosed in U.S. Pat. No. 3,577,358, the disclosure of which is incorporated herein by reference. Preferred polyisocyanates include polymeric diphenylmethyl diisocyanate and monomeric diphenylmethane diisocyanate being at least one of diphenylmethane-4,4′-diisocyanate, diphenylmethane-2,4′-diisocyanate, and diphenylmethane-2,2′-diisocyanate. Most preferably, the polyisocyanate component is polymeric diphenylmethyl diisocyanate. One example of a preferred polyisocyanate is, but is not limited to, Lupranate® M20 S, commercially available from BASF Corporation.
[0029] The polyisocyanate is present in the binder resin in an amount of from about 60 to 99.99 parts by weight based on 100 parts by weight of the binder resin. In a preferred embodiment, the polyisocyanate is present in an amount of from about 80 to 99.9 parts by weight based on 100 parts by weight of the binder resin, and most preferably from about 90 to 99.9 parts by weight based on 100 parts by weight of the binder resin.
[0030] Preferably, the insecticide is dissolved in a polar solvent to form an insecticide solution. The insecticide solution is then mixed with the polyisocyanate to form the binder resin with well-dispersed insecticide. It is to be appreciated that the fungicide may also be dissolved in the polar solvent to ensure that it is well dispersed. This mixing process may occur right before applying the resin to the wood substrates, such as using in-line mixing techniques before feeding the resin mixture into the blending equipment. The polar solvent is capable of dissolving at least 10 grams of the insecticide per one liter of the polar solvent.
[0031] In order to ensure that a sufficient amount of insecticide is added without adding too much polar solvent, the dissolvability of the insecticide is important. It is desirable to only add a low dosage of the insecticide that is sufficient to repel insect attacks. Therefore, it is important to ensure the low dosage is distributed throughout. If the solvent is capable of dissolving only less than 10 grams, then in order to have enough of the insecticide, more solvent would be needed. This creates the problem that the lignocellulosic composite material will not have sufficient physical properties, such as modulus of elasticity. When the lignocellulosic composite material is formed under elevated temperature, the solvent evaporates from the mixture. If too much solvent in added, the evaporating solvent creates a steam pressure within the forming lignocellulosic composite material and it hinders the physical properties.
[0032] It has been determined that certain polar solvents are capable of dissolving at least 10 grams of the insecticide per liter of solvent. For example, it has also been determined that water is not a sufficient polar solvent for certain insecticides, such as Fipronil, because it is capable of only dissolving 2.4 milligrams per liter of water. Generally, these polar solvents that are capable of dissolving at least 10 grams of the insecticide per liter are selected from at least one of an alcohol, a ketone, and an ester. More preferably, the polar solvent is selected from the group of octyl alcohol, isopropyl alcohol, methyl alcohol, acetone, carpryl alcohol, propylene carbonate, gamma-butyrolactone, 3-pentanone, 1-methyl-2-pyrrolidinone, and combinations thereof.
[0033] The insecticide is selected from at least one of the following: pyrazole insecticides, pyrrole insecticides, pyrethroid insecticides, amidinohydrazone insecticides, semicarbazone insecticides, and neo-neo-nicotinoid insecticides. In other words, the insecticide may be a pyrazole insecticide or a pyrrole insecticide, etc. The insecticide may also be a mixture or combination of these insecticides. Each of these insecticides attacks the insects in a different manner and is not intended to limit the subject invention. One example of a pyrrole insecticide is, but not limited to, chlorfenapyr. One example of a pyrethroid insecticide, is, but not limited to alphacypermethrin. One example of an amidinohydrazone insecticide, is, but not limited to hydramethylnon. One example of a semicarbazone insecticide, is, but not limited to BAS 320-I. One example of a neo-neo-nicotinoid insecticide is, but not limited to imidacloprid.
[0034] The pyrazole insecticide is typically available and used in at least one of a powder form and a granular form prior to being dissolved in the polar solvent. It is preferred that the pyrazole insecticide is an aryl pyrazole compound having the general formula of:
[0000]
[0035] wherein Z 1 may be an alkly or an aryl group, Z 2 is an amine, an alkyl, or a hydrogen, Z 3 is a sulfoxide and haloaklyl, and Z 4 is CN or methyl. Further, the aryl pyrazole may open the aromatic pentane ring to form the insecticide. The pyrazole insecticide may be selected from one of fipronil, ethiprole or acetaprole and combinations thereof.
[0036] More preferably, the pyrazole insecticide has the general formula of:
[0000]
[0037] wherein R 1 is one of CN and methyl, R 2 is S(O) n A, wherein A is a haloaklyl and n is 0, 1, or 2, R 3 is one of H, NH 2 , and alkyl, R 4 is an haloaklyl, R 5 is a halogen, and R 6 is a halogen.
[0038] Most preferably, the pyrazole insecticide is fipronil (5-amino-1-(2,6-dichloro-4-(trifluoromethyl)phenyl)-4-((trifluoromethyl)sulfinyl)-1H-pyrazole-3-carbonitrile) having the formula of C 12 H 4 Cl 2 F 6 N 4 OS and the following structure:
[0000]
[0039] The insecticide is present in an amount of from 0.001 to 10, preferably from 0.001 to 5, and most preferably from 0.001 to 2.5 parts by weight based on 100 parts by weight of the binder resin. The polar solvent is present in an amount of from 0.1 to 20 parts by weight based on 100 parts by weight of the binder resin. However, it is to be appreciated that the amount of the polar solvent depends upon the dissolvability of the insecticide in the polar solvent. Therefore, more of the polar solvent will be required if it can dissolve 10 grams of the insecticide per liter than if the polar solvent can dissolve 600 grams per liter.
[0040] Typical examples of fungicides that may be utilized with the subject invention include, but are not limited to, triazoles, benzimidazoles, morpholines, dicarboxamides or strobilurines. The fungicide may be added directly to the polyisocyanate or may be dissolved in the polar solvent as discussed above. Dissolving the fungicide in the polar solvent ensures the fungicide is well dispersed throughout the composite material. The fungicide is present in an amount of from 0.001 to 10, preferably from 0.001 to 5, and most preferably from 0.001 to 2.5 parts by weight based on 100 parts by weight of the binder resin. The method of forming the lignocellulosic composite material includes the steps of dispersing at least one of the insecticide and the fungicide in the polyisocyanate to form the binder resin. As discussed above, the insecticide may be dissolved in the polar solvent capable of dissolving at least 10 grams of the insecticide per one liter of the polar solvent to form the insecticide solution, which is then mixed with the polyisocyanate to form the binder resin. The insecticide is added in an amount of from 1 to 500 parts per million (PPM) based on dry weight of the lignocellulosic particles, preferably from 10 to 300, and most preferably from 20 to 250 parts per million based on dry weight of the lignocellulosic particles. The polyisocyanate is present in an amount of from 0.5 to 25 parts by weight based on 100 parts by dry weight of the lignocellulosic material.
[0041] After the binder resin is formed, the lignocellulosic mixture is formed by combining from about 75 to 99.5 parts by weight of the lignocellulosic particles based on 100 parts by weight of the lignocellulosic mixture with the binder resin in an amount of from 0.5 to 25 parts by weight based on 100 parts by weight of the lignocellulosic mixture. The lignocellulosic particles are resinated using the binder resin described above. The binder resin and the lignocellulosic particles are mixed or milled together during the formation of a resinated lignocellulosic mixture. Generally, the binder resin can be sprayed onto the particles while they are being agitated in suitable equipment. To maximize coverage of the particles, the binder resin is preferably applied by spraying droplets of the binder resin onto the particles as they are being tumbled in a rotary blender or similar apparatus. For example, the particles can be resinated in a rotary drum blender equipped with at least one spinning disk atomizer.
[0042] For testing on a lab scale, a simpler apparatus can suffice to resinate the particles. For example, a 5 gallon can is provided with baffles around the interior sides, and a lid with a hole large enough to receive the nozzle of a spray gun or other liquid delivery system, such as a pump sprayer. It is preferred that the binder resin be delivered as a spray. The particles to be resinated are placed in a small rotary blender. The blender is rotated to tumble the particles inside against the baffles, while the desired amount of binder resin is delivered with a spray device. After the desired amount of binder resin is delivered, the particles can be tumbled for a further time to effect the desired mixing of the particles with the binder resin.
[0043] The amount of binder resin to be mixed with the lignocellulosic particles in the resinating step is dependant upon several variables including, the binder resin used, the size, moisture content and type of particles used, the intended use of the product, and the desired properties of the product. The mixture produced during the resinating step is referred to in the art as a furnish. The resulting furnish, i.e., the mixture of flakes, binder resin, parting agent, and optionally, wax, wood preservatives and/or other additives, is formed into a single or multi-layered mat that is compressed into a particle board or flakeboard panel or another composite article of the desired shape and dimensions. The mat can be formed in any suitable manner. For example, the furnish can be deposited on a plate-like carriage carried on an endless belt or conveyor from one or more hoppers spaced above the belt. When a multi-layer mat is formed, a plurality of hoppers are used with each having a dispensing or forming head extending across the width of the carriage for successively depositing a separate layer of the furnish as the carriage is moved between the forming heads.
[0044] The lignocellulosic composite material may be formed of a single mat, or layer, having a thickness of from 0.1 inches to 2 feet with the insecticide and/or the fungicide dispersed throughout the layer, or formed of a plurality of mats, or layers, with each of the plurality of layers having a thickness of from 0.1 inches to 6 inches with the insecticide and/or the fungicide dispersed throughout each of the plurality of layers. The mat thickness will vary depending upon such factors as the size and shape of the wood flakes, the particular technique used in forming the mat, the desired thickness and density of the final product and the pressure used during the press cycle. The mat thickness usually is about 5 to 20 times the final thickness of the article. For example, for flakeboard or particle board panels of ½ to ¾ inch thickness and a final density of about 35 lbs/ft 3 , the mat usually will be about 0.1 to 6 inches thick.
[0045] Finally, the lignocellulosic composite material is formed by compressing the lignocellulosic mixture at an elevated temperature and under pressure. Press temperatures, pressures and times vary widely depending upon the shape, thickness and the desired density of the composite article, the size and type of wood flakes, the moisture content of the wood flakes, and the specific binder used. The press temperature can be from about 100° to 300° C. To minimize generation of internal steam and the reduction of the moisture content of the final product below a desired level, the press temperature preferably is less than about 250° C. and most preferably from about 180° to about 240° C. The pressure utilized is generally from about 100 to about 1000 pounds per square inch. Preferably the press time is from 50 to 350 seconds. The press time utilized should be of sufficient duration to at least substantially cure the binder resin and to provide a composite material of the desired shape, dimension and strength. For the manufacture of flakeboard or particle board panels, the press time depends primarily upon the panel thickness of the material produced. For example, the press time is generally from about 200 to about 300 seconds for a pressed article with a ½ inch thickness.
[0046] The following examples, illustrating the formation of the lignocellulosic composite material, according to the subject invention and illustrating certain properties of the lignocellulosic composite material, as presented herein, are intended to illustrate and not limit the invention.
EXAMPLES
[0047] The following examples describe the formation of a lignocellulosic composite material by adding and reacting the following parts.
[0000]
TABLE 1
Example 1
Example 2
Example 3
Example 4
Amount,
Amount,
Amount,
Amount,
gm
Pbw
gm
Pbw
gm
Pbw
gm
Pbw
Binder Resin
283.83
3.0
282.52
3.1
1182.44
4.8
1183.58
4.8
Polyisocyanate
282.42
—
282.24
—
1181.29
—
1181.29
—
Insecticide
1.41
—
0.28
—
1.15
—
2.29
—
Lignocellulosic
9076.38
97.0
9076.38
97.0
0.0
0.0
0.0
0.0
Particles A
Lignocellulosic
0.0
0.0
0.0
0.0
24566.56
95.2
24425.95
95.2
Particles B
Total
9360.21
100.0
9358.90
100.0
25749.0
100.0
25609.53
100.0
[0048] The polyisocyanate is LUPRANATE® M20SB, commercially available from BASF Corporation. The pyrazole insecticide is fipronil. The lignocellulosic particles A are a southern yellow pine mix having a moisture content of about 8.27%. The lignocellulosic particles B are Aspen particles having an average moisture content of about 6.76%.
[0049] In Examples 1 and 2, the lignocellulosic composite material was formed having a thickness of 0.437 inches with a density of about 39 lb/ft 3 . In Example 1, 1.41 grams of fipronil were dissolved in 5.03 grams of the polar solvent to form the insecticide solution. The fipronil was present in an amount of about 150 PPM based on the dry weight of the lignocellulosic particles. In Example 2, 0.28 grams of fipronil were dissolved in 1.00 grams of the polar solvent to form the insecticide solution. The fipronil was present in an amount of about 30 PPM based on the dry weight of the lignocellulosic particles. The polar solvent was 1-methyl-2-pyrrolidinone (NMP). NMP is capable of dissolving about 289 grams of fipronil per liter of NMP.
[0050] In Examples 3 and 4, the lignocellulosic composite material was formed having a thickness of 0.719 inches with a density of about 40 lb/ft 3 . In Example 3, 1.15 grams of fipronil were dissolved in 5 grams of the polar solvent to form the insecticide solution. The fipronil was present in an amount of about 50 PPM based on the dry weight of the lignocellulosic particles. In Example 4, 2.29 grams of fipronil were dissolved in 10 grams of the polar solvent to form the insecticide solution. The fipronil was present in an amount of about 100 PPM based on the dry weight of the lignocellulosic particles. The polar solvent in Examples 3 and 4 was 3-pentanone, which is capable of dissolving about 326 grams of fipronil per liter of 3-pentanone.
[0051] The insecticide solutions formed in each of the examples was then added to the polyisocyanate component to form the binder resin and the binder resin was then mixed with the lignocellulosic particles. The lignocellulosic particles were pressed under elevated temperature and pressure to form the composite materials. The composite materials were then tested to determine the insecticide potency based upon the number of days after treatment (DAT) with the results listed below as the mean percent knockdown or mortality at DAT.
[0000]
TABLE 2
Example 1
Example 2
Example 3
Example 4
Control
Eastern Subterranean Termite
1 DAT
51.1
7.7
0.0
4.9
1.1
2 DAT
75.0
44.0
16.1
46.2
1.1
3 DAT
89.8
82.4
74.1
79.2
1.1
4 DAT
95.5
98.9
93.9
89.4
1.7
5 DAT
96.6
100.0
90.9
95.8
1.7
6 DAT
97.7
—
96.0
97.7
1.7
[0052] The insecticidal potency of pyrazole insecticide in the lignocellulosic composite material was determined against workers of the eastern subterranean termite, Reticuliterme flavipes . The control was an ordinary, untreated oriented strand board. Petri dishes were used as containers for termite assay. Each Petri dish was set up with a thin layer of moistened sand. Two corners (triangle with 15×15×20 mm) of a composite material were placed directly onto the sand. Thirty termites were placed into the dishes, the lid replaced, covered with blotter paper, and then held in an incubator (25° C.). Data was collected at specified days after treatment listed above recording knocked down, or dead termites, and intoxicated termites.
[0053] In Examples 1-4, the mean percent mortality of termites approached 100 percent, whereas the Control only reached a mean percent mortality of 3.3 percent. It is to be appreciated that these results were observed only over a short period of time, whereas in practice, the composite material will be exposed for longer period of times. Therefore, the results for the treated composite material will provide a greater insecticide resistance over time relative to the Control.
[0054] While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. | A lignocellulosic composite material and a method for preparing the lignocellulosic composite material are disclosed. The composite material is formed from lignocellulosic particles and a binder resin. The binder resin comprises a polyisocyanate, at least one of insecticide and/or fungicide that are dispersed throughout the polyisocyanate. The insecticide and/or fungicide is also dispersed throughout the lignocellulosic particles. Since the insecticide and/or fungicide is dispersed throughout the composite material, the composite material is insect resistant and is able to withstand insect attacks and prevent fungus growth and decay. | 3 |
[0001] This application is a continuation application of U.S. Ser. No. 10/050,834, filed Jan. 15, 2002, now pending.
[0002] The invention disclosed and claimed herein deals with premium performance ball joints, systems in which they are used, and suspension systems in which the ball joint systems are employed. The ball joints, systems and suspension mechanisms are especially useful for racing vehicles in which premium performance is desired. As an additional feature, the products of this invention are especially appreciated because of the ability to quickly and easily replace or change the ball and shaft (ball stud combination) in the ball joints. The ball stud is what is damaged in accidents, and, it wears out first from normal use. Thus, the ability to change the ball stud rather than changing the entire ball joint is a decided advantage of this invention.
[0003] Unlike the lower ball joints, upper ball joints do not have the load between the sprung mass of the vehicle and the suspension spring to keep them seated. Most prior art ball joints used in the upper ball joint position use an internal spring over the ball and in the void space above the ball to hold the ball in place. In high cornering situations, the lateral force on the ball joint creates sufficient force to compress the spring and unseat the ball. This problem makes it impossible to maintain the optimum camber in the tire to maximize the tire contact patch on the roadway. This movement also causes minor directional changes in the automobile steering that are detrimental to stability of the automobile. Thus, the premium performance aspect of this invention is based on the fact that prior art ball joints used for the same applications, all have a mechanical means for applying pressure to the ball within the ball joint to accommodate wear as the ball joint is in use, while the ball joint of this invention has no such mechanical means. The lubricants that are commonly used in these types of ball joints provide the pressure required within the inventive ball joint for accommodating the wear of the ball joints of this invention. The result is a ball that has minimal restriction in movement because of the reduction in friction and is therefore essentially “free wheeling” within the housing in which it is contained, thus, providing ease of steering. Original equipment manufactured ball joints of the prior art create inconsistent amounts of resistance to suspension movement, most frequently around twenty pounds, while the ball joints of this invention have less than one pound of resistance. This is important to race drivers, as shock and spring rates are critical to within five pounds. It is not conceivable that automobile handling advantages could be built into the automobile by making small spring and shock rate changes while the ball joints are gradually losing resistance, or “freeing up” as they wear. The ball joints of this invention greatly reduce the “moving resistance target” caused by prior art tight ball joints.
BACKGROUND OF THE INVENTION
[0004] It is well known that ball joints and systems employing them are used in front wheel suspension of automotive vehicles. The ball joint lends flexibility for steering the wheels while accommodating changes in angles between the wheel and the suspension members. In conventional ball joints, a pin or shaft on which the wheel is mounted carries a ball, which is rigid with the shaft, the ball being housed in a housing wherein the ball is seated and retained. During both rotation and pivoting of the elongated shaft, the surface of the ball slides over a lining of the housing.
[0005] Typically, prior art ball joints are all constructed such that they have an open space or void at the top of the ball, wherein there is typically placed a means for asserting pressure on the top of the ball to accommodate any wear on the ball. Such means are, for example, springs under tension, which are placed on the top of the ball and retained by some kind of insert over the top of the ball. Also known by the inventors herein are ball joints in which the pressure is provided by compressible nylon particles that are situated in the open space and impinge on and essentially surround the exposed top surface of the ball.
[0006] All such ball joints require lubrication, and some means is provided to allow for the lubricant to be injected into the housing and onto and around the ball of the ball joint. Further, the ball per se often contains shallow, usually disconnected, channels in which the lubricant can take up residence. These channels help a situation that can occur in the ball joint in which the lubricant, contained within the housing, can block off all air into the housing and create a vacuum within the housing, which provides a lock. This lock is experienced when one tries to put grease into the housing, as the grease gun connector locks onto the grease zerk fitting and cannot be removed. The grooves not only provide a channel for the grease to reach the ball, but they also create vents that allow the grease to enter the ball joint housing and air to escape.
[0007] The instant invention eliminates or reduces the above-mentioned problems with ball joints and provides a premium performance ball joint wherein the ball and shaft is easily installed, removable, and easily replaced without having to replace the entire ball joint, and, furthermore, the ball joint system provides premium performance in the operation of automobiles.
THE INVENTION
[0008] Thus, this invention deals with novel ball joints, novel systems employing the ball joints, and suspension systems for automotive uses that employ the novel ball joint systems.
[0009] More specifically, there is provided a ball joint comprising in combination an elongated shaft having an upper end and a lower end and having a longitudinal axis running through said upper end and said lower end, wherein the elongated shaft has threads on its lower end. There is in addition, a ball rigidly fixed and surmounted on the upper end of the elongated shaft. The ball, at the highest point opposite the attachment of the elongated shaft, has a truncated flat face. There is also a retaining member having an upper surface and a lower end. The retaining member is provided with a lubricating port located in the upper surface of the retaining member. The lubricating port is openly connected to a duct, the duct necessarily providing a passageway for lubricants from the lubricating port to the truncated flat face of the ball. The retaining member is externally threaded on the retaining member lower end.
[0010] There is a housing having an outside surface, a middle portion, and a lower end. The housing is internally conformed at the lower end to seat the ball and retain it in the housing, and the seat allows a pivotal movement of the ball about the longitudinal axis of the elongated shaft relative to the housing. The middle portion of the housing is internally threaded to receive the retaining member and the middle portion is externally threaded on the outside surface. Finally, there is a fastening means for fastening the retaining member in the housing.
[0011] In another embodiment, there is a combination of the ball joint described just above, and a socket to provide a ball joint system. The socket comprises a cylindrical housing having a wall with an internal surface wherein the internal surface is threaded to receive the housing in it and the socket has a means of attachment for attachment near a terminal end of a carrier for the ball joint system.
[0012] Finally, there is an additional embodiment of this invention that is an automotive suspension system incorporating the ball joint systems described just above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a full view of a ball joint system of this invention that is fully assembled.
[0014] FIG. 2 is a full view of the ball and the elongated shaft of this invention.
[0015] FIG. 3 is a full view of the housing of this invention
[0016] FIG. 4 is a full top view of the housing of this invention without the retaining member in place
[0017] FIG. 5 is a full top view of the housing of this invention with the retaining member in place.
[0018] FIG. 6 is a full cross-sectional view of the housing of FIG. 4 through the lines 6 - 6 of FIG. 3 .
[0019] FIG. 7 is a full view of the retaining member of this invention.
[0020] FIG. 8 is a full cross-sectional view of the retaining member of FIG. 7 through the lines 8 - 8 of FIG. 7 .
[0021] FIG. 9 is a full view of a fully assembled ball joint system of this invention and including the socket.
[0022] FIG. 10 is a full top view of the socket of FIG. 9 .
[0023] FIG. 11 is a schematic drawing of one type of automotive suspension system showing the use of the ball joint systems of this invention.
[0024] FIG. 12 is a full view in perspective of a portion of the suspension system of FIG. 11 , wherein there is shown a wishbone support arm containing a ball joint system of this invention.
[0025] FIG. 13 is a full top view of the wishbone support arm of FIG. 12 .
DETAILED DESCRIPTION OF THE INVENTION
[0026] Turning now to the Figures, and with reference to FIG. 1 , which is a full view of a ball joint system 27 of this invention that is fully assembled. There is shown as the components thereof, an elongated shaft 2 , and the ball 3 (only a portion of the bottom of the ball is shown therein), the housing 4 , with external threads 5 , a retaining member 6 , and a fastening means 7 , which is a set screw 8 set into a threaded (not shown) opening 9 , in an upper flange 10 of the housing 4 .
[0027] It should be noted that the elongated shaft 2 is threaded at its lower end 11 , and that there is an opening 12 though the threaded portion 13 of the elongated shaft 2 to accommodate a cotter pin (not shown), or the like, to retain a nut 31 (see FIG. 9 ), which in turn retains the elongated shaft 2 in a portion of a suspension system that is discussed below. It is contemplated within the scope of this invention to provide ball joints wherein the shafts 2 are provided in various lengths. The reason for the various lengths is that in racing, it is desirable to alter the suspension angles and positions to affect handling, i.e., roll centers, camber gain and other related geometry. Having ball joints with variable length shafts gives the users an option for altering the suspension geometry of the automobile using the ball joints. Currently, racers will change or alter the spindles to make the same geometry changes, and this provides an increased cost, as the spindles are about 6 to 7 times more expensive than the ball joints of this invention.
[0028] FIG. 2 is a full view of the combination 1 of the ball 3 and the elongated shaft 2 without the remainder of the components being shown, for clarification. Thus there is shown the ball 3 , the elongated shaft 3 , a truncated flat surface 14 at the topmost point of the ball 3 , and the treaded portion 13 at the lower end 11 , along with the opening 12 . What is meant by “longitudinal axis running through said upper end and said lower end” is shown by the line 300 - 300 in FIG. 2 , which indicates the principal axis that the ball 3 would revolve around, it being understood that the ball will tilt from this axis within the housing 4 to provide flexibility in the ability of the ball 3 to coordinate with the suspension systems noted infra, and the degree of movement within the housing 4 is limited only by the contact of the elongated shaft 3 with the lower edge 15 of the housing 4 , and/or the connection that the elongated shaft 3 has with the suspension system and the wheel 33 shown in FIG. 11 .
[0029] It should be noted that the preferred combination 1 of ball 3 and elongated shaft 2 is that in which the two are joined as a unitary component. This combination is manufactured from hardened steel or the like to endure the wear that usually accompanies such devices. The truncated flat surface 14 is provided so that there is a space or void 25 (see FIG. 8 ) formed above the ball 3 when in the housing 4 . The space 25 is intended to contain lubricant, namely, a thickened oil or grease which is not shown in this Figure, but which can be any common lubricant known in the art. Filling the void 25 above the truncated surface 14 allows for pressure to be applied to the ball 3 , while in the housing 4 , and is employed to help seat the ball in the seat 18 (see FIG. 4 ) provided at the lower end of the housing 4 . The pressure created by lubricants inserted into the void 25 is also a means to help adjust the ball 3 in the housing 4 to accommodate for any wear on the ball 3 . As far as is known by the inventors herein, this means of accommodating for wear on the ball 3 is not known independently of mechanical means, or as a sole means for providing such pressure.
[0030] The housing 4 , which houses and seats the ball 3 is shown in FIG. 3 . With reference to this Figure, there is shown the threaded exterior surface 5 , which inserts into the socket 16 , that is described infra, the lower edge 15 , which in this Figure is beveled to fit into the bottom of the socket 16 , the flange 10 which is configured such that it can be used to turn the housing 4 into the socket 16 , and in this Figure, the flange 10 is shown as a hexagon configuration also any convenient configuration that allows the turning of the housing 4 is contemplated within the scope of this invention. The threaded exterior surface 5 is used to attach the housing to the support arm of a suspension system. This means for attaching the housing to the support arm of the suspension system is external threads 5 on the external surface of the middle portion of the housing. In the side surface of the flange 10 , there is shown a fastening means 7 for the housing 4 , to retain the retaining member 6 in the housing 4 , which fastening means 7 is comprised of a simple set screw combination wherein there is shown the threaded opening 9 , into which a set screw 8 is inserted and turned down to complete the fastening. The type of fastening means 7 is not critical in this invention, and any fastening means which will secure the retaining member 6 in the housing 4 and which is fairly simple to use, is acceptable.
[0031] With reference to FIG. 4 , which is a top view of the housing 4 , there is shown the flange 10 , the fastening means opening 9 , in phantom, the internal threads 17 for accommodating the external threads 18 of the retaining member 6 , and the seat 18 for the ball 3 , which is located near the bottom edge 15 of the housing 4 .
[0032] Further, with reference to FIG. 5 , which is a top view of the housing 4 , wherein there is shown the flange 10 , therein is situated in the housing 4 , a retaining member 6 , wherein there is shown the top 19 of the retaining member 6 , a concavity 20 in the top 19 , and detachedly fixed in the concavity 20 , a grease zerk fitting 21 . Generally, such grease zerk fittings 21 are threaded and screwed into a threaded opening and that is contemplated within the scope of this invention as well as any convenient means of inserting and fastening the grease zerk fitting 21 . Also shown in this Figure are indentions 22 , which are indented in the wall of the concavity 20 , which indentions 22 are useful for applying a wrench or some other viable means to turn the retaining member 6 in and out of the housing 4 . The indentions 22 are not critical to this invention and can be optionally included in the retaining member 6 , and can be configured other than as an indention as shown.
[0033] Reference should also be made to FIG. 6 , which is a cross-sectional view of the housing 4 , taken through line 6 - 6 of FIG. 4 , wherein there is shown the flange 10 , the opening 9 , the set screw 8 tail end, the external threads 5 , and the internal threads 17 , which accommodate the external threads 24 of the retaining member 6 (see also FIGS. 7 and 8 ).
[0034] With further reference to the retaining member 6 , reference should be made to FIG. 7 , which is a full view of the retaining member 6 , showing the top 19 and the external threads 24 . FIG. 8 is a full cross-sectional view of the retaining member 6 through line 8 - 8 of FIG. 7 , wherein, there is shown the top 19 , the external threads 24 , the concavity 20 , and the grease fitting 21 . Also shown is the duct 23 , which carries lubricant applied to the grease fitting 21 to be carried to the void 25 (see FIG. 8 ), wherein the ball 3 is shown and wherein the majority of the lubricant resides. Also shown in FIG. 6 are the shallow channels 26 which in the prior art ball joints are typically placed into the ball 2 , but which in this invention are placed in the interior of the socket 16 . The reason for this placement of the shallow channels 26 is primarily cost, as placing the shallow channels 26 in the socket 16 , means that expensive machining does not have to be done in the ball 2 , which is the part that is replaced more often.
[0035] Turning now to FIG. 9 , there is shown a full view of the fully assembled ball joint system 27 wherein components shown therein have like numbers for like components as shown in FIG. 1 , except, there is shown in addition, the socket 16 , into which the ball joint system 27 is screwed pursuant to the internal threads 28 of the socket 16 , and the external threads 5 on the housing 4 . The socket 16 is comprised of a hollow cylinder housing, which has a sidewall 29 and an upper rim 30 . The socket 16 is fastened securely into the support arms of a suspension system of an automobile or truck, which automotive suspension system is illustrated in the schematic drawing of FIG. 11 . The ball joint system 27 can be used for both the upper and lower support arms configuration. The fully assembled ball joint system 27 is then turned into the socket 16 and is secured to the socket 16 by any conventional securing means, such as set screws, retainer rings, or the like. Also shown in association with the ball joint system 27 of FIG. 9 is a threaded nut 31 , which can be turned onto the threads 13 of the elongated shaft 2 for attachment to a support means (axle stud) of a wheel of an automobile, and thereafter, the nut 31 is secured thereon by the insertion of a cotter pin, or the like, through the opening 12 .
[0036] Finally, turning to FIG. 11 , there is shown a schematic drawing of one type of automotive suspension system 32 , in which there is shown as the main components therein, a fully mounted wheel 33 for the automobile, a support stud (axle) 34 for the wheel 33 , wishbone support arms, upper 35 , and lower 36 , a strut or shock absorber 37 , having an surrounding auxiliary spring 38 , a support mechanism 39 that is attached to the frame of an automobile (not shown), an upper ball joint system 40 , and a lower ball joint system 41 , wherein the support arms 35 and 36 do not show as being attached to the lower and upper ball joint systems, 40 and 41 , respectively, in order to more clearly show the total configuration of the suspension system. The openings in the support arms 35 and 36 are shown in phantom as 42 and 43 , respectively. In actual use, the sockets 16 for both the upper 40 and the lower 41 ball joint systems would normally be inserted in the openings 42 and 43 respectively.
[0037] FIG. 12 is a full view in perspective of a wishbone support arm 35 or 36 with the ball joint system, either the upper 40 , or the lower 41 , inserted therein. In addition, FIG. 13 shows a full top view of the wishbone of FIG. 12 , wherein the ball joint system 40 or 41 is clearly visible. The support arms 35 and 36 are securely attached to the frame of the vehicle by the bar 45 , while the respective ends 44 and 46 are constructed to allow the rotation of the arms 35 and 36 per se to rotate around the bar 45 in an up and down mode for the support arms pursuant to the movement of the wheel 33 and support stud 34 while in use the vehicle is in use. This is also shown in FIG. 13 . | Ball joints, systems in which they are used, and suspension systems in which the ball joint systems are employed. The ball joints, systems and suspension mechanisms are especially useful for racing vehicles in which premium performance is desired. As an additional feature, the products of this invention are especially appreciated because of the ability to quickly and easily replace or change them. | 5 |
TECHNICAL FIELD
This document pertains generally, but not by way of limitation, to electronic timing circuits.
BACKGROUND
Oscillator circuits are used in determining timing of events in electronic circuits. Oscillator circuits have been used in determining timing in which to de-assert a reset signal, for example. Oscillator circuits also have been used in watchdog timeout circuits in determining timing in which to reset a counter on a device input, for example.
A supervisory circuit is commonly used to monitor one or more parameters of devices such as power supplies and microprocessors which must be maintained within certain limits, and to take appropriate action if a parameter goes out of bounds, creating an unacceptable or dangerous situation, for example. Supervisory circuits have been used during a power up sequence to delay active usage of a device until system power has come up to a correct level and stabilized. For example, when supply voltage of a device such as a microprocessor has just returned back to its normal operating voltage level after being in a low voltage supply state (i.e. brown-out state), or after emerging from a ‘hung’ state, a supervisory circuit may delay active usage of the microprocessor until after its supply voltage has been within a normal operating range for at least a predefined time out period.
In particular, for example, supervisory circuits have been used to de-assert one or more reset signals to place a device into an active usage state. In the past, some supervisory circuits have included timer circuitry to determine duration of a predefined reset time out interval that occurs prior to de-assertion of one or more reset signals used to place a device into the active usage state. Some prior supervisory circuits have provided variable reset timeout intervals. Some prior timers have provided reset timeout intervals that are externally-tunable via an off-chip component, rather than being already fixed and pre-defined on-chip. External tunability can provide the flexibility to use the same supervisor circuit and its component timer in different kinds of applications with varying reset timeout period requirements.
FIG. 1 is an illustrative schematic diagram showing a prior timer circuit 100 that includes a tunable capacitor (C ext ) 102 to provide a tunable reset timeout period. The tunable capacitor 102 ordinarily is provided as a programmable off-chip (external) capacitor. The timer works by charging and discharging the external capacitor 102 between two voltage levels V ref1 and V ref2 .
The timer circuit 100 includes first and second comparator circuits 106 , 108 coupled to compare a capacitor voltage VC of the tunable capacitor 102 with each of a first reference voltage V ref1 and a second reference voltage V ref2 . The comparator circuits 106 , 108 are further coupled to provide first and second comparison voltage signals V 1 , V 2 that transition in state in response to charging and discharging, respectively, of the capacitor 102 voltage VC. In other words, a value of the first comparison signal V 1 transitions in response to the capacitor 102 charging, and a value of the second comparison signal V 2 transitions in response to the capacitor 102 discharging. A latch circuit 110 is coupled to produce an output voltage VL having a value indicative of the most recently transitioned comparison voltage signal V 1 or V 2 . In other words, between occurrences of transitions of the first and second comparison signals, the latch circuit 110 stores a value that is indicative of the most recently provided one of the first and second comparison voltage signals. That is, the latch circuit 110 stores a value indicative of which switch state the switch 114 currently is in at times while the capacitor voltage is between the two reference levels, V ref1 and V ref2 .
The timer circuit 100 includes logic circuitry 112 and a switch 114 . The logic circuitry 112 is coupled to receive the VL signal, which is fed back from the latch 110 , and to also receive an Enable signal. In response to the Enable signal enabling the logic circuitry 112 , the logic circuitry provides as its output a V 1 signal that acts as an input to the switch 114 .
The switch 114 includes a PMOS device 116 and an NMOS device 118 having their drains coupled together so that the PMOS device 116 acts as a voltage pull-up device and the NMOS device acts as a voltage pull-down device. A first current source 120 is coupled to provide current I to a source of the PMOS device 116 . A second current sink 122 is coupled to sink a current I from a source of the NMOS device 118 . The drains of the PMOS device 116 and the NMOS device 118 are coupled to a switch output terminal 124 that is coupled to a first terminal of the tunable capacitor 102 . A second terminal of the tunable capacitor 102 is coupled to ground.
The timer circuit 100 includes a counter circuit 126 that is coupled to receive as input the VL signal produced by the latch. The counter circuit 126 operates to count occurrences of rising (or falling) edges of the VL signal. The counter circuit 126 provides a timeout signal (TO) in response occurrence of m VL rising edges. Thus, the timer circuit 100 delays provision of a timeout signal until a count of VL rising edges reaches m. The timeout signal can be used by a supervisor circuit to determine when to de-assert a reset signal, for example.
In operation, when the Enable signal is high (that is, when the timer 100 is enabled) the two comparators 106 , 108 sense when VC has reached one of the voltage thresholds, V ref1 or V ref2 , and in response to determining that a threshold has been reached, produce a signal V 1 or V 2 that transitions the latch 110 to a different state. The output VL of the latch 110 feeds back to the input logic circuit 112 , which controls the switch 114 to alternately turn on the pull-up PMOS device 116 or to turn on the NMOS pull-down device 118 , to alternately switch in and out the current sources 120 , 122 , to alternately charge and discharge the capacitor 102 . Meanwhile, the output of latch 110 is digitally divided by the counter 126 by a certain divide ratio m to generate the timeout signal TO after the occurrences of m transitions of the VL signal. The occurrence of the TO signal indicates that the reset timeout interval has elapsed.
With the capacitor charging and discharging currents I, the comparator thresholds V ref1 and V ref2 , and the counter divide ratio m all fixed on-chip, varying the external capacitance C ext effectively changes the charge and discharge rate of the capacitor, thus realizing a variable oscillator frequency and thus, a tunable timeout period.
Neglecting the comparator offset and propagation delay, it can be derived that the time-out period of for the prior timer circuit of FIG. 1 can be represented as,
Timeout
=
2
m
C
ext
I
(
Vref
1
-
Vref
2
)
.
From this equation, it can be seen that the time-out period is directly proportional to C ext . The time-out period is also a function of the current I, the divide ratio m, and the difference between the pre-defined comparator thresholds. A capacitor as the variable external device, as in the circuit in FIG. 1 can readily achieve a time-out period range of up to four orders of magnitude using a suitable range of commercially-available external capacitor values.
Using off-chip capacitors, however, can have some disadvantages. For example, some external capacitors have a poor absolute value, as well as both temperature and voltage coefficient, thereby degrading the time-out accuracy. Moreover, the time-out period is also heavily dependent on the accuracy of the on-chip bias currents I.
SUMMARY
In one aspect, a circuit includes a resistor coupled to a current source to provide a current to the resistor to produce a resistor voltage level. A programmable gain circuit is coupled to amplify the resistor voltage level based upon a selected gain. A voltage level detection circuit is coupled to identify a present amplified resistor voltage level. A selection circuit configured to select the gain based at least in part upon the identified present amplified resistor voltage level. A comparator circuit configured to transition between providing a signal having a first value and providing a signal having a second value based at least in part upon comparisons of a capacitor voltage level with the amplified resistor voltage level and with a second reference voltage. A reactive circuit element excitation circuit is configured to reverse excitation of the capacitor in response to the comparator circuit transitioning between providing the signal having the first value and providing the signal having the second value.
In another aspect, a circuit includes a resistor coupled to a voltage source to provide a voltage across the resistor to produce a resistor current level. A programmable gain circuit is coupled to amplify the resistor current level based upon a selected gain. A current level detection circuit coupled to identify the amplified resistor current level. A selection circuit is configured to select the gain based at least in part upon the identified amplified resistor current level. A comparator circuit is configured to transition between providing a signal having a first value and providing a signal having a second value based at least in part upon comparisons of a inductor current level with the amplified resistor current level and with a second reference current. A reactive circuit element excitation circuit configured to reverse excitation of the inductor in response to the comparator circuit transitioning between providing the signal having the first value and providing the signal having the second value.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustrative schematic diagram showing a prior timer circuit that includes a tunable capacitor to provide a tunable reset timeout period.
FIG. 2 is an illustrative schematic diagram showing a first embodiment of a timer circuit that includes a tunable resistor to provide a tunable reset timeout period in accordance with some embodiments.
FIG. 3 is an illustrative schematic diagram showing a second embodiment of a timer circuit that includes a tunable resistor to provide a tunable reset timeout period in accordance with some embodiments.
FIG. 4 is an illustrative drawing showing certain details of a latch circuit of the embodiment of FIG. 3 in accordance with some embodiments.
FIG. 5 is an illustrative timing diagram representing the operation of the second embodiment timer circuit of the FIG. 3 in accordance with some embodiments.
FIG. 6 is an illustrative schematic diagram of the second embodiment of FIG. 3 showing certain details of a first embodiment of the gain range circuitry in accordance with some embodiments.
FIG. 7 is an illustrative flow diagram of a current range determination process for use with the first embodiment of the gain range circuitry of FIG. 6 in accordance with some embodiments.
FIG. 8 is an illustrative chart showing example relationships between values of the target reference voltage range, tunable resistor, corresponding timeout delays, current values and n factors for use with the first embodiment of the gain range circuitry of FIG. 6 , in accordance with some embodiments.
FIG. 9 is an illustrative schematic diagram of the third embodiment of a timer circuit showing certain details of a second embodiment of a gain range circuitry in accordance with some embodiments.
FIG. 10 is an illustrative flow diagram of a voltage range determination process for use with the second embodiment of the gain range circuitry of FIG. 9 in accordance with some embodiments.
DESCRIPTION OF EMBODIMENTS
The following description is presented to enable any person skilled in the art to create and use a resistor controlled timer circuit with gain ranging. Various modifications to the embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the invention. Moreover, in the following description, numerous details are set forth for the purpose of explanation. However, one of ordinary skill in the art will realize that the invention might be practiced without the use of these specific details. In other instances, well-known data structures and processes are shown in block diagram form in order not to obscure the description of the invention with unnecessary detail. Identical reference numerals may be used to represent different views of the same item in different drawings. Flow diagrams in drawings referenced below are used to represent processes. A machine such as a controller is configured to perform these processes. The flow diagrams include modules that represent the configuration of a controller to perform the acts described with reference to these modules. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.
FIG. 2 is an illustrative schematic diagram showing a first embodiment of a timer circuit 1200 that includes a tunable resistor (R ext ) 1250 to provide a tunable reset timeout period in accordance with some embodiments. The timer 1200 works through alternate excitation and reversal of a reactive element 1260 , e.g., charging and discharging a voltage across a capacitor or increasing and decreasing current through an inductor. An excitation circuit 1214 is coupled to alternately excite and reverse excitation of the reactive element 1260 . The timer circuit 1200 includes comparator circuitry 1207 shown within dashed lines that includes at least one comparator circuit 1209 coupled to compare a reactive element reference value Refr eact with each of a first reference Ref 1 and a second reference Ref 2 . A first terminal of the comparator circuitry 1207 is coupled to receive a Ref 1 value. A second terminal of the comparator circuitry 1207 is coupled to receive a Ref 2 value.
The value Ref 1 is variable and is determined based at least in part upon the value of tunable resistor 1250 . More particularly, a bias circuit 1280 is coupled to provide a reference bias across a first terminal 1251 of the resistor 1250 and a second terminal 1252 of the resistor 1250 . The second terminal 1252 of the resistor 1250 also is coupled to a ground potential. The first terminal 1251 of the resistor 1250 also is coupled to provide an input signal to a programmable gain circuit 1286 , which provides a value Ref 1 as its output. A gain circuit 1286 is coupled to provide a Ref 1 value as a function of a reference signal value Ref resistor associated with the first terminal 1251 of the resistor 1250 .
The reactive element 1260 is a capacitor in some embodiments and an inductor in other embodiments. For an embodiment in which the reactive element 1260 is a capacitor, the bias circuit 1280 produces a current through the resistor 1250 and the Ref resistor is a voltage value, and Ref 1 and Ref 2 also are voltage values. For an embodiment in which the reactive element 1260 is an inductor, the bias circuit 1280 produces a voltage source across the resistor 1250 and the Ref resistor is a current value, and Ref 1 and Ref 2 also are current values.
The comparator circuitry 1207 provides an output signal V out to an output signal state storage circuit 1210 that that stores an indication of the state of the most recently occurring value of output signal. In some embodiments, the state storage circuit 1210 includes a latch circuit. The state storage circuit is coupled to provide a feedback signal FB, which acts as a feedback signal that controls reactive element input Ref react to the comparator circuitry 1207 . The comparator circuitry 1207 is coupled to provide the feedback signal FB signal having a first value in response to excitation of the reactive element 1260 and to provide the feedback signal FB having a second value in response to reversal of excitation of the reactive element 1260 . The excitation circuit 1214 is coupled to reverse excitation of the reactive circuit element 1260 in response to the FB signal transitioning between the first and second values. More particularly, for a capacitor reactive element 1260 , the excitation circuitry 1207 is configured to place a current source through the capacitor to ramp up or down (depending on the direction of the current flow) the voltage across the capacitor (not shown), and for an inductor reactive element 1260 , the excitation circuitry 1207 is configured to put a voltage across the inductor to ramp up or down (depending on the voltage polarity) the current through the inductor (not shown).
The timer circuit 1200 includes a counter circuit 1226 configured as a divider that is coupled to receive as input the FB. In accordance with some embodiments, the counter circuit 1226 operates to count occurrences of rising edges of the FB signal. The counter circuit 1226 provides a timeout signal (TO) in response to occurrence of m FB rising edges. Thus, the timer circuit 1200 delays provision of a timeout signal until a count of FB rising edges reaches m. The timeout signal can be used by a supervisor circuit to determine when to de-assert a reset signal, for example.
Reference gain-ranging circuitries 1282 , 1284 are used to select a tuning range of the comparator threshold Ref 1 to overcome comparator offset. More specifically, the comparator threshold Ref 1 is set so that the difference between the comparator thresholds Ref 1 and Ref 2 is large enough so that comparator offset does not become a significant source of error. To do this, before the first embodiment of the timer circuit 1200 is put into operation, during power-up for example, an ADC 1282 (analog to digital converter) performs an initial sampling and sensing of the value Ref 1 provided by the gain circuit 1286 based upon the Ref resistor value at the first resistor node 1251 . For an embodiment in which the reactive element is a capacitor, the gain circuit adjusts a voltage level of Ref 1 . For an embodiment in which the reactive element is an inductor, the gain circuit adjusts a current level of Ref 1 . In response to the determination of the value of Ref 1 , the range select circuit 1284 dynamically adjusts the Ref 1 provided by the gain circuit 1286 to within a range while setting a counter divider ratio for the counter 1226 to achieve a desired timeout interval. FIG. 3 is an illustrative schematic diagram showing a second embodiment of a timer circuit 200 that includes a tunable resistor (R ext ) 250 to provide a tunable reset timeout period in accordance with some embodiments. The tunable resistor 250 is provided as a programmable off-chip (external) resistor. The first timer works 200 through alternate excitation and reversal of excitation of a reactive element. In the second embodiment timer circuit 200 , the reactive element is a capacitor 260 , and excitation of the reactive element includes charging and discharging the capacitor 260 between two voltage levels V ref1 and V ref2 . The timer circuit 200 includes first and second comparator circuits 206 , 208 coupled to compare a capacitor voltage VC of the capacitor 260 with each of a first reference voltage V ref1 and a second reference voltage V ref2 . A first terminal of the capacitor 260 is coupled to the inverting inputs of the first and second comparators 206 , 208 . A second terminal of the capacitor 260 is coupled to ground. A first terminal of the tunable resistor 250 is coupled to a non-inverting input of the first comparator 206 . A second terminal of the tunable resistor 250 is coupled to ground. The voltage V ref2 is coupled to the non-inverting input of the second comparator 208 .
The value V ref1 is variable and is determined based at least in part upon the value of tunable resistor 250 . A programmable current source 586 produces a current I that flows through the tunable resistor 250 . In accordance with some embodiments, the value V ref1 is determined according to the relationship,
V ref1 =I×R ext
The value of V ref2 is selected to be sufficiently less than V ref1 and for the second comparator 208 to produce a transition of signal V 2 in response to discharge of the tunable capacitor 260 .
It will be appreciated that as compared to external capacitors, resistors typically have a relatively better absolute accuracy and less temperature drift, thus significantly improving the timing accuracy of capacitor-programmable timers. Moreover, it will be appreciated that tuning the tunable resistor 250 may include physically replacing one resistor with a different resistor or may include adjusting one or more tap connections to a fixed resistor, for example.
The comparator circuits 206 , 208 are further coupled to provide first and second comparison voltage signals V 1 , V 2 that transition in state in response to charging and discharging, respectively, of the capacitor 260 voltage VC. In other words, a value of the first comparison signal V 1 transitions in response to the capacitor 260 charging, and a value of the second comparison signal V 2 transitions in response to the capacitor 260 discharging. A latch circuit 210 is coupled to change state in response to changes in V 1 and V 2 so as to produce an output voltage VL state having a value indicative of the most recently transitioned comparison voltage signal V 1 or V 2 . In other words, between occurrences of transitions of the first and second comparison signals, the latch circuit 210 stores a state value VL that is indicative of the most recently provided one of the first and second comparison voltage signals. The stored latch state value VL is indicative of which switch state the switch 214 currently is in at times while the capacitor voltage is between the two reference levels, V ref1 and V ref2 .
The timer circuit 200 includes logic circuitry 212 and a switch 214 . The logic circuitry 212 is coupled to receive the VL signal, which is fed back from the latch 210 , and to also receive an Enable signal. In response to the Enable signal enabling the logic circuitry 212 , it provides as its output a V 1 signal that acts as an input to the switch 214 .
The switch 214 includes a PMOS device 216 and an NMOS device 218 having their drains coupled together so that the PMOS device 216 acts as a voltage pull-up device and the NMOS device acts as a voltage pull-down device. The gates of the both the PMOS device 216 and the NMOS device 218 are coupled to receive signal V 1 (voltage input), which in a current embodiments is a slightly phase shifted version of signal VL. A second current source 220 is coupled to provide current I to a source of the PMOS device 216 . A current sink 222 is coupled to sink a current I from a source of the NMOS device 218 . The drains of the PMOS device 216 and the NMOS device 218 are coupled to a switch output terminal 224 that is coupled to a first terminal of the capacitor 260 . A second terminal of the capacitor 260 is coupled to ground.
The timer circuit 200 includes a counter circuit 226 that is coupled to receive as input the VL signal produced by the latch. The counter circuit 226 operates to count occurrences of rising edges of the VL signal. The counter circuit 226 is configured as a divider circuit that provides a timeout signal (TO) in response to occurrence of m VL rising edges. More particularly, in accordance with some embodiments, the counter is configured to roll over to zero when count reaches m. Thus, the timer circuit 200 delays provision of a timeout signal until a count of VL rising edges reaches m. The timeout signal can be used by a supervisor circuit to determine when to de-assert a reset signal, for example.
FIG. 4 is an illustrative drawing showing certain details of a latch circuit 226 in accordance with some embodiments. The latch circuit 226 includes an inverter circuit 230 that acts as an interface to a state storage circuit 232 . The inverter 230 includes PMOS pull-up device 236 and an NMOS pull-down device 234 . A gate of the PMOS pull-up device 236 is coupled to receive the V 1 signal. A gate of the NMOS pull-up device 234 is coupled to receive the V 2 signal. The interface 230 output provides an input to a state storage circuit 232 that save the last defined state of the interface 230 output. The state storage circuit 232 outputs a latch output signal value VL, indicative of the most recently received signal, V 1 or V 2 .
It will be appreciated that the latch 210 itself acts as an interface between the first and second comparators 206 , 208 and the switch 214 . As will be clear from the timing diagram of FIG. 5 , the rising edge of the latch signal VL provides indications of occurrences of signal V 1 , which indicates that VC is greater than V ref1 . Conversely, the falling edge of the latch signal VL provides indications of occurrences of signal V 2 , which indicate that VC is less than V ref2 . A slightly phase shifted version of the latch signal VL is fed back to the switch 214 , which discharges the capacitor 260 in response to an indication that VC is greater than V ref1 and which charges the capacitor 260 in response to an indication that VC is less than Vref 2 .
The latch 210 also acts as an interface between the first and second comparators 206 , 208 and the counter 226 . A count advances (increments or decrements depending upon embodiment of the counter) in response to each rising edge of the latch signal VL. Each rising edge of the latch occurs only after both an occurrence of a V 1 signal and an occurrence of a V 2 signal.
Gain ranging circuitry 582 , 584 , in combination with the tunable resistor, to provide a tunable reset timeout period in accordance with some embodiments. An analog to digital converter (ADC) 582 is coupled to sample a voltage value Vref 1 . The ADC 582 is coupled to a range select circuit 584 configured to select a current multiplier n to use to determine a value n*I of a programmable current source 586 and to use to determine a corresponding counter divide ratio m/n for use in the second embodiment of the timer circuit 200 .
The programmability for the time-out period is implemented by varying the comparator threshold V ref1 , which is achieved by varying the value of the tunable resistor (R ext ) 250 . A limitation upon the practical timeout range of the first timer 200 is that in some applications, the comparators should be able to accurately handle wide range of magnitudes of V ref1 , such as a four orders of magnitude range of V ref1 . However, comparators that are accurate over a voltage range that can vary by four orders of magnitude can be expensive and difficult to implement, and therefore, impractical.
The gain-ranging circuitry 582 , 584 is used to fix a tuning range of the comparator threshold V ref1 to overcome the comparator offset. More specifically, the comparator threshold V ref1 is set so that the difference between the comparator thresholds is large enough so that comparator offset does not become a significant source of error. To do this, before the second embodiment of the timer circuit 200 is put into operation, during power-up for example, the ADC 582 performs an initial sampling and sensing of the value V ref1 for a selected value of resistor 250 . In response to a determination of the value of V ref1 , the range select circuit 584 dynamically adjusts the n factors so as to set V ref1 within a desired voltage range while setting a counter divider ratio to achieve a desired timeout interval. More particularly, the ADC 582 samples the V ref1 resulting from a sample current value I and a selected value for the tunable resistor 250 . It will be understood that in general, a larger value for the tunable resistor 250 is used to achieve longer timeout interval, and a smaller value for the tunable resistor 250 is used to achieve a shorter timeout interval. However, by increasing the value of current used to generate V ref1 for a smaller values of resistor 250 by a factor n, for example, a V ref1 value can be achieved for the smaller value of resistor 250 that is in the same range as a V ref1 value for a larger value of resistor 250 for which the current is not increased by the factor n. The increased current used with the smaller value of resistor 250 , which is scaled by a factor of n, is compensated for by making a corresponding scaling of the counter divider ratio m by the inverse of the same factor n, to achieve the expected shorter time-out period for the smaller value of the resister 250 .
Neglecting the comparator offset and propagation delay, and assuming that the current sources I are equally matched, the timeout period for the circuit of FIG. 3 can be represented as,
Timeout
=
2
(
m
/
n
)
C
1
I
(
Vref
1
-
Vref
2
)
=
2
m
C
1
n
I
(
n
*
I
Re
x
)
=
2
m
C
1
Re
x
It can be observed that the current I gets cancelled out in the equation, thus relaxing the accuracy requirement for the on-chip bias currents. Also, it is noted that the time-out period is ideally dependent upon the counter divide ratio m, the on-chip capacitor C 1 , and the external resistor R ex .
FIG. 5 is an illustrative timing diagram representing the operation of the timer circuit 200 of FIG. 3 in accordance with some embodiments. It is assumed that at time t 0 , the timer circuit 200 already is enabled and has just completed its first count and hence the count is 1 at t 0 . It is assumed that the counter 226 detects and counts a positive edge from VL. However in an alternative embodiment (not shown), a counter could be configured to detect a falling edge.
At time t 0 , V 1 and VL have logic low values, and the capacitor voltage VC is charging, i.e. increasing in value. V 1 has a logic level high value and V 2 has a logic level low value. The timeout signal (TO) has a logic level low value.
At time t 1 , the value of VC surpasses the value of V ref1 . In response to the capacitor 260 charging to a VC value greater than the value V ref1 , the first comparator 206 produces a transition of V 1 from the logic high level value to a logic level low value. In response to the transition of V 1 to a logic low level value, the latch circuit 210 produces a logic level low to high transition of VL. It will be appreciated that the latch circuit 210 produces a logic level low to high transition of VL in response to a falling edge transition of V 1 . In response to the rising edge of VL, the counter circuit 226 produces a count increment from 1 to 2. The value VL is fed back to the logic circuit 212 , which in turn provides V 1 , which is a phase shifted version of VL. The timeout signal (TO) still has a logic level low value.
At time t 2 , V 1 transitions from a logic level low value to a logic level high value. In response to the transition of V 1 from low to high, PMOS device 216 turns off and NMOS device 218 turns on and the capacitor 260 transitions from charging to discharging. The voltage V 2 remains at the logic level low value. The count remains 2. The timeout signal (TO) still has a logic level low value.
At time t 3 , the value of VC falls below the value of V ref1 . In response to the capacitor 260 discharging to a VC value less than the value V ref1 , the first comparator 206 produces a transition of V 1 from a logic level low value to a logic level high value. However, the latch circuit 210 continues to provide VL at a logic level high value. Thus, it will be appreciated that the latch circuit 210 does not produce a logic level transition of VL in response to a rising trailing edge transition of V 1 . The voltage VC of the capacitor 260 continues to discharge. The voltage V 2 remains at the logic level low value. The count remains 2. The timeout signal (TO) still has a logic level low value.
At time t 4 , the value of VC falls below the value of V ref2 . In response to the capacitor 260 discharging to a VC value less than the value V ref2 , the second comparator 208 produces a transition of V 2 from a logic low level value to a logic level high value. In response to the transition of V 2 to a logic level high value, the latch circuit 210 produces a logic level high to low transition of VL. It will be appreciated that the latch circuit 210 produces a logic level high to low transition of VL in response to a rising leading edge transition of V 2 . The value VL is fed back to the logic circuit 212 , which in turn provides a high to low transition of V 1 , which is a phase shifted version of VL. The voltage V 1 remains at the logic level high value. The count remains 2. The timeout signal (TO) still has a logic level low value.
At time t 5 , V 1 transitions from a logic level high value to a logic level low value. In response to the transition of V 1 from high to low, PMOS device 216 turns on and NMOS device 218 turns off and the capacitor 260 transitions from discharging to charging. The voltage V 1 remains at the logic level high value. The count remains 2. The timeout signal (TO) still has a logic level low value.
At time t 6 , the value of VC rises above the value of V ref2 . In response to the capacitor 260 charging to a VC value greater than the value V ref2 , the second comparator 208 produces a transition of V 2 from a logic level high value to a logic level low value. However, the latch circuit 210 continues to provide VL at a logic level low value. Thus, it will be appreciated that the latch circuit 210 does not produce a logic level transition of VL in response to a falling trailing edge transition of V 2 . The voltage VC of the capacitor 260 continues to charge. The voltage V 1 remains at the logic level high value. The count remains 2. The timeout signal (TO) still has a logic level low value.
At time t 7 , the value of VC again surpasses the value of V ref1 . In response to the capacitor 260 charging to a VC value greater than the value V ref1 , the first comparator 206 produces a transition of V 1 from the logic high level value to a logic level low value. In response to the transition of V 1 to a logic low level value, the latch circuit 210 produces a logic level low to high transition of VL. It will be appreciated that the latch circuit 210 produces a logic level low to high transition of VL in response to a falling leading edge transition of V 1 . In response to the rising edge of VL, the counter circuit 226 produces a count increment from 2 to 3. The value VL is fed back to the logic circuit 212 , which in turn provides V 1 , which is a phase shifted version of VL. The timeout signal (TO) still has a logic level low value.
At time t 8 , V 1 again transitions from a logic level low value to a logic level high value. In response to the transition of V 1 from low to high, PMOS device 216 turns off and NMOS device 218 turns on and the capacitor 260 again transitions from charging to discharging. The voltage V 2 remains at the logic level low value. The count remains 3. The timeout signal (TO) still has a logic level low value.
At time t 9 , the value of VC again falls below the value of V ref1 . In response to the capacitor 260 discharging to a VC value less than the value V ref1 , the first comparator 206 again produces a transition of V 1 from a logic level low value to a logic level high value. However, the latch circuit 210 continues to provide VL at a logic level high value. The voltage VC of the capacitor 260 continues to discharge. The voltage V 2 remains at the logic level low value. The count remains 3. The timeout signal (TO) still has a logic level low value.
The cycle continues until the count reaches m whereupon the timeout signal transitions from logic level low value to logic level high value. The transition of the timeout signal to a high value may be used to indicate to a supervisor circuit (not shown), for example, that reset timeout interval has completed, and that a device (not shown) under control of the supervisor now may be put into active use through de-assertion of a reset signal (not shown), for example. Also, in response to transition of the timeout signal to a high value, the Enable signal may be transitioned to a logic level low value causing the timer circuit to shut off and stop counting. Also, in accordance with some embodiments, internal nodes of the timer 200 may be clamped to a default state (not shown) in response to transition of the timeout signal to a high value.
FIG. 6 is an illustrative schematic diagram of the second embodiment of FIG. 3 showing certain details of first embodiment of the programmable current source 586 that is configured to adjust current through the resistor 250 so as to amplify voltage across it to obtain a V ref1 value that achieves an amplified comparator threshold voltage, so that comparator offset does not become a significant source of error, in accordance with some embodiments. A first (base) candidate current source 702 provides current I. A second candidate current source 704 provides current 10*I. A third candidate current source 706 provides current 100*I. A fourth candidate current source 708 provides current 1000*I. The range select circuit 584 selectively closes a first switch 712 , to select the first current source having value I; selectively closes a second switch 714 , to select the second candidate current source having value 10*I; selectively closes a third switch 716 , to select the third candidate current source having value 100*I; and selectively closes a fourth switch 718 , to select the fourth candidate current source having value 1000*I.
FIG. 7 is an illustrative flow diagram of a current range determination process 600 for use with the first embodiment of the gain range circuitry of FIG. 6 , to determine a scaling factor for use to keep V ref1 within a prescribed voltage range while achieving a desired timeout interval in accordance with some embodiments. The logic circuit 584 is configured to perform the process 600 during a startup phase before the timer circuit begins operating in a normal mode in which a counter 226 is incremented in response to cyclical charging and discharging of capacitor 260 . In accordance with some embodiments, a range of different candidate current values to act as the first current 586 are available each of which is a different factor n of a base current value. More specifically assuming that the candidate base current has a value I, the range of different current sources provide the range of candidate current values for the first current 586 . Table A sets forth an example set of candidate current values.
TABLE A
n (Factor)
Current Amplification Value
1
I
10
10*I
100
100*I
1,000
1,000*I
10,000
10,000*I
The range select circuit 584 is configured to implement the process 600 in accordance with some embodiments. More specifically, under control of the range select circuit 584 , the ADC 582 senses V ref1 , for a given selected value of resistor 250 , for each of the candidate current values of Table A in sequence, starting with the base current value I, until a value for the current and corresponding n factor are determined for which V ref1 is within the target voltage range. The determined current value and the corresponding n factor then are used during operation of the timer circuit 200 .
Referring to FIG. 7 , module 601 provides an initial current value through the resistor 250 . It is assumed in this embodiment that the initial current value is a lowest current value. Module 602 receives a V ref1 value sensed by the ADC 582 . Decision module 604 determines whether the sensed V ref1 value is within the predetermined target voltage range. In accordance with some embodiments, the predetermined voltage range is 0.1V to 1V. In response to a determination that V ref1 is not within the target voltage range, module 606 instructs the ADC 582 to obtain a sample using a next larger available candidate current value. Control next flows back to module 602 . However, in response to decision module 604 determining that V ref1 is within the target voltage range, module 608 selects the presently selected candidate current value for use during operation and module 610 applies a corresponding adjustment to the divider ratio to the counter circuit 226 . In accordance with some embodiments the adjustment to the counter divider ratio is approximately in inverse proportion to the current scaling. For example, in response to a determination that a current value 100*I results in V ref1 being in range, then the counter divider ratio is adjusted to be m/100. Module 612 starts up the counting operation of the timer circuit 200 .
FIG. 8 is an illustrative chart showing example relationships between values of the target reference voltage range, V ref1 , tunable resistor 250 , corresponding timeout delays, current values and n factors for use with the first embodiment of the gain range circuitry of FIG. 6 , in accordance with some embodiments. It is noted that target reference voltage range, V ref1 remains fixed at 0.1V to 1V for each combination of timeout delay, current value, and n factor. For example, if the tunable resistor 250 has a value R, then the timeout delay is approximately 1 ms and the current is selected to be approximately 1000*I. It will be appreciated that in this example, for resistor value 10000R, the n factor is 1 and the divider ration is m/1=m. However, if the tunable resistor 250 has a value 100R, then the timeout delay is approximately 100 ms and the current is 10*I or 100*I, whichever provides a value of V ref1 that is within range. It will be appreciated that in this example, for resistor value 100R, the n factor is 10 or 100 and the divider ratio is adjusted to be m/10 or m/100 depending upon which current value is selected. In accordance with some embodiments, the boundaries between the different ranges are not sharp. Even if the ADC 582 makes a small error in determining a sensed value for V ref1 , the comparator circuitry will operate properly.
FIG. 9 is an illustrative schematic diagram of the third embodiment of a timer circuit 800 showing certain details of a second embodiment of the gain range circuitry 802 that is configured to adjust the V ref1 voltage value using a constant current provided by current source 806 through resistor 250 , and a voltage amplifier 802 which amplifies the comparator threshold voltage so that comparator offset does not become a significant source of error, in accordance with some embodiments. Components of the third embodiment 800 that are the same as the third embodiment 200 are labeled with identical reference numbers and will not be described again. A voltage amplifier 802 is coupled to receive a voltage across resistor 250 as an input voltage and to provide as an output voltage an amplified input voltage by ×1, ×10, ×100 and ×1000 gain factors, which provides a V ref1 value in accordance with some embodiments.
FIG. 10 is an illustrative flow diagram of a voltage range determination process 1000 to determine a scaling factor for use to keep V ref1 within a prescribed voltage range while achieving a desired timeout interval in accordance with some embodiments. The logic circuit 804 is configured to perform process 1000 during a startup phase before the timer circuit begins operating in a normal mode in which a counter 226 is incremented in response to cyclical charging and discharging a capacitor 260 . In accordance with some embodiments, a range of different candidate voltage gain values are available each of which is a different factor n of a base voltage value IR ex . More specifically assuming that a current value I flows through the programmable resistor 250 , which has a value R ex , an output voltage IR ex acts as a basis for a range of candidate voltage gain values. Table B sets forth an example set of candidate current values.
TABLE B
n (Factor)
Voltage Amplification Value
1
IR ex
10
10*IR ex
100
100*IR ex
1,000
1,000*IR ex
The range select circuit 584 is configured to implement the process 1000 in accordance with some embodiments. More specifically, under control of the range select circuit 584 , the ADC 582 senses V ref1 , for a given selected value of resistor 250 , for each of the candidate voltage amplification values of Table B in sequence, starting with the base voltage value IR ex , until a value for the voltage gain and corresponding n factor are determined for which V ref1 is within the target voltage range. The determined voltage gain value and the corresponding n factor then are used during operation of the timer circuit 200 .
Referring to FIG. 10 , module 1001 provides an initial voltage value output by the voltage amplifier circuit 802 . It is assumed in this embodiment that the initial voltage value is a lowest current value. Module 1002 receives a V ref1 value sensed by the ADC 582 . Decision module 1004 determines whether the sensed V ref1 value is within the predetermined target voltage range. In accordance with some embodiments, the predetermined voltage range is 0.1V to 1V. In response to a determination that V ref1 is not within the target voltage range, module 1006 instructs the ADC 582 to obtain a sample using a next larger available candidate voltage gain value. Control next flows back to module 1002 . However, in response to decision module 1004 determining that V ref1 is within the target voltage range, module 1008 selects the presently selected candidate voltage gain value for use during operation and module 1010 applies a corresponding adjustment to the divider ratio of the counter circuit 226 . In accordance with some embodiments the adjustment to the counter divider ratio is approximately in inverse proportion to the voltage amplification. For example, in response to a determination that a voltage value 100*IR ex results in V ref1 being in range, then the counter divider ratio is adjusted to be m/100. Module 1012 starts up the counting operation of the timer circuit 800 . The foregoing description and drawings of embodiments are merely illustrative of the principles of the invention. Various modifications can be made to the embodiments by those skilled in the art without departing from the spirit and scope of the invention, which is defined in the appended claims. | A timer circuit is provided comprising: a resistor; a programmable gain circuit coupled to amplify the reference level based upon a resistor and a selected gain; a detection circuit coupled to identify the amplified reference level based upon a resistor; a selection circuit configured to select the gain based at least in part upon the identified amplified reference level based upon a resistor; a comparator circuit configured to transition between providing a signal having a first value and providing a signal having a second value based at least in part upon comparisons of a reactive circuit element excitation level with the amplified reference level based upon a resistor and with a second reference level; and reactive circuit element excitation circuit configured to reverse excitation of the reactive circuit element in response to the comparator circuit transitioning between providing the signal having the first value and providing the signal having the second value. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Korean Application Nos. 2007-37140, filed Apr. 16, 2007, and 2007-93284, filed Sep. 13, 2007, in the Korean Intellectual Property Office, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Aspects of the present invention relate to an image forming apparatus, and more particularly, to a compact image forming apparatus that can be used on a desktop.
[0004] 2. Description of the Related Art
[0005] Generally, the size of an image forming apparatus is determined by the size of sheets of usable paper. Moreover, image forming apparatuses for use in offices are designed so that large capacity paper cassettes, network printing functions, and various sizes of paper can be used. As a result, the size of image forming apparatuses has increased.
[0006] On the other hand, image forming apparatuses for use in the home are designed for compactness and low noise rather than high speed and powerful functions, because such image forming apparatuses are used less frequently than image forming apparatuses for office use.
[0007] FIG. 1 illustrates a conventional multifunction peripheral (MFP) as an example of an image forming apparatus. The conventional MFP includes a scanning unit and a printing unit. Referring FIG. 1 , the MFP includes a first body 10 in which the printing unit is mounted, and a second body 20 in which the scanning unit is mounted.
[0008] The first body 10 is configured such that, if needed, an electrophotographic type image forming apparatus or an inkjet type image forming apparatus may be provided. The first body 10 of FIG. 1 , in which an electrophotographic type image forming apparatus is provided, includes a paper cassette 11 , a pickup unit 12 , a feeding unit 13 , a developing unit 14 , a transferring unit 15 , a fixing unit 16 , a discharging unit 17 , and a light emitting unit 18 .
[0009] The second body 20 , which is provided above the first body 10 , is the scanning unit and includes a plate 21 on which a document is placed, a charge coupled device (CCD) module 22 that is mounted on a bottom surface of the plate 21 so as to move from side to side, and a plate cover 23 that is designed to cover the plate 21 .
[0010] However, the conventional MFP has been developed without taking into consideration the need for miniaturization. As a result, the dimensions of conventional MFPs are too large to fit on desktops. Accordingly, a separate space is required for the MFP, resulting in an inconvenience to a user.
SUMMARY OF THE INVENTION
[0011] Aspects of the present invention provide to a compact image forming apparatus suitable for desktop use.
[0012] According to an aspect of the present invention, there is provided an image forming apparatus including: a first body including a developing unit to perform an image forming operation on a print medium; and a second body provided above the first body to pivot between a closed position and an open position in relation to the first body, the second body including a light emitting unit, wherein the light emitting unit is directly above the developing unit when the second body is in the closed position, and the developing unit is exposed to an outside of the image forming apparatus when the second body is in the open position.
[0013] The second body may include a scanning unit, and a height of the first body may be approximately two or three times greater than that of the second body.
[0014] The first body may have a height of less than 125 mm, and the first and second bodies may have a combined height of less than 165 mm.
[0015] The first body may have a height of 110 mm to 125 mm, and the first and second bodies may have a combined height of 160 mm to 170 mm.
[0016] A weight of the first body may be greater than that of the second body.
[0017] The weight of the first body may be at least 1.5 to 2.5 times that of the second body.
[0018] An opening angle between the second body and the first body may be approximately 40° to 80°.
[0019] The first body may include a feeding unit, a developing unit, a transferring unit, a fixing unit and a discharging unit.
[0020] A print medium picked up by the feeding unit may be printed and discharged after a feeding direction is changed only once.
[0021] The direction in which the feeding unit slides open may be the same as the direction in which the print medium is discharged by the discharging unit.
[0022] The second body may include a scanning unit to scan a document.
[0023] The scanning unit may include: a plate on which the document is placed; a scanning module that moves from side to side on the plate, the scanning module being provided below the plate; and a plate cover that is pivotably attached to the second body by a hinge to cover the plate by movement around the hinge.
[0024] An initial position of the scanning module may be on a side opposite a hinge point at which the second body is attached to the plate cover by the hinge.
[0025] The first body may include a groove in which a print media support member is adapted to slide and which is formed in a portion in which the print medium is discharged.
[0026] According to another aspect of the present invention, there is provided an image forming apparatus including: a first body including a developing unit to perform an image forming operation on a print medium, and a feeding unit to stack print media and to feed the print medium toward the developing unit in a first direction; and a second body provided above the first body to pivot between a closed position and an open position in relation to the first body, the second body having a same width as the first body and including a scanning unit to scan a document and a light emitting unit, wherein the light emitting unit is directly above the developing unit when the second body is in the closed position, the developing unit is exposed to an outside of the image forming apparatus when the second body is in the open position, the feeding unit slides open in a second direction that is opposite the first direction, and the print medium is discharged from the first body in the second direction after the image forming operation is performed thereon.
[0027] The first body may have a height of 110 mm to 125 mm, and the first and second bodies may have a combined height of 160 mm to 170 mm.
[0028] A weight of the first body may be greater than that of the second body.
[0029] The weight of the first body may be at least 1.5 to 2.5 times greater than that of the second body.
[0030] An opening angle between the second body and the first body may be approximately 40° to 80°.
[0031] According to yet another aspect of the present invention, there is provided an image forming apparatus including: a first body including a developing unit to perform an image forming operation on a print medium, and a feeding unit to stack print media and to feed the print medium toward the developing unit in a first direction; and a second body provided above the first body to pivot between a closed position and an open position in relation to the first body, the second body including a scanning unit to scan a document, wherein the feeding unit slides open in a second direction that is opposite to the first direction, and the print medium is discharged from the first body in the second direction after the image forming operation is performed thereon.
[0032] According to still another aspect of the present invention, there is provided an image forming apparatus including a feeding unit to stack print media; a conveying roller to convey the print media fed by the feeding unit; a transferring section to transfer an image onto the print media conveyed by the conveying roller; and a fixing section to fix the image transferred by the transferring section, wherein a route from the conveying roller to the transferring section and/or a route from the transferring section to the fixing section enables the print media to be bent in a substantially reverse direction with respect to a print media route, which is reversed in the conveying roller.
[0033] The print media route may be substantially reversed adjacent to the conveying roller.
[0034] The fixing section may be disposed in a gap between the transferring section and an upper portion of the conveying roller.
[0035] The upper portion of the conveying roller may be disposed above the transferring section and the fixing section.
[0036] The image forming apparatus may further include a discharging unit to discharge the print media conveyed through the fixing section. The discharging unit may be disposed in the same direction as that in which the print media is conveyed from the transferring section to the fixing section.
[0037] A photoconductive medium may face a transferring unit in the transferring section, and a heating device may face a pressing device in the fixing section. If the photoconductive medium is disposed above the transferring unit, the rigidity of the photoconductive medium may be greater than that of the transferring unit, and if the photoconductive medium is disposed below the transferring unit, the rigidity of the photoconductive medium may be less than that of the transferring unit. If the heating device is disposed above the pressing device, the rigidity of the heating device may be greater than that of the pressing device, and if the heating device is disposed below the pressing device, the rigidity of the heating device may be less than that of the pressing device.
[0038] The discharging unit may include a print media support member to stack the print media conveyed through the fixing section.
[0039] The image forming apparatus may further include a groove in which a print media support member is adapted to slide.
[0040] The image forming apparatus may further include a device to open the groove when the print media support member is attached, and to close the groove when the print media support member is detached.
[0041] The image forming apparatus may further include an elastic member disposed adjacent to the device.
[0042] According to still another aspect of the present invention, there is provided an image forming apparatus including a feeding unit to stack print media; a conveying roller to convey the print media fed by the feeding unit; a transferring section to transfer an image onto the print media conveyed by the conveying roller; and a fixing section to fix the image transferred by the transferring section, wherein the upper portion of the conveying roller is disposed above the transferring section and the fixing section.
[0043] The fixing section may be disposed above the transferring section.
[0044] Additional aspects and/or 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 by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] These and/or other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of the embodiment, taken in conjunction with the accompanying drawings of which:
[0046] FIG. 1 is a schematic view of a conventional multifunction peripheral (MFC);
[0047] FIG. 2 is a perspective view of an image forming apparatus according to an embodiment of the present invention;
[0048] FIG. 3 is a front view of the image forming apparatus shown in FIG. 2 ;
[0049] FIG. 4 is a side view of the image forming apparatus shown in FIG. 2 ;
[0050] FIG. 5 is a perspective view of an image forming apparatus according to another embodiment of the present invention; and
[0051] FIG. 6 is a side view of the image forming apparatus shown in FIG. 5 .
[0052] FIGS. 7A to 7D are views of a print media support member of the image forming apparatus shown in FIG. 5 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0053] Reference will now be made in detail to the present embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below in order to explain the present invention by referring to the figures.
[0054] FIG. 2 is a perspective view of an image forming apparatus according to an embodiment of the present invention, FIG. 3 is a front view of the image forming apparatus shown in FIG. 2 , and FIG. 4 is a side view of the image forming apparatus shown in FIG. 2 . Referring to FIGS. 2 through 4 , the image forming apparatus includes a first body 100 and a second body 200 .
[0055] The first body 100 includes a printing unit mounted therein, a feeding unit 110 , a developing unit 120 , a transferring unit 130 , a fixing unit 140 and a discharging unit 150 . The feeding unit 110 is mounted on the first body 100 so as to slide open when a button 111 is pressed. However, it is understood that according to other aspects, other methods and devices may be used to slide the feeding unit 110 out. For example, the feeding unit 110 may include a handle such that the feeding unit 110 is manually slid out by pulling the handle. Furthermore, the feeding unit 110 holds a plurality of sheets of print media. The print media is any media on which an image forming apparatus prints. For example, the print media may be paper or transparency sheets. In order to reduce the height of the image forming apparatus, the feeding unit 110 may, although not necessarily, hold approximately 100 sheets of print media.
[0056] As shown in FIG. 4 , the developing unit 120 is detachably mounted on the first body 100 , and prints an image on a surface of a print medium while rotating in close contact with the transferring unit 130 . A photoconductive medium 121 mounted in the developing unit 120 may, although not necessarily, have a diameter of approximately 20 mm in order to minimize a size of the image forming apparatus.
[0057] The fixing unit 140 includes a heating roller 141 and a pressing roller 142 . The fixing unit 140 applies heat and pressure to the print medium passing through the developing unit 120 and the transferring unit 130 , and fixes the image on the surface of the print medium. A heat insulating member 143 is mounted above the fixing unit 140 to prevent heat emitted from the fixing unit 140 from being transmitted to the second body 200 .
[0058] The discharging unit 150 includes a plurality of roller units 151 provided in positions adjacent to the fixing unit 140 . The discharging unit 150 discharges sheets of print medium passing through the fixing unit 140 towards a front portion of the first body 100 . The front portion of the first body 100 is a portion from which the feeding unit 110 may be detached and the printed sheets of print media may be discharged.
[0059] The discharged sheets of print media may drop onto a surface on which the first body 100 is provided, or may be dropped on to a print media support member 152 that is mounted on the front portion of the first body 100 (as shown in FIG. 4 ). The print media support member 152 is adapted to slide in a groove 101 (illustrated in FIGS. 2 and 3 ) provided in the front portion of the first body 100 .
[0060] As shown in FIGS. 7A to 7B , the print media support member 152 may be attached onto the groove 101 provided in the front portion of an external frame 1 of the first body 100 . Additionally, a cover 102 may be included in an inlet of the groove 101 to elastically open and close the groove 101 . Here, the elastic movement of the cover 102 may be made by an elastic member 103 , such as a leaf spring or a coil spring, which is connected to the cover 102 and has an elastic force.
[0061] If the elastic member 103 is disposed above the cover 102 , as shown in FIGS. 7A and 7B , the print media support member 152 may be inserted from the left upper side to the right lower side, so it is possible to open and close the groove 101 by the movement of the cover 102 without separately having the elastic member 103 . In this situation, a hinge point h may be disposed in the upper side in order to rotate the cover 102 .
[0062] Alternatively, if the elastic member 103 is disposed below the cover 102 , as shown in FIGS. 7C and 7D , it is difficult for the cover 102 to return to the original position itself, so the elastic member 103 is required.
[0063] As shown in FIG. 4 , the developing unit 120 , transferring unit 130 , fixing unit 140 and discharging unit 150 are mounted in order above the feeding unit 110 , and form a C-shaped print medium feeding path toward the front portion of the first body 100 . Accordingly, the direction in which the feeding unit 110 slides open may be the same as the direction in which the print medium is discharged by the discharging unit 150 . Thus, it is possible to reduce the height H 1 of the first body 100 by removing unnecessary space in the interior of the first body 100 .
[0064] Referring to FIGS. 2 through 4 , the second body 200 includes a light emitting unit 240 and a scanning unit including a plate 210 , a scanning module 220 , and a plate cover 230 . Additionally, the second body 200 has the same width as the first body 100 , and is mounted to pivot open and closed on the first body 100 .
[0065] The plate 210 is made of a light permeable material, such as glass. The scanning module 220 is mounted so as to be able to be moved from side to side on the bottom surface of the plate 210 . The plate cover 230 is mounted to pivot open and closed on the second body 200 and a hinge point 231 . The initial position of the scanning module 220 is on a side of the second body 200 opposite that of the hinge point 231 (as shown in FIG. 4 ). Accordingly, the scanning module 220 may scan images of documents placed on the plate 210 . Specifically, the initial position of the scanning module 220 may be provided in the front portion of the second body 200 , and the hinge point 231 may be provided in the rear portion of the second body 200 . However, it is understood that according to other aspects, the scanning module 220 may be initially provided in a middle portion of the second body 200 or on a same side of the second body 200 as the hinge point 220 .
[0066] If the initial position of the scanning module 220 is on the front portion of the second body 200 , a document may be placed on the plate 210 in the front portion of the second body 200 . Accordingly, the hinge point 231 of the cover 230 may have a simple configuration, and an angle between the plate 210 and the cover 230 can be reduced when the cover 230 is closed to cover the document.
[0067] The light emitting unit 240 is mounted in an open space of a lower part of the second body 200 and exposes the photoconductive medium 121 of the developing unit 120 mounted in the first body 100 . Thus, because the light emitting unit 240 is mounted in a remaining open space of the second body 200 , the height of the image forming apparatus can be less than that of an apparatus in which the light emitting unit 240 is mounted in the first body 100 .
[0068] A portion of the second body 200 that faces the fixing unit 140 is provided to cover the fixing unit 140 . That is, the fixing unit 140 protrudes upwardly (towards the second body 200 ) from the first body 100 because the heat insulating member 143 is mounted thereon. Accordingly, the second body 200 includes a housing groove 250 provided to face the fixing unit 140 in order to house the fixing unit 140 .
[0069] An opening angle between the second body 200 and the first body 100 may, although not necessarily, be approximately 40° to 80. If the opening angle is too small, a user may experience inconvenience when removing jammed paper. Conversely, if the opening angle is too large, a hinge portion 260 that rotatably connects the first body 100 and the second body 200 may break due to the weight of the second body 200 .
[0070] In order to prevent the image forming apparatus from flipping due to inertia caused by the weight of the second body 200 when opening the second body 200 , the height H 1 of the first body 100 may be greater than that of the second body 200 (for example, approximately two to three times greater). The first body 100 may, although not necessarily have a height H 1 less than 125 mm, and the first body 100 and the second body 200 may, although not necessarily, have a combined height H 2 less than 165 mm. For example, the first body 100 may have a height H 1 less than 114 mm, and the first body 100 and the second body 200 may have a combined height H 2 of less than 163 mm. Furthermore, to prevent flipping, the weight of the first body 100 may be greater than that of the second body 200 (for example, by a magnitude of at least 1.5 to 2.5 times greater).
[0071] The direction in which the feeding unit 110 slides open, the direction in which the print media housed in the feeding unit 110 is discharged, and the direction in which the scanning unit 220 moves from side to side may be the same. Accordingly, when a user prints or copies on a second side of a paper (on which printing has already been performed on a first side), the user can conveniently use the image forming apparatus without confusion.
[0072] It is understood that aspects of the present invention can be applied to an image forming apparatus including only a printing unit without scanning and copying functions. FIGS. 5 and 6 illustrate an image forming apparatus according to another embodiment of the present invention, implemented without the second body 200 as described above with reference to FIGS. 2 through 4 . Referring to FIG. 5 , the image forming apparatus includes a main body 310 , a feeding unit 320 , a developing unit 330 , a transferring unit 340 , a fixing unit 350 , a discharging unit 360 , and a cover 370 that is mounted to open and close in order to, for example, remove jammed paper or maintain the above mentioned components. The cover 370 includes a light emitting unit 380 mounted therein. The main body 310 may, although not necessarily, have a height of less than 125 mm. The main body 310 has the same configuration as the first body 100 described with reference to FIGS. 2 through 4 , so a description thereof is omitted here.
[0073] Hereinafter, operations of the image forming apparatus according to aspects of the present invention will be described. Referring to FIG. 4 , the image forming apparatus according to an embodiment of the present invention includes a first body 100 in which the printing unit is mounted, and a second body 200 in which the scanning module 220 is mounted. The second body 200 may be opened and closed from the first body 100 (i.e., pivoting up and down from the first body 100 ).
[0074] In order to reduce the height of the first body 100 , a C-shaped paper feeding path is provided to change a paper feeding direction once. Specifically, a developing unit 120 , a transferring unit 130 , a fixing unit 140 , and a discharging unit 150 are arranged in order above the feeding unit 110 to provide the C-shaped paper feeding path. Accordingly, the first body 100 may have height H 1 of less than 125 mm, and the first body 100 and the second body 200 may have height H 2 of less than 165 mm. As a result, the image forming apparatus can be directly mounted on a desktop, for example, without a separate space required.
[0075] The image forming apparatus having a low height as described above may be placed conveniently from a user (for example, directly on a desktop), so it is not necessary for the user to travel a far or inconvenient distance to a position in which the image forming apparatus is placed in order to perform copying, scanning, and/or printing. Additionally, the print medium may be printed on so that a printed surface is visible upon discharge, making it possible to immediately check the printing results. Furthermore, the user may stack print media by attaching a print media support member 152 onto a groove 101 (as illustrated in FIG. 4 ), if needed, or may allow the output print media to be piled on a surface on which the image forming apparatus is mounted.
[0076] If paper jamming occurs during printing or copying, or if maintenance of the developing unit 120 or the fixing unit 140 is needed, the user may lift the second body 200 so that the developing unit 120 and the fixing unit 140 are exposed and easily accessible.
[0077] The first body 100 has a height and/or a weight greater than the second body 200 , so it is possible to prevent the image forming apparatus from flipping due to inertia during rotation of the second body 200 when the user opens the second body 200 . Additionally, the opening angle between the first body 100 and the second body 200 may be approximately 45°. Accordingly, a user can easily reach into a gap between the first body 100 and the second body 200 to change the developing unit 120 or to remove jammed paper. In addition, it is possible to prevent the second body 200 or the hinge portion 260 connecting the first body 100 and the second body 200 from being broken due to excessive opening of the second body 200 .
[0078] As illustrated in FIGS. 5 and 6 , the image forming apparatus according to another embodiment of the present invention does not include the second body 200 having the scanning unit.
[0079] According to aspects of the present invention described above, a user can conveniently place an image forming apparatus (for example, on a desktop), and accordingly, the user can more conveniently operate the image forming apparatus. Additionally, a specialized image forming apparatus can be provided to a user who primarily prints or copies in small quantities.
[0080] Although a few embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in this embodiment without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents. | An image forming apparatus including: a first body including a developing unit to perform an image forming operation on a print medium, and a second body provided above the first body to pivot between a closed position and an open position in relation to the first body, the second body including a light emitting unit, wherein the light emitting unit is directly above the developing unit when the second body is in the closed position, and the developing unit is exposed to an outside of the image forming apparatus when the second body is in the closed position. A user can place the image forming apparatus on a desktop, which increases convenience in using the apparatus. Additionally, a specialized image forming apparatus can be provided to a user who mainly wants to print and copy in small quantities. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a Division of application Ser. No. 09/342,758 filed Jun. 29, 1999, now allowed, the contents of which are hereby incorporated by reference.
FIELD OF INVENTION
[0002] This invention relates to automobile passive restraint safety devices and, more particularly, to pyrotechnic gas generator units for inflating automobile airbags.
BACKGROUND OF THE INVENTION
[0003] Large numbers of people are killed or injured annually in automobile accidents wherein the driver and/or passengers are thrown forward so as to impact against solid surfaces within the vehicle. Consequently, there has been considerable development of passive restraint systems for use with these vehicles. The term “passive” means that the driver or passenger need not do anything to benefit from the device, as opposed to seat belts which are considered to be an “active” restraint system. One system which has been extensively investigated senses rapid deceleration of the vehicle such as that which occurs upon a primary impact between an automobile and, for example, another car. It thus initiates inflation of a bag between the interior surface of the car and the vehicle occupant prior to the occurrence of any secondary collision between the driver and/or passengers and the interior of the car. Airbags have been in widespread use for more than a decade, but accounts of injuries and fatalities caused by their explosive deployment have raised concerns about their safety. Airbag inflation speeds of nearly 200 miles per hour or more are common to compensate for the driver's or the passenger's forward motion during a frontal impact. Inflation of the bag must therefore occur within milliseconds of the primary impact in order to restrain any occupants before they are injured due to secondary collisions against the solid surfaces within the vehicle
[0004] As noted above, there are in the prior art various devices which cause a protective bag to inflate in front of an automobile driver or passenger to cushion the impact with the steering wheel, dashboard or other interior vehicle surface. Usually the device is activated by an inertial switch responsive to a primary crash impact This inertial switch in turn causes an inflator apparatus to quickly inflate a collapsed bag into a protective position in front of the driver or passenger.
[0005] The inflating gas is generally supplied either from a source of compressed air or other compressed gas, such as shown in Chute, U.S. Pat. No. 3,411,808 and Wissing et al., U.S. Pat. No. 3,413,013, and a number of other patents in the crash restraint field. In several other prior art patents (e.g., U.S. Pat. No. 3,880,447 to Thorn et al.; U.S. Pat. No. 4,068,862 to Ishi et al.; U.S. Pat. No. 4,711,466 to Breed; and U.S. Pat. No. 4,547,342; U.S. Pat. No. 4561675 and U.S. Pat. No. 4,722,551 to Adams et al.), the bag is inflated by igniting a pyrotechnic propellant composition and directing the gaseous combustion products produced thereby directly into the bag.
[0006] The first technique discussed above for inflating an airbag requires a reservoir of gas stored at a very high pressure, which may be discharged into the bag as soon as an impact is sensed. In order to obtain a sufficient volume of gas for inflating a vehicle occupant restraint bag, however, a relatively large reservoir of gas, at pressures of 3000 psi or more is required. To open the gas reservoir in the very short time interval required for ensuring the safety of the vehicle occupants, explosive arrangements have been employed in the prior art for bursting a diaphragm or cutting through a structural portion of the reservoir. Such explosive arrangements have significant inherent safety problems, such as the production of shrapnel by the explosion, as well as the relatively high sound level reached within the passenger compartment due to the explosion. The psychological factor of having these explosives in each automobile also cannot be ignored.
[0007] The second technique discussed above employs a pyrotechnic gas generator, or explosive gas generator, having a rapidly burning propellant composition stored therein for producing substantial volumes of hot gaseous products which are then directed into the inflatable bag. Some compositions are available which produce a sufficiently low temperature combustion gas such that the gas may be substantially directed into the bag without danger to the vehicle's occupants. Other systems produce a high temperature combustion product requiring means for cooling the gas before it is introduced into the bag.
[0008] Many forms of gas generators or inflators utilizing combustible solid fuel gas generating compositions for the inflation of crash protection, i.e., “airbag”, restraint systems are known in the prior art. Commonly encountered features among generators utilized for this purpose include: (1) an outer metal housing, (2) a gas generant composition located within the housing, (3) means to ignite the gas generant responsive to a signal received from a sensor positioned at a location removed from the inflator, and (4) means to filter and to cool the gas, positioned between the propellant composition and a plurality of gas discharge orifices defined by the generator housing.
[0009] One such gas generator includes an annular combustion chamber which is bounded by a welded outer casing or housing structure. The combustion chamber encloses a rupturable container or cartridge that is hermetically sealed and which contains a solid gas generant in pelletized form, surrounded by an annular filter assembly. The device further includes a central ignition or initiator zone and a toroidal filter chamber adjoining and encircling the combustion chamber. An inner casing or housing structure is located in close surrounding and supporting relationship to the rupturable container, the inner casing being formed by a cylinder having uniformly spaced peripheral ports or orifices near one end. These orifices provide exit holes to facilitate the flow of gas from the combustion chamber.
[0010] EP-0842828A1 discloses an apparatus for enhancing the operation of an airbag generator based on the use of an explosive device combined with an oxide or zeolite molecular sieve which is coated or applied to the interior surface of a chamber containing stored gas to assist in supplying gas to the airbag in the final phase of the airbag deployment
[0011] Pyrotechnic devices generate gases at high temperatures and produce potentially toxic materials. It is an objective of the present invention to reduce the amount of toxic gases generated during the deployment of an airbag to protect the occupant or driver of the vehicle.
[0012] It is an objective to reduce the potential hazard to a driver or passenger of a vehicle employing passive restraints by reducing the temperature of the gases generated by a pyrotechnic inflator.
[0013] It is an objective of the present invention to provide a safe method of storing gas and to provide a process for scavenging of toxic gases generated in the deployment of an airbag system.
SUMMARY OF THE INVENTION
[0014] The present invention provides two novel improvements to airbag inflators of the prior art to significantly reduce the potential hazard to the driver or passenger of the vehicle. By the pre-loading of the molecular sieve zeolites with gases such as air, nitrogen, or carbon dioxide, the invention provides for rapid airbag inflation by the rapid desorption of this pre-loaded gas. This additional amount of gas evolved reduces the amount of explosive required to inflate the bag which reduces the amount of toxic gases generated by the explosion itself, and the expansion of the stored gas provides a substantial amount of cooling. Following the evolution of the stored gas and combined with the heat provided by the explosion, the adsorbent is now in an activated form and moving freely, or fluidized, within the airbag. It is at this point, the adsorbent additionally provides the remediation of toxic waste gases generated by the exploding inflator device. Molecular sieve zeolites, particularly zeolite X, having been exchanged with lithium or calcium provide both high-capacity gas storage and enhanced toxic waste gas adsorption. The use of molecular sieve zeolites reduces risk of injury to occupants of vehicles from exposure to hot, toxic waste gases following airbag deployment.
[0015] In one embodiment, the present invention is an explosive airbag inflator comprising a pyrotechnic to produce a generated gas and a zeolite molecular sieve which was pre-loaded with a stored gas. The generated gas comprises toxic compounds. The zeolite molecular sieve is disposed in a zeolite layer adjacent to the pyrotechnic. Upon detonation, a sufficient amount of zeolite molecular sieve is present to reduce the temperature of the generated gas and to scavenge at least a portion of the toxic compounds passed to the airbag.
[0016] In another embodiment, the present invention is an explosive airbag inflator comprising a cup having a hollow interior and an open end, a layer of pyrotechnic disposed in the hollow interior, a layer of zeolite molecular sieve pre-loaded with nitrogen or carbon dioxide and disposed on the layer of pyrotechnic, and a membrane or rupture disk disposed over the layer of zeolite molecular sieve.
[0017] In a further embodiment, the present invention is a process for reducing the temperature of an inflating airbag. The process comprises the steps of detonating an airbag inflator comprising a pyrotechnic adjacent to a zeolite molecular sieve. The molecular sieve was pre-loaded with a stored gas. The pyrotechnic provides a generated gas which comprises toxic compounds. The stored gas from the zeolite molecular sieve is desorbed and expanded in the detonation to cool the generated gas and to fluidize at least a portion of the zeolite molecular sieve. At least a portion of the toxic compounds is adsorbed on the zeolite molecular sieve.
BRIEF DESCRIPTION OF THE DRAWING
[0018] The FIGURE is a side view of the apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Inside airbags are pyrotechnic materials which produce gas to fill the airbag with the products of a chemical reaction. Most pyrotechnics used in airbags employ chemical reactions which produce nitrogen such as sodium azide or nitrocellulose. In pyrotechnic systems for airbag inflation, when the main chemical component in the airbag inflator is sodium azide, the sodium azide is mixed together with potassium nitrate and silicon dioxide. This mixture is generally ignited by means of an electrical impulse which results in a detonation or deflagration that liberates a predetermined volume of predominantly nitrogen gas which fills the airbag. The detonation proceeds according to the following major chemical reaction:
2NaN 3 →2Na+3N 2 (1)
[0020] The sodium by-product of reaction reacts with potassium nitrate to generate additional amounts of nitrogen according to the following reaction:
10Na+2KNO 3 →K 2 O+5Na 2 O+N 2 (2)
[0021] The combination of equations (1) and (2) provide an opportunity for the following third reaction to take place:
K 2 O+Na 2 O+SiO 2 →alkaline silicate (3)
[0022] The alkaline silicate, or glass, produced by reaction (3) is a stable compound which does not burn any further. All of these reactions are highly exothermic and occur very rapidly resulting in the production of hot gases. Generally, the components of a pyrotechnic device provide an explosion that releases hot gas at a rate which is sufficient to fill a driver-side airbag (about 35 to 40 liters in volume) within about 35 milliseconds from the time the pyrotechnic device is fired. Other pyrotechnic devices known in the art with different pyrotechnic formulations may evolve more heat and deliver hot gases at even higher temperatures.
[0023] The present invention is directed to the cooling of gases generated by airbag inflators which employ pyrotechnics to provide a generated gas to inflate the airbag. When pyrotechnics are detonated, they produce a generated gas at high temperatures. Pyrotechnics such as sodium azide produces primarily nitrogen gas. Nitrocellulose on detonation produces nitrogen and oxides of nitrogen and carbon monoxide. The reactions produced on detonation of the pyrotechnics are highly exothermic and produce gases at temperatures approaching 3000° C. U.S. Pat. No. 3,912,561 to Doin et al. discloses the gas generating pyrotechnic composition which comprises a fuel selected from the group consisting of alkali metal azides and alkaline earth metal azides combined with an alkali metal oxidant, a nitrogenous compound, and optionally an additive such as silica for reacting with the solid combustion residues. The contents of U.S. Pat. No. 3,912,561 are herein incorporated by reference.
[0024] Airbags generally range in size from as low as 30 liters for a small driver-side airbag up to about 70 liters for a passenger-side airbag. These airbags must be inflated in a sufficiently short period of time, preferably less than about 50 milliseconds (ms), which prevents injury to the driver or the passenger from striking the inside of the vehicle. Inflation time for a driver-side airbag is typically about 35 ms and inflation time for a passenger-side airbag is about 55 ms. Longer inflation times for the passenger-side are permitted because of the longer pathway between the occupant and the interior surface of the vehicle. If the airbag is inflated too aggressively, the bag itself will become hazardous to the driver and passengers. Therefore, typical airbags must be inflated rapidly and allowed to begin a deflation process all within a very short period time. It is believed that the problem of handling airbag deployment can be viewed by recognizing the definition of pressure. Pressure is the net rate of momentum transfer per unit area. Furthermore, the characteristic of the gas assures us that the distribution of molecular velocities is a function of gas temperature. Thus, higher temperatures have higher velocities and higher distributions of gas velocities. Therefore, a higher average molecular velocity implies a higher average pressure and a more aggressive deployment. For a 40-liter airbag, the total gas release potential is about 1.12 moles of nitrogen from the gas generated by the pyrotechnic which is equivalent to about 70 grams of a typical sodium azide compound of the prior art.
[0025] When the pyrotechnic produces or generates the gas to inflate the airbag, the generated gases are produced at the temperature of the reaction which typically ranges between about 2400° and about 2700° C. As these gases are produced, they undergo an expansion into the airbag which provides some cooling. However, the cooling provided by this natural expansion of the generated gases into the airbag still results in very hot gases entering the airbag. If the gas generated by the pyrotechnic is cooled to a still lower temperature, then additional moles of gas are required to inflate the airbag. The present invention provides the cooling of the hot generated gases by absorbing some of the heat by desorbing the stored gases from the zeolite molecular sieve. It is the heat of desorption of the stored gases which provides the cooling. Additional cooling is provided by the further expansion of the stored gases into the airbag while providing additional moles of gas to maintain the safe inflation of the airbag within the very short deployment time required.
[0026] The additional stored gas is supplied by pre-loading an inert gas such as nitrogen or carbon dioxide on a zeolite molecular sieve. Nitrogen is preloaded on a zeolite molecular sieve such as zeolite X by activating the zeolite molecular sieve in the conventional manner and exposing the zeolite molecular sieve at an elevated adsorption pressure ranging from about 5 to about 70 atmospheres (atm) to a gas stream comprising nitrogen. More preferably, the elevated adsorption pressure comprises a pressure between about 30 and about 70 atm. The zeolite molecular sieve capacity for nitrogen at about 68 atm is about 12.6 weight percent. Preferably, the zeolite molecular sieve comprises a highly exchanged zeolite X with a cation selected from the group consisting of sodium, lithium, calcium and mixtures thereof. More preferably, the zeolite molecular sieve comprises a highly exchanged zeolite X having been at least 67 percent exchanged with a cation selected from the group consisting of lithium, calcium and mixtures thereof. Most preferably, the zeolite molecular sieve comprises a highly exchanged zeolite X having been at least 80 percent exchanged with a cation selected from the group consisting of lithium, calcium and mixtures thereof. Preferably, the zeolite molecular sieve comprises a particle size between about 1.4 and about 2.0 mm.
[0027] The stored gas can comprise nitrogen or carbon dioxide. Carbon dioxide has the added advantage in this application in that carbon dioxide can be stored as adsorbed gas on the sieve, or encapsulated into the zeolite molecular sieve. By the term “encapsulated,” it is meant that the zeolite molecular sieve is activated in the conventional manner and exposed to a gas stream comprising carbon dioxide at a high adsorption pressure of about 60 to 80 atm and a high adsorption temperature around 125° C. (400 Kelvin) to about 177° C. (450 Kelvin) to adsorb the carbon dioxide, depending upon the amount of carbon dioxide to be stored. Following the adsorption step, the zeolite molecular sieve is pore closed by quickly cooling the zeolite molecular sieve to about room temperature and slowly reducing the pressure to about 1 to about 5 atm. Carbon dioxide capacities of up to about 20 weight percent of the zeolite molecular sieve can be achieved in this manner When encapsulation is employed for example with carbon dioxide, preferably the zeolite molecular sieve is selected from the group consisting of potassium exchanged zeolite A, potassium exchanged erionite, sodium exchanged clinoptilolite, and mixtures thereof. Carbon dioxide can be stored or encapsulated and employed in an airbag system at relatively low pressure (about 1 to about 5 atm) compared to the pressure required to store nitrogen or other inert gas.
[0028] Once the zeolite molecular sieve has been pre-loaded with the stored gas, the zeolite molecular sieve should be maintained at a storage pressure to maintain the level of the stored gas in the zeolite molecular sieve This is accomplished by sealingly covering the zeolite molecular sieve with a membrane or a rupture disk which will maintain the desired pressure of the stored gas.
[0029] According to the present invention, the zeolite molecular sieve is positioned adjacent to the pyrotechnic such that on detonation, a portion of the heat of the pyrotechnic reaction will be employed to desorb the stored gas from the zeolite molecular sieve. In addition, the force of the pyrotechnic detonation is employed to fluidize at least a portion of the zeolite molecular sieve into the airbag with the generated and stored gases. As the now desorbed zeolite molecular sieve cools, it adsorbs toxic compounds generated in the detonation such as oxides of nitrogen and carbon monoxide. The evolution of the stored gas from the zeolite molecular sieve provides cooling of the gases passed to the airbag and it provides the additional gas required to quickly inflate the airbag to compensate for the cooler gas in the airbag. Preferably, the pre-loaded zeolite molecular sieve is 25 to about 70 weight percent of the pyrotechnic charge mass.
[0030] Zeolitic molecular sieves in the calcined form may be represented by the general formula:
Me 2/n O:Al 2 O 3 :x SiO 2
[0031] where Me is a cation, x has a value from about 2 to infinity, and n is the cation valence. Typical well-known zeolites which may be used include: chabazite—also referred to as zeolite D, clinoptilolite, EMC-2, zeolite L, ZSM-5, ZSM-11, ZSM-18, ZSM-57, EU-1, offretite, faujasite, erionite, ferrierite, mordenite, zeolite A, ZK-5, zeolite rho, zeolite Beta, boggsite, and silicalite. The adsorbent of the present invention will be selected from these zeolite adsorbents, cation exchanged forms of these zeolites, and mixtures thereof.
[0032] The term “pore opening” refers to the pore diameter of the adsorbent within the crystal structure of the adsorbent. Zeolite molecular sieves have pores of uniform opening, ranging from about 3 to about 10 angstroms, which are uniquely determined by the unit structure of the crystal. These pores will completely exclude molecules which are larger than the opening of the pore. The preferred adsorbents for use with the present invention include synthetic and naturally occurring zeolites with a silica-to-alumina ratio greater than about 2 to about 3 and having a pore opening larger than 4.3 angstroms. More particularly, synthetic and naturally occurring zeolites having a FAU structure as defined in the “Atlas of Zeolite Structure Types,” by W. M. Meier and D. H. Olson, issued by the Structure Commission of the International Zeolite association, (1987), on pages 53-54 and pages 91-92, are preferred. The above reference is hereby incorporated by reference. Most preferably, the zeolite adsorbent for use with the present invention will have a silica-to-alumina ratio greater than or equal to about 2 and a pore opening greater than about 8 angstroms.
[0033] It is often desirable when using crystalline molecular sieves that the molecular sieve be agglomerated with a binder in order to ensure that the adsorbent will have suitable particle size. Although there are a variety of synthetic and naturally occurring binder materials available such as metal oxides, clays, silicas, aluminas, silica-aluminas, silica-zirconias, silica-thorias, silica-berylias, silica-titanias, silica-alumina-thorias, silica-alumina-zirconias, mixtures of these and the like, silica binders are preferred. Clay is preferred because it may be employed to agglomerate the molecular sieve without substantially altering the adsorptive properties of the zeolite. The choice of a suitable binder and methods employed to agglomerate the molecular sieves are generally known to those skilled in the art and need not be further described herein.
[0034] The results of both laboratory evaluations using stored gas on zeolite molecular sieve in rapid depressurization tests and engineering simulation of stored gas and pyrotechnic gas inflators show an advantage for combining the functions of gas storage by zeolite adsorbents with the gas and heat releases of pyrotechnic compounds to significantly reduce the temperature of the gas delivered to the airbag. The zeolite hybrid generator can inflate the airbag with nitrogen gas within time periods that are very comparable with existing pyrotechnic devices while delivering the gas at temperatures that are much cooler than the gas delivered by the solely pyrotechnic devices
DETAILED DESCRIPTION OF THE DRAWING
[0035] Referring to the FIGURE, a side view of the apparatus of the present invention is shown. According to the FIGURE, the airbag inflator comprises a shell 10 having a bottom 15 and a surround 35 which forms the sides of the shell. The bottom is sealingly attached to the sides of the shell forming an interior shell zone. A layer of a pyrotechnic 25 comprising sodium, azide or nitrocellulose is disposed on the bottom of the shell in a layer of explosive. A layer of zeolite particles 30 is disposed above the layer of pyrotechnic 25 . The layer of zeolite is maintained at a storage pressure of between about 30 and about 80 atm by the placement of a rupture disk 20 over the zeolite layer. The storage pressure will vary somewhat with the type of gas and the amount of gas stored, as well as the cost of the shell and rupture disk required to contain the stored gas. The rupture disk is sealingly disposed on the wall of the shell by any means well known in the art to hermetically seal the rupture disk to the sides of the shell.
EXAMPLES
[0036] The following examples are meant to illustrate the advantage of combining the gas storage of zeolite adsorbents and the use of pyrotechnic compounds in a hybrid gas generator for inflating airbags. Such hybrid inflators can deliver equal or greater volumes of gas at rates which are comparable to pyrotechnic devices at gas temperatures which are significantly lower than gas delivered by a solely pyrotechnic device.
Example I
[0037] Based on the chemical equations presented hereinabove as equations (1), (2), and (3), it is well known that a sodium azide based pyrotechnic will release about 1.4 to about 1.6 moles of nitrogen per 100 grams of the pyrotechnic charge which includes sodium azide (NaN 3 ), potassium nitrate (KNO 3 ), and silicate (SiO 2 ) which is sufficient to deploy a driver-side airbag in a passenger vehicle.
[0038] An apparatus to measure and characterize the gas storage capacity of an adsorbent was assembled. The test apparatus comprised a high-pressure containment vessel that was attached to a high-pressure gas cylinder with additional ports that allowed the vessel to be depressurized either through a large-diameter port that is controlled by a large orifice ¼ turn ball valve, or through a small needle valve, which in turn leads to a gas volume measurement device commonly called a wet test meter. The former allows a rapid and relatively non-restricted depressurization and the latter allows a slower, controlled depressurization of the vessel with measurement of the gas that is released. The high-pressure vessel had an internal volume of 310 cc. The high-pressure vessel was connected to a large orifice ¼ turn ball valve. The orifice of the ball valve was about 22 mm (0.85 inches) in diameter. The pipe that connects the vessel to the valve had an inside diameter of about 22 mm (0.88 inches). From the downstream end of the ball valve to the atmosphere, there was a short length of pipe having an inside diameter of about 22 mm (0.88 inches) and at the downstream of the end of the pipe, there was an expansion nozzle. The expansion nozzle provided a transition from an inside diameter of about 22 mm (0.88 inches) up to an inside diameter of about 34 mm (1.33 inches) over a length of about 15 mm (0.6 inches). Inside the vessel were two sets of 60 mesh screens. These screens were set inside the vessel to provide an adsorbent zone having a volume of approximately 260 cc between the screens. The capacity of the empty high-pressure vessel was determined to contain approximately 0.874 moles of nitrogen gas at about 68 atm pressure and ambient temperature. It was found that the empty high-pressure vessel could be depressurized from 68 atm to about 1 atm in about 50 milliseconds (0.050 seconds).
Example II
[0039] The adsorbent zone of Example I was filled with a first zeolite adsorbent (A) having a FAU structure with a nominal silica-to-alumina ratio of 2.45 and having a ratio of Li cations to Li+Na, which is a minimum of 96 percent and typically 97 percent. The zeolite adsorbent was characterized as small beads having a particle size distribution characterized as 20×50 mesh. The average particle size of these small beads was 0.46 mm before ion exchange. Approximately 155 grams of activated adsorbent was added to the high-pressure vessel. The adsorbent occupied approximately 260 cc. This left about 50 cc of non-adsorbent filled space. The adsorbent material also had voids in the macropores and interstitial spaces between particles that contribute non-selective gas storage space that amounted to about 163 cc, giving a total non-selective storage space of 214 cc. Slow depressurization experiments showed the capacity of the high-pressure vessel filled with the adsorbent of this Example II had a nitrogen capacity of about 1.184 moles and required about 180 milliseconds to be depressurized from about 68 atm to about 1 atm.
Example III
[0040] In Example III, the zeolite adsorbent of Example II was replaced with a second zeolite adsorbent (B) comprising a FAU structure having a silica-to-alumina ratio of approximately 2.3 and having about 67 percent of the cation sites, normally occupied by Na + , replaced by Ca ++ . About 159.2 grams of this material was loaded into the nominal 260-cc space between the screens of the high-pressure vessel. The material had a particle size distribution that was characterized as 10×20 mesh with an average particle size of about 1.46 mm. Slow depressurization experiments showed that at a pressure of about 68 atm, approximately 1.122 moles of nitrogen were released as the pressure of the vessel was reduced to 1 atm. The dynamic depressurization of the high pressure containing the zeolite adsorbent of Example II required about 100 milliseconds for the pressure to be reduced from about 68 atm to about 1 atm.
Example IV
[0041] In Example IV, the zeolite adsorbent of Example I was replaced with a third zeolite adsorbent (C) comprising another FAU, having a nominal silica-to-alumina ratio of about 2.3 and having most of the cation sites replaced by Li so that the ratio of Li to Li plus sodium was a minimum of 94 percent and more typically about 97 percent. This zeolite adsorbent (C) has a particle size distribution that is characterized as 8×12 mesh, having an average particle size of 1.9 mm. In the slow depressurization test, approximately 1.2 moles of gas were released between about 68 atm and 1 atm. Over the slow depressurization test of zeolite (C), the stored gas dropped in temperature by 46 Kelvin. The valve remained open until the adsorbent material had returned to room temperature. The rapid depressurization time for depressurizing the gas from about 68 atm to about 21.7 atm was about 28.9 milliseconds (about 0.029 seconds).
[0042] The hereinabove described experimental device deviated from a real gas inflator in at least two important ways. Inflator performance measurement was in all cases limited by the opening time of the ball valve, that starts the rapid blow down, and by the size of the orifice through which the gas flow passes. In a more realistic experiment, there will be a larger and less restrictive orifice and a more rapid opening time. Engineering simulations of the results characterized the opening time of the valve from a zero orifice time to full throat as 0.027 seconds and the orifice area was limited by the about 21.6 mm (0.85-inch) diameter of the valve throat. With respect to the zeolite adsorbent evaluation, it was surprisingly discovered that there was a remarkable trend with bead size of the adsorbent. As the bead size increased, the net resistance to flow out of the system decreased in what appeared to be a linear fashion.
Example V
Comparison of N 2 Hybrid Inflator to Pyrotechnic
[0043] Based on the results of the above Examples I-IV, a mathematical model was constructed to simulate the operation of a hybrid zeolite inflator to compare the operation of a hybrid zeolite system, wherein a portion of the inflation gas is provided from storage in the zeolite and a portion of the inflation gas is supplied from the generation of gas by a pyrotechnic and delivered to an airbag. The heat released by the pyrotechnic device is employed to heat the zeolite to promote the desorption of the stored gas. The total inflation gas is the calculated gas delivery from the model plus the gas released by the pyrotechnic device. Literature shows driver-side airbag examples ranging from as low as 30 liters up to about 70 liters. For the purposes of this Example V, a 40-liter volume airbag, a minimum over pressure of about 0.1283 atm, (1.88 psig), and a final gas temperature of 277° C. (550 Kelvin) are selected as the basis for comparison to the basic pyrotechnic device.
TABLE I Nitrogen Released from Increasing Mass of Zeolite Mass average Pressure inside the Mass of temperature fully inflated bag molecular Mass of gas released of the 40-liter bag sieve, to the airbag expanded gas, at the end of grams within 50 ms, moles ° C. (Kelvin) 50 ms., atm 0 0.6225 2435 (2708) 3.458 5 0.6436 1706 (1979) 2.613 10 0.6649 1305 (1578) 2.15 20 0.7083 884 (1158) 1.683 30 0.7511 652 (926) 1.4268 40 0.7906 504 (778) 1.268 50 0.8273 400 (674) 1.144 60 0.8622 324 (597) 1.055 70 0.8960 264 (537) 0.9871 50 Pyrotechnic 1.1200 MS 0.2020 Gas 0.1833 Total 1.5053
[0044] The model uses a pyrotechnic charge of about 70 grams of NaN 3 to inflate a 40-liter driver-side airbag, with incremental added amounts of zeolite adsorbent, pre-loaded with nitrogen. The dynamic gas release and average gas temperature of the gas delivered to the airbag are determined by the model. When zeolite molecular sieve which was pre-loaded with nitrogen is incorporated into the pyrotechnic inflator over a range of from 5 to about 70 grams of zeolite, significant cooling of the product gases resulted which still delivered an airbag pressure in a 40-liter airbag of about 1 atm. At about 50 grams of nitrogen pre-loaded zeolite molecular sieve, the pressure delivered to the airbag is sufficient to inflate the airbag with a desired level while reducing the delivered temperature at 50 ms after the detonation by a factor of about 6. The gas temperatures calculated and shown in Tables I and II represent the temperature of the gas at the entrance to the airbag. Significant further cooling will take place within the airbag but is not considered in this analysis. The results in Table I show an advantage for combining the functions of gas storage by zeolite adsorbents with the gas and heat releases of pyrotechnic compounds to significantly reduce the temperature of the gas delivered to the airbag. The zeolite hybrid generator can inflate the airbag with nitrogen gas within time periods that are very comparable with existing pyrotechnic devices while delivering the gas at temperatures that are much cooler than the gas delivered by the solely pyrotechnic devices. Pressures less about 1.13 atm inside the fully inflated airbag at the end of 50 ms will inflate the airbag, but not aggressively enough to provide the same performance as that of the pyrotechnic device.
Example VII
Comparison of CO 2 Hybrid Inflator to Pyrotechnic
[0045] Based on the simulation of the hybrid zeolite inflator of Example VI, a simulation for the use of zeolite pre-loaded with stored carbon dioxide is considered. The results shown in Table II show that the temperature of the combined generated gases and stored gasses is reduced from about 2400° to about 391° C. by the placement of about 50 grams of zeolite molecular sieve pre-loaded with carbon dioxide at a storage pressure of about 5 atm while still generating sufficient pressure inside the airbag at the end of a 50 ms inflation period while reducing the delivered temperature by about a factor of 4. As in Example VI, significant further cooling in the airbag is not considered.
TABLE II Mass of Nitrogen plus CO 2 Released Pressure inside a Mass of Mass averaged fully inflated Molecular temperature of the 40-liter bag Sieves, Mass of Gas Released expanded gas, at the end of grams within 50 ms, moles ° C. (Kelvin) 50 ms, atm 0 0.6225 2435 (2708) 3.458 10 0.6649 1304 (1578) 2.15 50 0.8273 391 (665) 1.1286 50 Pyrotechnic 1.1200 MS 0.2300 Gas 0.0135 Total 1.3635
[0046] The addition of the carbon dioxide pre-loaded or encapsulated molecular sieve zeoite to the inflator system at pressures less than about 5 atm provides significant reduction in the temperature of the gas delivered to the airbag without the need for high-pressure gas storage in the inflator. | Molecular sieve zeolites are incorporated in the inflator device to assist in the inflation of airbags in passenger vehicles. The pre-loading of the molecular sieve zeolites with gases such as air or nitrogen or carbon dioxide provides for rapid airbag inflation and following inflation, additionally provides the remediation of at least a portion of the toxic waste gases generated by the exploding inflator device. Molecular sieve zeolites, particularly zeolites X, having been exchanged with lithium or calcium, provide high-capacity gas storage and enhanced toxic waste gas adsorption. The use of molecular sieve zeolites reduces risk of injury to occupants of vehicles from exposure to hot, toxic waste gases following airbag deployment. | 2 |
FIELD OF THE INVENTION
This invention relates generally to electrically operated valves, such as fuel injectors for injecting fuel into an internal combustion engine, and particularly to a bearing cartridge for such a valve.
BACKGROUND AND SUMMARY OF THE INVENTION
The movement of certain electrically-operated valves, such as certain fuel injectors, comprises a needle that is reciprocated axially within the interior of the valve's body in response to electrical energization and de-energization of an electro-mechanical actuator to thereby selectively open and close a flow path through the valve. The needle of some fuel injectors has a rounded tip end that, when the actuator is not energized, seats on a frusto-conical valve seat at the fuel injector's nozzle end to close a flow path through the fuel injector. When the actuator is energized, the needle is axially displaced to unseat its tip end from the seat and thereby open the flow path. The typical actuator is a solenoid that is mounted on the valve body and that has a guided armature to which the needle is operatively connected.
Such a fuel injector also comprises two axially spaced apart bearings that, in conjunction with the guided armature provide guidance for the axial reciprocation of the needle. For assuring proper operation and avoiding leakage when the flow path is closed, the precision and alignment of such bearing arrangements is vital. First, the bearings individually need to be highly circular. Second, they must be highly concentric, not just with each other, but also with the guided armature and the valve seat. Third, the bearings' cylindricity must be highly precise, particularly, if they have a significant length/diameter ratio. Lack of precision in the individual bearings and in their mounting arrangement on the valve body is apt to lead to loss of a fuel injector's performance. For example, faults may appear as objectionable wear, if the tolerance in the clearance of the fit between the needle and the bearings is not sufficiently strict; as objectionable leakage, if the bearings are eccentric to the valve seat, even if the bearings themselves are correctly mutually concentrically aligned; as needle jamming, if the bearings are misaligned or lack proper cylindricity; or as erratic dynamic flow, if the bearing/needle clearance is too loose and the bearings are not sufficiently precisely aligned.
Since the bearings mount on the valve body, the process of manufacturing the valve body and/or the valve body's constructional features may have an effect on the ability to secure precise bearing alignment. For instance, constructional features that are required for the valve body may impair the ability to process its manufacture in a way that is most conducive to securing a precise bearing alignment. For example, features of interest, such as bores for the bearings, are typically disposed far apart axially with the intent of providing maximum needle stability. Consequently, they are typically machined from opposite axial ends of the valve body, a process that is ordinarily completed only after multiple chuckings of the valve body. Such procedures of chucking the part, machining one end, and then re-chucking the part to machine the opposite end, inherently create some loss of accuracy. Moreover, when the outside diameter of the valve body is rough-machined by a form-tool, as it typically is for expediency, such processing may not provide sufficiently precise surfaces to which the machining of the bores for the bearings can be referenced. Thus, while it is desired that the bearing bores be spaced axially far apart for needle stability, the fact that they are machined in the manner just described undercuts the ability to attain greater precision in bearing alignment.
Accordingly, it is seen that a need exists for improving on the existing state of the art.
This need is met by providing a bearing cartridge according to the present invention. The bearings are disposed in a metal tube that is itself disposed in a bore in the valve body. The metal tube is machined to have very accurate I.D. and O.D. cylindricities and concentricity. One end of the tube is accurately counterbored to accept one bearing and a valve seat which have previously been joined together to form a bearing/seat assembly. The opposite end of the tube is also counterbored slightly larger than the outside diameter of the other bearing to allow the latter to float radially during its assembly to the tube so that it will align to the first bearing. The two bearings can thus be precisely mutually aligned, since both are installed in the tube with reference to a diameter that was accurately machined in a single chucking of the tube. The bearings and tube constitute the bearing cartridge.
The bearing cartridge can itself be accurately installed in the valve body since it has a precision O.D. and since those features of the main bore in the valve body that control the accuracy of cartridge installation can themselves be accurately machined in a single chucking of the valve body. The fact that the invention provides a fuel injector with a separate bearing cartridge opens some new processing options. The cartridge can be tested as a unit before it is assembled into the valve body, and in the unlikely event that errors are detected, the cartridge can be scrapped thereby avoiding the necessity of scrapping a completed fuel injector. Likewise, leakage testing of a cartridge/needle/actuator sub-assembly combination can be performed before final assembly into a fuel injector thereby avoiding the possibility of having to scrap completed fuel injectors if such testing is performed later and reveals that leakage is unacceptable.
The use of a cartridge also allows the valve lift to be set without the use of a lift shim, as described in commonly assigned U.S. Pat. No. 4,610,080. With the actuator fixed on the valve body, axial positioning of the cartridge will be effective to adjust the lift with all components, save the cartridge, in final position. When the correct lift is measured, the cartridge is fixed in place, such as by welding. If such welding is performed hermetically, it can seal the O.D. of the cartridge to the valve body, eliminating an otherwise required 0-ring seal.
The invention, and the features, advantages, and benefits that characterize it, are disclosed in the following detailed description of a presently preferred embodiment that illustrates the best mode contemplated at this time for carrying out the invention. The description is accompanied by drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal cross sectional view of an exemplary fuel injector embodying principles of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a representative fuel injector 10 having a generally cylindrical valve body 12 of non-magnetic material such as non-magnetic stainless steel. Valve body 12 has a main longitudinal axis 13. Radial holes through the sidewall of valve body 12 are covered by a filter screen to form the fuel injector's inlet 14. The inlet is axially bounded by O-ring seals 16, 18 that seal to the sidewall of a socket of a cylinder head or manifold (not shown) into which the fuel injector is inserted when in use. This configuration for the inlet is representative of what is sometimes referred to as a side-feed injector.
Body 12 has an upper end 20 that is closed but has electrical terminals 21 extending in sealed manner through the closure for connection to a source of electric current for operating the fuel injector. Body 12 also has a lower end that forms an outlet nozzle 22, which is actually part of the bearing cartridge 25 of the present invention.
Cartridge 25 comprises a metal tube 26, an upper guide bearing 28, a lower guide bearing 30, and a valve seat member 32. The latter two parts 30 and 32 are joined together to form a bearing/seat sub-assembly that is assembled into the lower end of tube 26, and that is suitably sealed to the wall of the tube so that fuel cannot leak past the installed sub-assembly. Cartridge 25 is disposed in a bore 33 of valve body 12 that is coaxial with axis 13.
The movement of fuel injector 10 comprises a needle 34 and an armature 36. The actuator of the fuel injector comprises a solenoid 38, which in cooperation with a bias spring 40, operates the movement. Needle 34 passes through guide bearings 28 and 30. The needle's upper end is attached to the center of armature 36; its lower end contains a rounded tip 42. FIG. 1 shows the fuel injector in closed condition with solenoid 38 not energized so that spring 40 forces tip 42 to seat on a central frusto-conical seat 44 in the upper face of valve seat member 32, closing a small hole 46 leading from the bottom of seat 44 to the lower face of seat member 32. When solenoid 38 is energized by suitable electric current, it exerts an attractive force on armature 36 that overcomes the spring bias force so that as a result tip 42 is unseated to open hole 46. In use, the fuel injector is operated by repeatedly pulsing solenoid 38 to reciprocate needle 34 in suitably timed relation to operation of the engine combustion chamber with which it is associated.
Both guide bearings 28 and 30 are circular annular in shape having respective central circular holes through which needle 34 passes. They also have further hole structure that allows liquid fuel to pass through them. Valve seat member 32 and lower guide bearing 30 are assembled together to precisely align valve seat 44 with the central circular hole in lower guide bearing 30 such that the two are precisely coaxial.
The I.D. and O.D. of tube 26 are machined to have very accurate I.D. and O.D. cylindricities and concentricity. The lower end of tube 26 is accurately counterbored at 48 to accept the bearing/seat sub-assembly, 30/32 with a precision fit, and after the sub-assembly has been inserted into the counterbore and abutted with an internal shoulder 50 at the upper and of the counterbore, it is joined to the tube in any suitable manner, such as by welding. The upper end of tube 26 is also counterbored at 52, but to a diameter that is slightly larger than the outside diameter of upper guide bearing 28. When the latter has been disposed in this counterbore against an internal shoulder 54 at the lower end of the counterbore, it can float radially so that it can precisely align with guide bearing 30 before it is joined to the tube. A precision fixture is used to secure this alignment, and then the upper guide bearing is joined to the tube. The central holes in the two guide bearings through which needle 34 is to pass have thus been made highly concentric, since both are installed in the tube with reference to a diameter that was accurately machined in a single chucking of the tube.
The O.D. of tube 26 contains a groove in which an O-ring seal 56 is placed prior to insertion of the cartridge into bore 33. This will provide sealing of the cartridge to the bore. If the joining of tube 26 to valve body 12 is performed hermetically to circumferentially seal between the two, it is possible that seal 56 can be eliminated.
Body 12 actually comprises two body parts 12A and 12B that are joined by means of a joint with the internal parts of the fuel injector having been assembled into the interior. Bore 33 is in body part 12B. A diametrically larger bore 60 is also in body part 12B as an upward continuation of bore 33 and includes a ledge 62 just below its upper rim. Solenoid 38 comprises a stator 64 having a lower circular end that is disposed on ledge 62 in the completed fuel injector. Ledge 62 is bounded by the sidewall 66 of a circular counterbore which has been machined into part 12B to be precisely concentric with bores 33 and 60. The lower circular end of stator 64 is machined to fit precisely within sidewall 66 in the finished fuel injector, thus making solenoid 38 precisely concentric with bores 33 and 60, and hence with cartridge 25. By making ledge 62 precisely perpendicular with sidewall 64, and making the lower end face of the stator perpendicular to the sidewall of the stator, the lower end face of the stator will be precisely perpendicular to axis 13. And with needle 34 precisely perpendicular to the surface of armature 36 that radially overlaps the lower end face of stator 64, precise parallelism of the stator/armature interface will be attained, thereby providing a uniform gap around its full circumference, which is typically a desirable attribute in magnetic actuator design.
The valve lift is set before the cartridge is joined to the valve body. The fuel injector is operated and the cartridge is positioned within bore 33 until the proper lift is measured. The cartridge is then joined to the body. An adjustment means 67 that is accessible at the exterior of the upper end of the fuel injector is also provided.
While a presently preferred embodiment of the invention has been illustrated and described, it should be appreciated that principles are applicable to other embodiments. | Two annular guide bearings that guide the needle are mounted in a tube which is disposed in a bore of the valve body, rather than being mounted directly on the valve body bore. This arrangement affords the opportunity for better alignment the bearings with the solenoid actuator and with the valve seat. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a catalyst for purifying exhaust gases which very efficiently removes nitrogen oxides, carbon monoxide and hydrocarbons, which are the noxious components of exhaust gases from internal combustion engines, and the like. The catalyst of the present invention has high mechanical strength and durability at high temperatures.
2. Description of the Prior Art
Various catalysts have been suggested up to the present for removing the noxious components from exhaust gases discharged from various combustion devices. Catalysts containing platinum, palladium or rhodium as an ingredient supported on an alumina carrier are considered to have a relatively superior purifying activity. However, these catalysts are still unable to meet the requirements for the purification of motor vehicle exhaust gases because they cannot remove nitrogen oxides, CO and hydrocarbons from the exhaust gases in high efficiency, and they do not have superior strength and durability at high temperatures. Therefore, a need continues to exist for a catalyst of improved efficiency for removing noxious components from exhaust gases.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a catalyst for efficiently and effectively removing noxious components from exhaust gases.
Briefly, this object and other objects of the present invention as hereinafter will become more readily apparent can be attained by a catalyst for purifying exhaust gases, comprising platinum (Pt), palladium (Pd) or both supported on a carrier, said carrier being a porous body consisting essentially of alumina-magnesia spinel (MgAl 2 O 4 ) or alumina-magnesia spinel and ceria.
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 diagram showing the relationship between the particle diameter of alumina and the average pore diameter of the resulting carrier;
FIG. 2 is a diagram showing the relationship between the pore diameter of the carrier and its pore volume; and
FIG. 3 is a diagram showing the relationship between the calcination temperature and the spinel content of the carrier.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides a catalyst which can remove noxious components, i.e., nitrogen oxides (NO x ), carbon monoxide (CO) and hydrocarbons (HC), from exhaust gases in high efficiency. The catalyst exhibits an especially superior effect for the simultaneous removal of noxious components from gases discharged from an internal combustion engine which is operated at an air-fuel ratio (the weight ratio of air to gasoline fed into the internal combustion engine) of from 12.0 to 18.0. Since the porous carrier of the catalyst of the present invention contains magnesia-alumina (MgAl 2 O 4 ) spinel, the catalyst has high mechanical strength at high temperatures. Furthermore, even when it is used at high temperatures, the crystal structure of the alumina does not change as in the case of general alumina carriers, and the losses in surface area and the reductions in strength which accompany the above changes are obviated. Moreover, the catalyst exhibits good durability at high temperatures.
As far as the porous carrier is concerned, it is preferred that the alumina and magnesia components which constitute the porous body be present each in an amount of not more than 25% by weight based on the spinel. ##EQU1##
One or both of alumina and magnesia in the carrier may be present in the spinel carrier dependent on the indicated ratios, uniformity of the mixed powders, or the sintering conditions such as sintering temperature. According to comparative tests involving three kinds of catalysts, each of which consists of spinel, 4 wt.% of ceria, and 0.16 wt.% of palladium and then either alumina or magnesia or neither of these two components, and each of which have substantially the same surface area and apparent specific gravity as each other, the catalyst containing magnesia is superior to the other catalysts in reducing exhaust gas impurities for a gas having an air-fuel ratio of 13. However, the catalyst containing alumina is superior for oxidizing the components of an exhaust gas having an air-fuel ratio of 16. These results lead to the conclusion that a catalyst containing both alumina and magnesia is preferred for the treatment of exhaust gases having widely varying air-fuel ratios. If the alumina or magnesia is present in too large an amount, however, the aforesaid effect attributed to the presence of spinel cannot be achieved. On the other hand, the above effect can be achieved even when the alumina and magnesia are present in only small amounts, i.e., not less than 1 percent.
Preferably, the porous carrier has an average pore diameter of 0.01 to 2 microns. If the average pore diameter falls outside the above-specified range, it is difficult for the catalyst to exhibit superior activity for the purification of exhaust gases.
Platinum, palladium or both metals can be supported on the porous carrier body in the same way that catalyst ingredients are ordinarily supported on a carrier. For example, the porous body can be dipped into a solution of raw materials of catalyst ingredients such as platinum nitrate, chloroplatinic acid, palladium nitrate or palladium chloride. The treated carrier can then be dried and calcined. When the carrier is immersed in the solution, the total amount of the catalyst ingredients deposited is preferably 0.01 to 5% by weight based on the weight of the porous body. If the amount is less than 0.01%, the purifying activity of the catalyst is low. On the other hand, if its amount is more than 5%, no corresponding increase in activity can be observed.
In the present invention, the aforesaid porous body is produced, for example, by mixing a magnesia powder and an alumina powder, molding the mixture into the desired shape and heating it to form a porous sintered body. Alternatively, the surface of a porous sintered body of alumina powder can be impregnated with a magnesium compound, such as magnesium nitrate or magnesium chloride, convertible to magnesia upon heating, and then the impregnated porous body is heated at 1000° to 1600° C. to react the alumina with magnesia on the surface of the alumina powder sintered body. By this technique, a spinel of MgO and Al 2 O 3 is formed on the surface portion of the sintered alumina particles.
In the first of the two methods for producing the porous sintered body described above which starts from alumina and magnesia powders, a molded article composed of a mixture of both is calcined at 1000° to 1600° C. At temperatures below 1000° C., the calcination is insufficient, and the amount of MgAl 2 O 4 spinel which forms is too small. Moreover, the strength of the carrier is weak. When the calcination temperature exceeds 1600° C., the particles of MgAl 2 O 4 spinel grow excessively, and the pore volume of the porous body decreases. When the calcination is carried out at 1200° to 1600° C., alumina reacts with magnesia and more than 75% of the components react to form MgAl 2 O 4 spinel. Accordingly, a carrier having better thermal stability and strength can be obtained. Since the spinel is formed by the reaction of equimolar amounts of magnesia and alumina, unreacted magnesia or alumina remains in the carrier. Equimolar amounts of magnesia and alumina correspond to a weight ratio of alumina to magnesia (alumina/magnesia) of 2.6:1.
To obtain a porous body having an average pore diameter of from 0.01 to 2 microns, an alumina powder having an average particle diameter of 0.01 to 2 microns is used. That is, the diameter of an alumina powder controls the average pore diameter of the resulting carrier. The "particle diameter", used herein, denotes a weight average particle diameter.
Suitable sources of alumina include not only α-alumina, but also other types of aluminas such as γ-alumina.
The magnesia powder which is mixed with the alumina powder and the like, has been found by a scanning electron microscope to serve as the most suitable binder for the alumina powder in the porous sintered body. Therefore, the particle diameter of the magnesia powder is not particularly limited. In order for the magnesia powder to be mixed almost uniformly with the alumina powder thereby forming spinel with alumina, and in order to make the pure diameter of the resulting carrier nearly uniform, the use of a magnesia powder having a particle diameter of 0.1 to 500 microns is preferred. Thus, the magnesia powder serves as the binder to form the skeleton of the spinel and to reinforce the skeleton.
In the preparation of the carrier, the ratio of the alumina powder to the magnesia powder (alumina/magnesia) ranges preferably from 1.5:1 to 3.5:1 by weight. If the weight ratio is less than 1.5:1, the amount of the magnesia is too large. As a result, the magnesia crystallizes by the heat of calcination to form large crystals composed only of magnesia, and therefore, the number of pores in the carrier decreases. Furthermore, the alumina and ceria particles are coated by large amounts of magnesia, and the desired carrier is difficult to obtain. If the weight ratio is larger than 3.5:1, the amount of magnesia is too small. This state results in weakened bonding to the alumina, and the strength of the carrier is likely to be reduced.
The amount of ceria or the cerium compound, calculated as cerium oxide (ceria), mixed with the magnesia powder and the alumina powder in the preparation of the carrier is 0.05 to 20% by weight based on the total weight of the magnesia and alumina powder; this in view of the aforesaid reason for the presence of ceria in the carrier.
Examples of the cerium compound convertible to ceria by heating are cerium acetate, cerium carbonate and cerium nitrate. These cerium compounds are converted to ceria by decomposition during the calcination of the powdered mixture. The particle diameter of the powdered ceria or cerium compound is not particularly limited. But preferably, it has an average particle diameter of from 0.01 to 2 microns. Furthermore, because the carrier contains ceria, entry or liberation of oxygen into or from the surface of the carrier is easy so that reactions on the catalyst surface are stabilized. Presumably, entry and liberation of oxygen into and from the carrier occurs with relative ease because ceria is present among the MgAl 2 O 4 spinel particles forming the matrix of the carrier, and cerium (Ce) and oxygen (O), the elements constituting ceria, relatively easily combine with, or separate from, each other to form CeO 2 , or Ce 2 O 3 and O 2 . This leads to the understanding that for example, when a catalyst supported on the above carrier is placed in an oxygen-deficient condition (in a reducing atmosphere), oxygen is liberated from ceria and contributes to the reaction, and when the oxygen becomes excessive (in an oxidizing atmosphere), Ce combines with oxygen to change again to ceria and thus contributes to the reaction.
In calcining the mixed powder, a small amount of an organic paste such as dextrin is admixed with the mixed powder. The mixture is molded into the desired size by a tablet-forming machine, or the like, and then is calcined by an electric furnace, or the like.
Molding of the mixed powder is performed to produce any desired shape of the carrier such as a pillar, granule or honeycomb shape. In order to save fine alumina powder as a source material or to improve other characteristics of the catalyst, it is possible to use as a mother matrix a granular composition or a honeycomb structure of α-alumina, cordierite, silicon nitride, or the like. A carrier based on the mother matrix can be prepared by mixing the mother matrix with a slurry of spinel or a mixture of alumina and magnesia. Thereafter, the carrier obtained is calcined.
The present catalyst is particularly designed for the purification of exhaust gases, the catalyst comprising platinum, palladium, or both supported on a carrier, and the carrier being a porous body consisting of alumina-magnesia spinel (MgAl 2 O 4 ) and ceria (CeO 2 ) or spinel, alumina (Al 2 O 3 ), magnesia (MgO) and ceria, the amount of each of the alumina and magnesia being not more than 25% by weight and not less than 1% by weight based on the spinel.
In addition to acting as a catalyst for the purification of exhaust gases, the present catalyst exhibits very high activity for the removal of nitrogen oxides from exhaust gases.
The present catalyst is also especially useful as a three-way catalyst for conversions involving exhaust gases which vary widely in air-fuel ratios. The three-way effect of the present catalyst can be attributed to the fact that since the porous body contains ceria, the adsorption and desorption of oxygen onto and from the surface of the catalyst becomes easy, and reactions on the catalyst surface are activated. The ease of adsorption and desorption of oxygen is presumably because ceria is present among the MgAl 2 O 4 spinel particles, and cerium (Ce) and oxygen (O), the constituent elements of ceria, combine with, or separate from each other relatively easily to become CeO 2 or Ce 2 O 3 and O 2 .
The amount of ceria in the support preferably ranges from 0.05 to 20% by weight based on the total weight of the spinel, alumina and magnesia components. If the amount of ceria is less than 0.05% by weight, it is difficult to obtain the above described effect attributed to the presence of ceria. If the amount of ceria is larger than 20% by weight, the above effect increases, but the bonding of the spinel particles to one another weakens thereby reducing the strength of the catalyst, and the above described effect attributed to the presence of spinel is difficult to obtain.
One process for producing the porous carrier of the present invention comprises mixing magnesia powder, alumina powder and powdered ceria or a cerium compound convertible to ceria by heating, and calcining the mixture. In this case, moreover, if an alumina powder having an average particle diameter of 0.01 to 2 microns is used, a porous carrier of the above composition having an average pore diameter of 0.01 to 2 microns can be obtained.
The ceria or the cerium compound is mixed with the other components of the substrate in an amount of 0.05 to 20% by weight calculated as cerium oxide (ceria) based on the total weight of magnesia and alumina because of the above discussed reason for incorporating ceria in the porous carrier.
Examples of cerium compounds convertible to ceria by heating are cerium acetate, cerium carbonate, and cerium nitrate. These cerium compounds change to ceria by decomposition during the calcination of the mixed powder. The particle diameter of the powder of ceria or the cerium compound is not particularly limited, but preferably, it has an average particle diameter of 0.01 to 2 microns.
The porous body containing ceria can also be produced by impregnating a magnesium compound into the surface of a porous body consisting only of alumina, heating the impregnated porous body to form spinel on its surface, then impregnating the product with a cerium compound, and heating the impregnated body to support ceria thereon.
Having generally described this invention, a further understanding can be obtained by reference to certain specific examples which are provided herein for purposes of illustration only and are not intended to be limiting unless otherwise specified.
The following Examples 1 to 5 show the carriers of the present invention and Examples 6 to 10 show the catalysts of the present invention.
EXAMPLE 1
Five types of alumina powder having an average particle diameter of 0.04, 0.15, 0.3, 0.8 and 1 micron, respectively were selected. To each of the alumina powders were added a magnesia powder having an average particle diameter of 1 micron and a ceria (cerium oxide) powder having an average particle diameter of 1 micron. The separate groups of materials were thoroughly mixed, and then molded into spherical pellets having a diameter of about 3 mm by a "Marumelizer" (Trade Mark) (pelletizer). The weight ratio of the alumina powder to the magnesia powder was 2.6:1, and the weight ratio of the ceria powder to the alumina and magnesia powders combined was 0.1:1. The first two alumina powders were γ-alumina powders and the others were α-alumina powders.
The pellets were then dried by an electric dryer, and calcined at 1350° C. for 10 hours in an electric furnace to form a carrier.
The resulting carriers were each analyzed for their component make-up by an X-ray diffraction method. It was found that all of the carriers consisted of MgAl 2 O 4 spinel and ceria, and very small amounts of alumina and magnesia were detected.
The average pore diameter of each of the carriers was measured by a porosimeter. The results are shown in FIG. 1 by line A in which the abscissa represents the particle diameter of the alumina powder, and the ordinate represents the average pore diameter of the carrier.
It can be observed from FIG. 1 that a carrier having nearly the same average pore diameter (microns) as the particle diameter (microns) of the alumina powder can be obtained. (For example, when the particle diameter is 0.3 micron, the average pore diameter is about 0.3 micron). Furthermore, it can be observed from this that by selecting the particle diameter of the alumina powder, a carrier having the desired average pore diameter can be obtained.
EXAMPLE 2
Four types of alumina powders having an average particle diameter of 0.04, 0.15, 0.3 and 1 micron respectively, a magnesia powder having an average particle diameter of 1 or 50 microns, and a cerium oxide powder or cerium acetate powder having a particle diameter of 1 micron were taken. These materials were mixed in proportions of 65% by weight alumina powder, 25% by weight magnesia powder and 10% of cerium oxide. The mixed powder batches were molded, and calcined in the same way as shown in Example 1 to form a carrier. The manufacturing conditions are shown in Table 1.
The pore diameters (D), and the pore volumes dv/d log D for the pore diameters, of the resulting carriers were measured. The results are shown in FIG. 2 by curves 1 to 5 for the respective manufacturing conditions, in which the abscissa represents the pore diameters (microns) on a logarithmic scale and the ordinate represents the pore volumes (cm 3 /g) on a scale of equal division.
TABLE 1______________________________________Rarticle Particlediameter diameter Cerium compound Number ofof alumina of magnesia and particle curve inNo. (microns) (microns) diameter FIG. 2______________________________________1 0.04 1 cerium acetate 1 (1 micron)2 0.15 1 cerium oxide 2 (1 micron)3 0.3 1 cerium oxide 3 (1 micron)4 0.3 50 cerium acetate 4 (1 micron)5 1.0 50 cerium oxide 5 (1 micron)______________________________________
For the above materials, the pore diameter (D) denotes the pore diameter distribution of varying sizes for each carrier. The pore volume [dv/d (log D)] denotes the pore volume (cm 3 ) which exists within the range of d(log D)=0.1 at the pore diameter D (microns). The alumina powders Nos. 1 and 2 were γ-alumina powders and the alumina powders Nos. 3, 4 and 5 were α-alumina powders.
It can be observed from FIG. 2 that the distributions of the pore volumes with respect to the pore diameters (D) are steep ganssian-shaped with respect to the central line, and the pore diameters are distributed within a relatively narrow range.
Analysis of the above carriers by an X-ray diffraction method showed that in all of the carriers analyzed, MgAl 2 O 4 spinel and cerium oxide were present.
EXAMPLE 3
A γ-alumina powder having an average particle diameter of 0.04 micron and a magnesia powder having an average particle diameter of 1 micron were mixed in a γ-alumina/magnesia ratio of 2.6:1 by weight. To each mixture was also added and mixed 10% by weight of a cerium oxide powder having an average particle diameter of 1 micron. In the same way as in Example 1, the mixture was molded, dried, and calcined for 10 hours at varying temperatures. The content of MgAl 2 O 4 spinel in the resulting carrier was measured. The mixing ratio between the magnesia and the γ-alumina was such that when they were completely reacted (100% reacted), all of the calcined product formed the above spinel. The measurement was made by an X-ray diffraction analysis method. The results are shown in FIG. 3 by curve B, in which the abscissa represents the calcining temperature (°C.), and the ordinate represents the spinel content (%).
As is evident from FIG. 3, the spinel is formed in an amount of about 20% at a calcining temperature of 1000° C., about 75% at 1180° C. and about 100% at 1300° C.
EXAMPLE 4
An α-alumina powder having an average particle diameter of 0.3 micron and a magnesia powder having an average particle diameter of 1 micron were mixed in an α-alumina/magnesia weight ratio of 2.8:1. To each mixture was added and mixed a cerium oxide powder having an average particle diameter of 1 micron in an amount of 5, 10, 15 and 20% by weight, respectively, based on the weight of the mixture. Each of the mixed powders obtained was molded and calcined in the same way as in Example 1 to form a carrier. For comparison, a carrier containing no cerium was prepared.
The amount of oxygen adsorption was measured with respect to the resulting carriers. Specifically, each of the carriers was reduced with hydrogen at 500° C. for 1 hour, and after deaeration, the amount of oxygen absorbed at 0° C. was measured. The results are shown in Table 2.
TABLE 2______________________________________ Amount of Amount of oxygen CeO.sub.2 added absorbed (mole/gNo. (wt. %) carrier)______________________________________6 5 1.6 × 10.sup.-67 10 3.0 × 10.sup.-6 Invention8 15 3.8 × 10.sup.-69 20 4.3 × 10.sup.-610 None 0 Comparison______________________________________
It is evident from Table 2 that absorption of oxygen occurs in a cerium-containing carriers.
Accordingly, when a catalyst supported on the carrier of this invention is used in a reaction in which an oxidizing atmosphere and a reducing atmosphere are alternately generated, the reaction on the catalyst surface is stabilized by the absorption and liberation of oxygen onto and from the carrier.
EXAMPLE 5
A γ-alumina powder having an average particle diameter of 0.04 micron, a magnesia powder having an average particle diameter of 1 micron and a cerium oxide powder having an average particle diameter of 1 micron were mixed under the conditions shown in Table 3 to form spherical pellets having a diameter of 3 mm, and calcined at 1350° C. for 10 hours to produce a carrier. The composition of the carrier prepared and the compressive destruction strengths and surface areas of each carrier were measured, and the results are shown in Table 4.
TABLE 3______________________________________ Mixing ratio of the materials(wt. %) Al.sub.2 O.sub. 3 /MgONo. Al.sub.2 O.sub.3 MgO CeO.sub.2 weight ratio______________________________________11 69 21 10 3.512 65 25 10 2.6 Invention13 58 32 10 1.814 55 30 15 1.815 76 14 10 5.4 Comparison16 49 41 10 1.2______________________________________
TABLE 4__________________________________________________________________________ Composition of the carrier (wt. %) ##STR1## ##STR2## destructionCompressive areaSurfaceNo. MgAl.sub.2 O.sub.4 Al.sub.2 O.sub.3 MgO CeO.sub.2 (wt. %) (wt. %) strength (kg) (m.sup.2 /g)__________________________________________________________________________11 74 16 0 10 22 0 20 1012 88 2 0 10 2 0 15 22 Invention13 81 0 9 10 0 11 12 2014 60 11 14 15 18 23 13 1515 49 41 0 10 84 0 30 6 Comparison16 68 0 22 10 0 32 8 15__________________________________________________________________________
It is evident from Table 4 that the carriers of this invention (Nos. 11 to 14) exhibit a compressive strength of as high as 12 kg or more, and a surface area of as high as 10 m 2 /g or more. In contrast, the comparative carrier (No. 15) containing a larger amount of Al 2 O 3 and the comparative carrier (No. 16) containing a larger amount of MgO have a lower surface area or strength, and are therefore inferior.
When the carriers in accordance with this invention were subjected to a heat resistance test at 1000° C. for 50 hours, they retained the characteristics of a carrier.
EXAMPLE 6
An α-alumina powder having an average particle diameter of 0.1 micron and a magnesia powder having an average particle diameter of 0.3 micron were mixed in the ratios shown in Table 5, to form several different carriers. A small amount of water was added to each mixture and they were thoroughly mixed. Each mixture was molded into spherical pellets having a diameter of about 3 mm by a pelletizer. The pellets were heated at 1350° C. for 10 hours in an electric furnace to form porous bodies as carriers having the compositions shown in Table 5 and the pore volumes, average pore diameters and surface areas shown in Table 6.
Then, each of the resulting carriers was dipped into an aqueous solution of platinum nitrate or an aqueous solution of palladium nitrate, dried, and calcined in the air at 600° C. for 3 hours to prepare platinum (Pt) catalysts (Nos. A1 to A3) and palladium (Pd) catalyst (No. A4) shown in Table 7. Furthermore, platinum was deposited on the above carrier in the same way as above, and then palladium was again deposited to prepare a platinum-palladium (Pt-Pd) catalyst (No. A5).
To evaluate the purifying activities of these catalysts, each of the catalysts was filled in a quartz tube and kept at 500° C. An exhaust gas from an internal combustion engine of an automobile was introduced into the tube at a space velocity of 30,000/hour. The exhaust gas was obtained by operating the internal combustion engine such that the air-fuel ratio was changed periodically by 0.8 upward or downward of the theoretical air-fuel ratio (A/F=14.55) within a period of 0.5 second. The average concentrations of the noxious components in the exhaust gas in the above operation were approximately 0.1% for nitrogen oxides (NO x ), 0.62% for carbon monoxide (CO), 0.05% for hydrocarbons (HC), 12% for carbon dioxide (CO 2 ), 0.2% for hydrogen (H 2 ), 0.54% for oxygen (O 2 ), 13% for water (H 2 O), and the remainder being nitrogen (N 2 ), all by volume.
The purifying activity of each catalyst was rated by the percent removal of the above noxious components. The results are shown in Table 8.
For comparison, a platinum catalyst (No. S1) and a palladium catalyst (No. S2) were prepared in the same way as above except that commercially available, conventional γ-alumina spherical particles (carrier No. C1) were used as the catalyst carriers. The conventional particles had a diameter of 2 mm and consisted only of a sintered body of γ-alumina. The catalysts were evaluated in the same manner as described above. The data for the comparative catalysts are shown in Tables 5 and 8.
TABLE 5______________________________________ Starting powder Composition ofCarrier (%) the carrier (%)No. Alumina Magnesia MgAl.sub. 2 O.sub.4 Al.sub.2 O.sub.3 MgO______________________________________1 74 26 92 8 --2 58 42 81 -- 193 76 24 85 15 --______________________________________ (%) is by weight
TABLE 6______________________________________ Average pore SurfaceCarrier Pore volume diameter areaNo. (cm.sup.3 /g) (microns) (m.sup.2 /g)______________________________________1 0.35 0.3 62 0.32 0.3 5 Invention3 0.30 0.3 4Cl 0.50 0.02 100 Comparison______________________________________
TABLE 7______________________________________Catalyst No. A1 A2 A3 A4 A5 S1 S2Carrier No. 1 2 3 1 1 C1 C1______________________________________Amount of Ptdeposited 0.12 0.12 0.12 -- 0.06 0.12 --(wt. %)Amount of Pddeposited -- -- -- 0.15 0.10 -- 0.15(wt. %)______________________________________
TABLE 8______________________________________ Invention ComparisonCatalyst No. A1 A2 A3 A4 A5 S1 S2______________________________________Percent NO.sub.x 85.3 89.2 82.3 80.4 85.6 66.9 43.3removal(%) CO 97.5 98.5 96.5 98.0 98.0 66.9 61.1 HC 96.3 96.5 96.0 94.4 96.0 91.0 58.6______________________________________
It is evident from the above table that the catalysts of the present invention have a much higher purifying activity than the comparative catalysts (Nos. S1 and S2) on all of the noxious components tested.
EXAMPLE 7
Catalysts having ceria in a porous body were prepared. Specifically, an α-alumina powder having an average particle diameter of 0.3 micron (66% by weight), 24% of a magnesia powder having an average particle diameter of 1 micron and 10% of a ceria powder having an average particle diameter of 1 micron were mixed, and worked up in the same way as described in Example 6 to form a porous body as a carrier (Carrier No. 4, see Table 9). The carrier consisted of 83% of MgAl 2 O 4 , 7% of alumina and 10% of ceria (CeO 2 ), and had a pore volume of 0.35 cm 3 /g, an average pore diameter of 0.3 micron and a surface area of 6 m 2 /g.
In the same way as described in Example 6, the catalysts shown in Table 9 were prepared using the above carrier, and then their activities for purifying exhaust gases were measured. The results of measurement are shown in Table 9.
Table 9 also gives the percent removal of comparative catalysts (Nos. S3 and S4) obtained by depositing ceria on the same conventional γ-alumina carrier (No. C1) as shown in Example 6 to prepare a carrier (No. C2), and supporting platinum or palladium on this carrier in the same way as described in Example 6. The No. C2 carrier had been prepared by impregnating the No. C1 carrier with a 10% aqueous solution of cerium nitrate, drying the impregnated carrier, and heating it in air at 600° C. for 3 hours. Ceria was present on its surface. The No. C2 carrier had a pore volume of 0.5 cm 3 /g, an average pore diameter of 0.02 micron, and a surface area of 98 m 2 /g.
TABLE 9______________________________________ Invention ComparisonCatalyst No. A6 A7 A8 S3 S4Carrier No. 4 4 4 C2 C2______________________________________Amount of Ptdeposited 0.11 -- 0.05 0.12 --(wt. %)Amount of Pddeposited -- 0.14 0.09 -- 0.15(wt. %)Percent NO.sub.x 92.2 90.4 92.2 70.3 53.0removal(%) CO 97.8 97.7 97.5 74.0 71.1 HC 99.3 95.5 98.0 93.0 63.0______________________________________
It is evident from Table 9 that catalysts containing ceria in the porous body exhibit a high purifying effect, and have a particularly higher purifying activity than the catalysts not containing ceria in the carrier (Table 8) for the removal of nitrogen oxides. It is also evident that the catalysts (S3 and S4) having the carrier (No. C2) prepared by depositing ceria on the conventional carrier have much lower activities than the catalysts of the present invention.
EXAMPLE 8
Carriers (Nos. 5 and 6) were prepared by depositing magnesia or ceria on the No. 1 carrier shown in Example 6, and platinum was deposited on the carrier to form catalysts. The magnesia-deposited carrier (No. 5) was the one in which MgAl 2 O 4 spinel, alumina and magnesia were present on the carrier surface. The ceria-deposited carrier (No. 6) was prepared by depositing ceria on the surface of a porous body having spinel formed therein, and thus, spinel, alumina and ceria were present on the carrier surface.
The No. 5 carrier was prepared by dipping the No. 1 carrier in a 30% aqueous solution of magnesium nitrate, drying the carrier, and calcining it in the air at 600° C. for 3 hours. The No. 6 carrier was prepared by dipping the No. 1 carrier in a 10% aqueous solution of cerium nitrate, and working it up in the same manner as described in the preparation of the No. 5 carrier. The magnesium nitrate and cerium nitrate were converted by the heating treatment to magnesia and ceria, respectively, and supported on the carrier surface. The magnesia and ceria were present each in an amount of about 2% by weight based on the total weight of the carrier.
The properties of the carriers Nos. 5 and 6 are shown in Table 10.
Using carriers Nos. 5 and 6, platinum in the amounts indicated in Table 11 was deposited on each carrier to form the catalysts. The activities on these catalysts in purifying exhaust gases were measured in the same way as described in Example 6, and the results are shown in Table 11.
TABLE 10______________________________________ Average poreCarrier Pore volume diameter Surface areaNo. (cm.sup.3 /g) (microns) (m.sup.2 /g)______________________________________5 0.35 0.3 66 0.35 :0.3 6______________________________________
TABLE 11______________________________________Catalyst No. A9 A10Carrier No. 5 6 -Amount of Ptdeposited (wt. %) 0.12 0.11______________________________________ NO.sub.x 94.4 96.8Percentremoval CO 99.3 99.1(%) HC 97.9 99.9______________________________________
It is evident from the above data that the carrier having magnesia co-existent with spinel and alumina on the surface layer and the carrier having ceria present in like manner also lead to excellent purifying activities.
EXAMPLE 9
Catalysts were prepared by using a porous body obtained by forming MgAl 2 O 4 spinel on the surface of a γ-alumina carrier, and a porous body obtained by further depositing ceria on the porous body.
Commercially available γ-alumina particles (carrier No. C1) shown in Example 6 were dipped into a 30% aqueous solution of magnesium nitrate, dried, and heated in the air at 1000° C. for 4 hours to form a carrier having MgAl 2 O 4 spinel formed on its surface (No. 7). Furthermore, ceria was deposited on the surface of the carrier No. 7 in the same way as in Example 8 to form a carrier (No. 8) having the spinel and ceria on its surface.
The properties of the carriers Nos. 7 and 8 are shown in Table 12.
Platinum-supported catalysts shown in Table 13 were prepared by using these carriers in the same way as described in Example 6. The activities of these catalysts in purifying exhaust gases were measured in the same way as described in Example 6, and the results are shown in Table 13.
TABLE 12______________________________________ Average pore Pore volume diameter Surface areaCarrier No. (cm.sup.3 /g) (microns) (m.sup.2 /g)______________________________________7 0.4 0.1 168 0.4 0.1 16______________________________________
TABLE 13______________________________________ Catalyst No. A11 A12Carrier No. 7 8Amount of Ptdeposited (wt. %) 0.11 0.10______________________________________ NO.sub.x 89.7 91.0Percentremoval (%) CO 96.9 97.7 HC 98.8 99.8______________________________________
It is evident from Table 13 that the catalyst having MgAl 2 O 4 spinel or a mixture of the spinel and ceria formed on its surface layer also have a high purifying activity.
EXAMPLE 10
Catalysts were prepared by depositing platinum, palladium or both on the No. 1 carrier shown in Example 6. The activities of these catalysts in removing CO and HC in an oxygen-rich atmosphere were measured. The measurement of the purifying activities in this Example was intended to determine the performance of the catalysts as so-called "oxidation catalysts" for purifying exhaust gases. This is distinguished from the measurements in Examples 6 to 9 above which are directed to the examination of the performance of so-called "three-way catalysts" for removing NO x , CO and HC simultaneously.
Accordingly, the exhaust gas introduced into each tested catalyst layer in this Example was one which was obtained by adding air to the exhaust gas used in Examples 6 to 9 thereby including much oxygen into the gas. The gas consisted of 0.9% of CO, 0.045% of HC, 12% of CO 2 , 0.09% of NO x , 0.18% of H 2 , 2% of O 2 , 13% of H 2 O and the balance being nitrogen.
The preparation of the carrier, the preparation of the catalysts, and the measurement of the purifying activities were effected in the same way as described in Example 6 except as noted above.
The amounts of catalyst ingredients deposited and the results of measurement of purifying activity are shown in Table 14.
This table also shows the data for comparative catalysts (S5 to S7) obtained by depositing catalysts ingredients in the same way as above on the conventional γ-alumina carrier (No. C1) shown in Example 6.
TABLE 14______________________________________ Invention ComparisonCatalyst No. A13 A14 A15 S5 S6 S7Carrier No. 1 1 1 C1 C1 C1______________________________________Amount of Ptdeposited (wt. %) 0.12 -- 0.06 0.12 -- 0.06Amount of Pddeposited (wt. %) -- 0.17 0.10 -- 0.17 0.10Percent CO 100 100 100 100 100 100removal(%) HC 98 96 98 83 79 84______________________________________
It is evident from Table 14 that the catalysts in accordance with this invention exhibit a CO removing activity equivalent to the catalysts formed from the conventional carriers, and exhibit a much higher HC removing activity than the catalysts formed from the conventional carrier.
Catalysts were prepared in the same manner as above using carrier (No. 4) of the present invention containing ceria which is shown in Example 7, and the purifying activities of the catalysts were measured. The results showed a CO removal of 100% and a HC removal of almost 100%.
Having now fully described this invention, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit or scope of the invention set forth herein. | A catalyst for removing nitrogen oxide, carbon monoxide and hydrocarbon impurities from exhaust gases comprising a porous carrier consisting essentially of alumina-magnesia spinel; and a metal supported thereon selected from the group consisting of platinum, palladium and mixtures thereof. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for producing a rare earth element-doped glass which exhibits properties of the rare earth by a sol-gel process.
2. Description of the Related Art
In the production of a glass optical fiber such as quartz glass optical fiber, techniques for producing a highly pure material and controlling optical structure have been almost completed, and the glass optical fiber is practically and widely used.
Since it was found that a glass added with, for example, Nd 3+ ions as active ions could generate a laser beam in the 1960s, it has been confirmed that a glass added with various rare earth elements such as Er 3+ , Yb 3+ , Ho 3+ or Tm 3+ can also generate a laser beam. This is because the laser transition in the trivalent rare earth element ions is the f-f transition so that it gives a narrow spectrum width in the glass.
The glass has many advantages for practical use, in that it can provide a large size mass compared to a crystalline material, and it is homogeneous and easily processed. In addition, the glass can be easily processed in a fiber form and used to assemble a telecommunication optical fiber system.
Two methods are known for addition of the rare earth element to the glass optical fiber, such as a quartz glass optical fiber, a vapor phase method and a solution impregnating method.
The vapor phase method includes a method comprising heating a chloride of a rare earth element to vaporize it, and introducing the vaporized chloride into a reaction tube together with a quartz glass-forming raw material, such as silicon tetrachloride, in order to form a glass which contains the rare earth element. Another type of vapor phase synthesis is a method comprising heating a mass of silica particles to vitrify it in an atmosphere comprising a vapor of the rare earth elements. This adds the rare earth element to the glass.
Typically, the solution impregnating method comprises dipping a mass of silica particles into a solution of the rare earth element in an alcohol or water, evaporating the alcohol or water and sintering the mass of silica particles to produce a glass containing the rare earth element.
The above conventional methods for producing the rare earth element-doped glass are based on the techniques for producing quartz glass optical fibers and have various merits in quality and productivity. However, by the vapor phase method, the rare earth element is added to the glass in an amount of several ppm to several ten ppm. When the solution impregnating method is used, the rare earth element can be added in an amount up to several thousand ppm. However, the amount of the impregnated rare earth element varies due to the bulk density profile in the mass of silica particles. This makes it difficult to produce a glass in which the rare earth element is uniformly added.
SUMMARY OF THE INVENTION
One object of the present invention is to provide a method for producing a rare earth element-doped glass in which the rare earth element is homogeneously doped.
Another object of the present invention is to provide a method for producing a rare earth element-doped glass by which the doped amount of the rare earth element can be controlled.
These and other objects of the present invention can be achieved using a method for producing a rare earth element-doped glass of the present invention, which method comprises hydrolyzing a metal alkoxide of the formula:
M(OR).sub.4
wherein M is a metal and R is an alkyl group, wherein the hydrolysis takes place in a liquid medium selected from the group consisting of alcohols containing water, in the presence of a compound of a rare earth element and condensing the hydrolyzed material to form a rare earth element-doped glass.
The doped glass produced by this method is suitable for making an optical devices such as a fiber laser, a glass laser or an optical switch.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing a relationship between pH values and the bulk density of the gel,
FIG. 2 is a Raman spectra for erbium-doped glass produced in Example 3 and the pure SiO 2 glass, and
FIG. 3 is a graph showing a relationship between the charged amount of erbium and the doped amount of erbium in Example 5.
DETAILED DESCRIPTION OF THE INVENTION
In the present invention, any of the metal alkoxides from which a glass is produced by the so-called solgel process may be used. Specific examples of the metal alkoxide are Si(OR) 4 , Ge(OR) 4 , Al(OR) 3 , Ti(OR) 4 , B(OR) 3 and mixtures thereof. The alkyl group R is preferably a straight or branched alkyl group having 1 to 8 carbon atoms. Specific examples of the alkyl group are a methyl group, an ethyl group, a n-propyl group, an isopropyl group, a n-butyl group and a tert.-butyl group. When Si(OR) 4 is used as the metal alkoxide, a quartz glass is formed.
The compound of rare earth element to be used in the present invention is preferably at least one compound of an element selected from the group consisting of lanthanide and actinide elements. Examples of the lanthanoid elements are La, Ce, pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu. Examples of the actinide elements are Ac, Th, Pa, U, Np, Pu, Am, Cm, Bk, Cf, Es, Fm, Md, No and Lr. Among them, the lanthanide elements which generate the laser, such as Er, Yb, Ho, Tm, Nd, Eu, Tb and Ce are more preferred.
Examples of the compound of the rare earth element are chloride, nitrate, sulfate, acetate, etc.
In the method of the present invention, the metal alkoxide is added to the alcohol containing water and hydrolyzed in the presence of at least one compound of the rare earth element. Preferred examples of the alcohol are methanol, ethanol, n-propanol, isopropanol and butanol.
The hydrolysis conditions may be substantially the same as those employed in the conventional hydrolysis of the metal alkoxide.
The pH of the mixture may affect the conditions of the later formed gel. The pH of the present mixture is preferably adjusted to be in a range between 6 and 9 with an alkali solution such as aqueous ammonia. When the gel is formed through hydrolysis of Si(OR) 4 in the pH range between 7 and 9, it is not cracked during drying. This allows production of a large size bulk. The reason for this may be explained from a relationship between the pH of the mixture for hydrolysis and a bulk density of the synthesized gel. As shown in FIG. 1, the bulk density is minimized in the pH range between 7 and 9. A gel having the small bulk density has large pores therein so that water or other liquids for easily evaporate and the gel is hardly cracked during drying.
The amount of the added rare earth element depends on the solubility of the rare earth element compound. In general, the rare earth element chloride such as NdCl 3 , YbCl 3 , HoCl 3 or TmCl 3 is soluble in water and has large solubility in the alcohol. In this case the rare earth element chloride can be practically used.
An amount of the rare earth element to be added to the glass depends on the solubility of rare earth element compound in the alcohol or water and is usually from 100 to 100,000 ppm. For example, 50 grams of NdCl 3 can be dissolved in 100 grams of water. Such solubility is practically satisfactory at a practical level. Since the rare earth element is added in a liquid phase, it can be homogeneously added to the glass. The amount of the rare earth element added to the glass can be adjusted by changing the amount of the rare earth element compound which is added to the starting mixture. This is one of the advantages of the present invention.
In the conventional methods, the rare earth element is added to the synthesized glass, which results in the rare earth element and the glass-forming elements are not being sufficiently bonded. In such case, the rare earth element forms clusters or crystals, which adversely affect the generation of laser or optical properties of the doped glass. However, in the present invention, the rare earth element is trapped in the network of the glass during formation of the glass from the metal. This produces glass with good quality and properties.
If the amount of the rare earth element compound is increased to increase the doped amount of the rare earth element, atoms of the rare earth element associate together so that the properties of the rare earth element cannot be effectively utilized. This may be because, in the quartz glass, the rare earth atoms which are independently doped in the SiO 2 network cannot coordinate the oxygen ions sufficiently so that the network is unstabilized by strain generated in the network. Then, the rare earth atoms associate together to restabilize the network.
To prevent the association of the rare earth atoms, co-doping of the rare earth element with other metals such as Al or P is effective.
Accordingly, in an embodiment of the present invention in which Si(OR) 4 is used as the metal alkoxide, it is preferred that the rare earth element compound and other metal alkoxide are previously hydrolyzed to prepare a solution containing the rare earth element, this solution is added to the mixture of Si(OR) 4 and the alcohol containing water. The previous hydrolysis may be carried out at a reaction temperature of 20° to 40° C. for 1 to 3 hours in the presence of a catalyst such as hydrochloric acid or aqueous ammonia. Preferred examples of the other metal alkoxide are alkoxides of Ge, Al, P and B. Further, a glass-forming element such as Wo and Te may be used. Preferably Al and P are used as the other metal alkoxide. Usually, 5 to 6 moles of the other metal is used per one mole of the rare earth element.
As hydrolysis of the metal alkoxide proceeds in the alcohol containing water, a sol is formed and then the sol is changed to a gel.
The gel is heated and dried. The drying is carried out at a temperature of at least 60° C., preferably from 60° C. to 200° C., for example from 120° C. to 200° C. When the drying temperature is lower than 60° C., residual water cannot be sufficiently removed.
The dried gel is then dehydrated, preferably in a chlorine-containing atmosphere, and then is vitrified at a sufficiently high temperature, for example, higher than 200° C. in a helium atmosphere or under vacuum. This gives a glass containing the rare earth element in the form of an oxide.
PREFERRED EMBODIMENTS OF THE INVENTION
The present invention will be illustrated by the following Examples.
EXAMPLE 1
Silicon tetramethoxide (500 ml), water (250 ml), 0.1N HCl (20 ml) and erbium chloride (3.3 g) dissolved in methanol (50 ml) were charged in a beaker and mixed with a magnetic stirrer for about two hours. Then, the mixture was poured in a messcylinder made of polytetrafluoroethylene (Teflon, a trade mark), and the messcylinder was sealed with an aluminum adhesive tape and kept standing at 60° C. for one day. After making several holes in the aluminum tape, the mixture in the messcylinder was kept standing at 60° C. for ten days to obtain a dried gel.
The dried gel was dehydrated in an atmosphere containing 7% of chlorine at 800° C. for about two hours followed by heating in a helium atmosphere at 1300° C. for two hours to obtain a transparent pink glass. Elemental analysis of the glass revealed that it contained about 1 % by weight of erbium.
Example 2
In a mixture of aluminum methoxide (5 ml), ethanol (10 ml) and 0.1N aqueous ammonia (0.1 ml), and erbium chloride (3.3 g) was dissolved and stirred for two hours. Then, silicon tetramethoxide (500 ml), water (500 ml), ethanol (750 ml) and 0.1N aqueous ammonia (20 ml) were added to the mixture and stirred for two hours.
The resulting mixture was poured in a messcylinder made of polytetrafluoroethylene (Teflon, a trade mark), and the messcylinder was sealed with an aluminum adhesive tape and kept standing at 35° C. for one day to form a gel. Then, the mixture was heated to 80° C. over two days. After making small holes in the aluminum tape, the mixture in the messcylinder was kept standing at 80° C. for five days, heated to 150° C. over four days, kept standing at 100° C. for one day and then evacuated under vacuum at 200° C. to obtain a dried gel.
The dried gel was heated to 1200° C. at a heating rate of 1° C./min. and kept at that temperature for two hours to obtain a transparent glass. Elemental analysis of the glass revealed that it contained 1% by weight of erbium.
EXAMPLE 3
In the same manner as in Example 2, a SiO 2 glass containing 0.7% by weight or 2.1% by weight of erbium was produced and its Raman spectrum was recorded and compared with the Raman spectrum of pure SiO 2 . The spectra are shown in FIG. 2. The peaks indicated by the arrows are assigned to SiO 2 and are not affected by the addition of erbium. This result means that erbium is homogeneously dispersed in the erbium-doped glass.
EXAMPLE 4
To a mixture of phosphorus methoxide (6 ml), ethanol (12 ml) and water (6 ml), 0.1N hydrochloric acid (0.5 ml) and neodymium chloride (3.4 g) were added and stirred at 30° C. for two hours to hydrolyze phosphorus methoxide. To this mixture, silicon methoxide (500 ml), water (500 ml), ethanol (750 ml) and 0.1N aqueous ammonia (20 ml) were added and stirred for one hour. The resulting mixture was charged in a messcylinder made of polytetrafluoroethylene (Teflon, a trade mark), and the messcylinder was sealed with an aluminum adhesive tape and kept standing at 35° C. for one day to form a gel. Then, the mixture was heated to 80° C. over two days. After making small holes in the aluminum tape, the mixture in the messcylinder was kept standing at 80° C. for five days, heated to 150° C. over four days and kept standing at that temperature for one day followed by evacuation under vacuum at 200° C. for eight hours to obtain a dried gel.
The dried gel was heated in the air to 350° C. at a heating rate of 1° C./min. to remove the residual carbon. Thereafter, the gel was heated to 800° C. at a heating rate of 1 C./min. and a chlorine gas was introduced in the messcylinder to dehydrate the gel. The dehydrated gel was heated to 1200° C. at a heating rate of 1° C./min. and kept at that temperature for two hours to obtain a transparent glass. Elemental analysis of the glass revealed that it contained 1% by weight of neodymium.
EXAMPLE 5
Silicon tetramethoxide (100 ml), ethanol (220 ml), water (100 ml), 0.1N aqueous ammonia 720 ml) and erbium chloride.hexahydrate (ErCl 3 .6H 2 O) (0.93 g) were mixed and stirred with a magnetic stirrer for about 15 minutes. Then, the mixture was poured in a messcylinder made of polytetrafluoroethylene (Teflon, a trade mark), and the messcylinder was sealed with an aluminum adhesive tape and kept standing at 35° C. for two days. After making several holes with a diameter of 0.1 mm in the aluminum tape, the mixture in the messcylinder was kept standing at 80° C. for five days, at 100° C. for two days, at 130° C. for two days and at 150° C. for two days to obtain a dried gel.
The dried gel was heated with an electric furnace in an oxygen atmosphere at 350° C. for two days to burn out the residual carbon followed by dehydration in a chlorine atmosphere at 800° C. for two hours. Then, the dehydrated gel was heated in a helium atmosphere at 1200° C. to obtain a transparent pink glass. Elemental analysis of the glass revealed that it contained about 1% by weight of erbium. The glass contained no scattering materials, which indicated that Er atoms did not form clusters and were homogeneously dispersed in the glass.
With changing the charged amount of erbium methoxide, erbium-doped glass was produced. The relationship between the charged amount of erbium methoxide and the amount of doped erbium is shown in FIG. 3. The doped amount of erbium was measured by atomic absorption analysis. The results indicate that erbium was added to the glass at a yield of 70%.
EXAMPLE 6
In the same manner as in Example 5 except that silicon tetramethoxide (100 ml), ethanol (270 ml), water (100 ml), 0.1N aqueous ammonia (70 ml) and uranium chloride (UCl 3 ) (5.8 g) were used, a glass doped with 1% of uranium was produced. | A rare earth element-doped glass in which the rare earth element is homogeneously doped is produced by a method coprises hydrolyzing a metal alkoxide of the formula:
M(OR).sub.4
wherein M is a metal and R is an alkyl group in a liquid medium selected from the group consisting of alcohols and water in the presence of a compound of a rare earth element and condensing the hydrolyzed material to form a rare earth element-doped glass. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to an assay; more particularly, it relates to a method for the determination of fructosamines or other glycated proteins in biological materials.
Fructosamines are glycated proteins, present in biological materials, for example blood serum. "Glycation" is defined as the non-enzymatic glycosylation of proteins, such as serum albumin, by the condensation of reducing sugars, such as glucose, with the protein, (see Roth, M., (1983), Clin. Chem., 29, 1991). The reaction of glucose with albumin involves the nucleophilic attack of the carbonyl group of glucose on free amino groups on the protein. The thus-formed Schiff base may hydrolyse back to glucose and protein or it may undergo an Amadori rearrangement, (see Hodge, J.E., (1955), Adv. Carbohydr. Chem., 10, 169-205), to form a ketoamine structure. This reaction sequence is illustrated in accompanying FIG. 1. The Amadori compound is stabilised by equilibration of the linear ketoamine structure into several cyclic, hemiketal conformations in solution. The principal sites of glycation are the ε-amino groups of lysine residues and the α-amino group of the protein's terminal amino acid. Once formed, the stable ketoamine structure remains with the protein throughout its life-span.
Many disease states are characterised by unusually high or low levels of specific components of the body's metabolism. If the normal concentration range of a component in a healthy population is known then the detection of abnormal levels of this component provides a useful indication of metabolic disorder caused by disease. The purpose of clinical diagnostic tests, therefore, is to allow the performance of qualitative and quantitative analysis on body fluids, such as blood, urine and spinal fluid, as well as on tissue and other materials. The information obtained from these tests is useful to physicians in the monitoring and treatment of disease. For the information to be meaninfgul, the tests performed must be reliable and accurate. Generally, diagnostic assays make use of some unique chemical property of the analyte as the basis of the assay method. A sample of the body fluid or other material containing the analyte to be measured, generally after a suitable work-up, is contacted with a reagent which is designed to interact with the analyte in a specific way so that a measurable signal is produced. Thus, a chemical assay would involve a reagent that reacts with the analyte in a measurable way, without reacting with other components of the sample. Ideally, the reaction between the reagent and the analyte should be so specific that no other substances will react in the same manner. However, in chemical based assays, this is seldom the case and interfering side reactions are often a problem.
This problem may frequently be overcome by designing an enzyme based assay. Enzymes, by the very nature thereof, are highly specific for their substrate molecules. Although an enzyme depends on the chemical properties of its substrate to perform a specific reaction the enzyme must first recognise the physical and chemical "shape" of the substrate so that binding may occur. Only then may the enzymic reaction take place. In an enzyme based assay, therefore, a reagent containing an enzyme specific for the analyte is usually used to bind and transform the analyte in a way that is measurable. Enzyme based diagnostic assays may therefore offer advantages of specificity over chemical methods.
The level of fructosamine present in blood is governed by the concentration of sugars, such as glucose, in solution in serum. As fructosamines have a half-life of 2-3 weeks in serum, the level of fructosamine present reflects the average blood glucose levels over a period of 1-3 weeks. Thus, measurement of this parameter is a useful means of monitoring glycaemic control in diabetes mellitus.
At present, there are several established non-enzymic methods for measuring levels of serum fructosamines. For example, one method involves the separation of glycated from unglycated proteins by affinity chromatography, (see Diabetes, (1980) , 29, 1044-1047).
Immobilised m-aminophenyl-boronic acid complexes with the cis-diol groups of the glycating sugars under alkaline conditions. Unbound materials are removed by washing with buffer and the fructosamines are eluted by high concentrations of sorbitol. The levels of fructosamine in the eluent may then be measured by absorbance at 280 nm or by chemical methods. The disadvantages of such a method are that free glucose must first be removed from the samples and that the amount of glycated protein that binds to the immobilised m-aminophenyl-boronic acid is critically dependant on chromatographic conditions. This may therefore reduce the accuracy of the method.
Another known method involves the detection of the breakdown products of acid hydrolysis of the ketoamine bonds. Treatment of glycated proteins with strong acids at elevated temperatures, such as 6 mol/l HCl at 95° C., causes hydrolysis of the glycated lysine residues and yields a specific product, N-(2-furoylmethyl)-L-lysine (furosine). Furosine is measured by HPLC using a reverse phase column and simultaneous UV detection at 254 and 280 nm, (see J. Clin. Chem. Clin. Biochem., (1981), 19, 81-87). Human serum albumin containing a known amount of glycated lysine residues is used for calibration. However, the method is time consuming and unsuitable for routine work or automation.
Acid hydrolysis of fructosamine is also used in another method in which treatment with weak or diluted acids yields 5-hydroxymethyl-2-furfuraldehyde. This product may be determined spectrophotometrically at 280 nm after HPLC separation. However, a more convenient method involves the reaction of the furfural product with 2-thiobarbituric acid, which results in a derivative with an absorbance maximum at 443 nm (see FEBS Lett., (1976), 71, 356-360). This procedure has been partially automated using dedicated equipment; however, the accuracy of the results depends on several factors including the level of protein in the samples, the conditions of the acid hydrolysis and the removal of glucose.
A further method which has recently replaced many of the above procedures depends on the reducing ability of fructosamine in alkaline solutions. One such method involves the addition of a serum sample to carbonate buffer, pH 10.35, containing nitroblue tetrazolium (NBT). The NBT is reduced, probably via a superoxide radical intermediate, and the absorbance of the formazan product is measured at 550 nm. The method relies on the observation that most interfering components in serum react in the first 10 minutes and hence specific serum reducing activity is measured between 10 and 15 minutes. The procedure is rapid and has been automated on a variety of analysers for clinical diagnostic use. However, the specificity of the method for glycated proteins has been questioned and it has been shown that non-specific components may lead to interference and misinterpretation of the results. In addition, the fructosamine level is influenced by the level of albumin in the sample and so the results may need to be adjusted, especially in cases of hypoalbuminaemia.
An object of the present invention is to provide a method for measuring serum fructosamine levels as an indicator of diabetic control, for example, which offers significant advantages over the existing methods. In order to do this, it was necessary to provide enzymes capable of using glycated proteins as substrates.
SUMMARY OF THE INVENTION
The present invention provides a method for the determination of glycated protein in a sample characterised in that it comprises treating the sample with a protease and treating the protease-treated sample with a ketoamine oxidase, a product of this reaction being measured. (It is a characteristic of the present ketoamine oxidases that the reaction produces a sugar osone and hydrogen peroxide, either of which may be measured by conventional means as an indication of glycated protein content of the sample.)
Preferably, the ketoamine oxidase is obtainable from the bacterial groups Klebsiella or Corynebacterium, from the fungal genera Fusarium or Acremonium or from the yeast genus Debaryomyces; more preferably, the ketoamine oxidase is obtainable from Debaryomyces vanrijiae var. vanrijiae. Generally, a protease pre-treatment is carried out using a protease selected from proteinase K, pronase E, ananain, thermolysin, subtilisin and bovine pancreatic proteases. The protease treatment is preferably performed in the presence of a suitable detergent, in particular SDS, "Brig 35" and "Tween 20". It is commonly more convenient to measure the hydrogen peroxide involved, rather than the osone, and this may easily be done by the known Trinder method.
The present invention further provides a kit for the determination of glycated protein in a sample characterised in that it comprises a protease and a ketoamine oxidase.
The present invention also provides a ketoamine oxidase characterised in that it catalyses the oxidation of the carbon atom in position 1 of a sugar moiety cf a glycated protein with consequent hydrolytic disruption of an amine bond to release a sugar osone and hydrogen peroxide from an amino acid and a process for the production thereof which comprises the use of a model substrate, preferably butylamino-deoxy-fructose (BADF), as inducer and/or screen. Preferred sources of such enzymes are as given above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the reaction of glucose with a protein to form a Schiff base. The Schiff base may hydrolyze back to glucose and protein, or it may undergo an Amadori rearrangement to form a fructosamine.
FIG. 2 depicts two model substrates: fructosyl valine (FV) and butylamino deoxy fructose (BADF).
FIG. 3 is an illustration of the oxidation of fructosyl valine by ketoamine oxidase.
FIG. 4 is a pH/activity profile of ketoamine oxidase prepared from Debaryomyces vanrijiae var. vanrijiae.
FIG. 5 is a pH/stability profile of ketoamine oxidase prepared from Debaryomyces vanrijiae var. vanrijiae.
FIG. 6 shows the rate of reaction, measured in fructosamine concentration, of ketoamine oxidase with human serum albumin.
FIG. 7 depicts the mean absorbance and fructosamine concentration of ketosamine oxidase reacted with human serum albumin.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention involves the use of such an enzyme specific for ketoamine compounds of the Amadori type. The present method, being enzyme based, has a high level of specificity for such compounds. A further advantage of the present invention is that the enzyme used is an oxidase which releases H 2 O 2 as a byproduct of the reaction. The H 2 O 2 released may readily be measured, preferably by means of the widely used Trinder method, (see Ann. Clin. Biochem., (1969), 6, 24-27), thus providing a method for measurement of fructosamines that is easily automated on existing autoanalysers.
The screen for the desired enzymic activities was based on well-established microbiological techniques. The selection technique depends oil the use of a defined culture medium in which the sole source of some essential atom, such as nitrogen, is supplied as the proposed target molecule or analyte. This minimal culture medium is then inoculated with a range of environmental samples. Of the many microorganisms that will be present in these samples, only those that are able to produce suitable enzymes to breakdown the target analyte will be able to release the limiting nutrient and grow. Microorganisms that grow on this medium may then be isolated and the required enzyme activity extracted.
This method is particularly suitable for use with simple or low molecular weight target molecules. However, when the target molecule is large and complex, such as fructosamine, the method is significantly less reliable. This is because in a large target molecule there may be more than one of the limiting atoms which may be released by a variety of means. For instance, if fructosamine were used, in a selective medium, as the sole source of nitrogen for growth, many microorganisms would have the ability to extract nitrogen from this molecule by means of proteolytic enzymes. Due to the abundance of nitrogen atoms in fructosamine, no selective pressure is placed on the organisms in the medium to rely on the nitrogen in the ketoamine portion of the protein for growth. This analyte is therefore unsuitable for use in selective culture media.
Thus, because of these limitations, a different approach in the design of the selective medium was used. Model target molecules were designed which closely resembled the unique ketoamine bond of the true analyte, fructosamine, yet which contained no other nitrogen atoms apart from that in the ketoamine bond itself. To liberate the nitrogen from these molecules in a culture medium would require the cleavage of the ketoamine bonds in some manner by an appropriate enzyme. Thus, any organism which grew on this medium should have, as part of its metabolic makeup, an enzyme or enzymes capable of using ketoamine groups as substrate. Once isolated, these enzymes could then be screened for ability to act on the larger fructosamine molecules.
As described earlier, the ketoamine bond of fructosamines involves glucose and the amino acid lysine. The simplest model compound for this analyte would be a glycated lysine, i.e. fructosyl lysine. However, as lysine contains two nitrogen containing amino groups, fructosyl lysine would suffer a similar disadvantage to fructosamine as sole nitrogen source in a selective medium, that is, nitrogen could be released from this molecule without necessarily breaking the target ketoamine bond. The closely related molecule, fructosyl valine (see accompanying FIG. 2), which contains a single nitrogen atom was therefore prepared as a model substrate. Fructosyl valine was prepared by a known method, (see Keil, et al, Acta. Chem. Scand., (1985), B39, 191-193). This model ketoamine compound was used as the nitrogen source in an environmental screen for ketoamine metabolising activities. A number of microorganisms capable of degrading fructosyl valine were isolated using this method.
A disadvantage of the small size of the amino acid in fructosyl valine is that the free carboxyl group of the amino acid is in close proximity to the ketoamine bond between the sugar and the amino acid. It is possible that this carboxyl group could facilitate the breakage of the ketoamine bond by promoting acid-base catalysis at the fructosyl valine ketoamine bond. As this does not occur in the target, fructosamine, a second model substrate was designed which had no reactive group close to the ketoamine bond. This second model, BADF, was again prepared by a known method, (see Micheel and Hogemann, Chem. Bet., (1960), 93, 238) and is illustrated in accompanying FIG. 2. A further microbial screen was performed using BADF as the sole source of nitrogen in a minimal medium and a number of isolates were found which were capable of oxidising ketoamine bonds. A number of the desired ketoamine oxidase enzymes, of differing characteristics, were extracted from the microbial isolates produced by the screens.
The reaction catalysed by these novel ketoamine oxidase enzymes is illustrated in accompanying FIG. 3. Such an enzyme catalyses the oxidation of the carbon atom in position 1 of the sugar moiety with a consequent hydrolytic disruption of the amine bond to release a sugar osone from the amino acid. In this oxidation reaction, oxygen acts as the electron acceptor and hydrogen peroxide is produced as a byproduct.
Preferred sources of the present ketoamine oxidase enzymes are the bacterial groups Klebsiella or Corynebacterium, the fungal genera Fusarium or Acremonium and the yeast genus Debaryomyces. Particularly good results may be obtained in accordance with the present invention when using such a ketoamine oxidase obtained from Debaryomyces vanrijiae var. vanrijiae.
Debaryomyces vanrijiae var. vanrijiae may be cultured in a single step Malt Extract Broth medium. The production of ketoamine oxidase is especially facilitated by the inclusion in the medium of a ketoamine model compound, such as fructosyl valine or BADF, as an inducer. The organism may be cultured at from 15° to 40° C. over a pH range of from 5 to 9, for example. The preferred conditions for the growth are generally 22°-28° C. and pH 6.0-8.0. Growth of the organism and production of the enzyme generally takes 1-6 days.
Alternatively, the production of such an enzyme may take place in a two-stage process. The organism may be inoculated into a nutrient-rich medium, such as Tryptone-Soya medium, so that high biomass is produced. Once maximum biomass is achieved, generally in 1-3 days, the cells may be harvested by centrifugation and placed into a minimal salts medium containing a quantity of a ketoamine model compound as inducer. The cells may be incubated in this medium to allow induction and this step may take 2-24 hours.
In one presently-preferred embodiment, the process according to the present invention for the detection of glycated proteins comprises pretreatment of the sample of glycated protein to be assayed, such as fructosamine in serum, with a proteolytic reagent containing proteases, such as proteinase K, pronase E, ananain, thermolysin, subtilisin and bovine pancreatic proteases. The predigestion may be performed in the presence of a detergent, such as sodium lauryl sulphate (SDS), "Brij 35" or "Tween 20". The pretreated sample may then be contacted with a ketoamine oxidase preparation selected from the bacterial groups Klebsiella or Corynebacterium, from the fungal genera Fusarium or Acremonium or from the yeast genus Debaryomyces.
By this means, the glycated lysine groups in the fructosamine may be liberated from the protein and may then be cleaved with the release of glucosone. A characteristic of the oxidation of glycated amino acids by the ketoamine oxidase is the stoichiometric formation of hydrogen peroxide by the enzyme. The thus-formed hydrogen peroxide may be measured enzymatically. One option is to include with the preparation of ketoamine oxidase a predetermined quantity of horseradish peroxidase and suitable chromogenic substrates for this enzyme, such as 4-amino phenazone and sodium N-ethyl-N-(2-hydroxy-3-sulphopropyl)-m-toluidine (TOOS). In this case, the hydrogen peroxide formed by the action of the ketoamine oxidase is used by the peroxidase to oxidise the chromogenic substrates.
This reaction results in colour formation in the assay mixture which may be detected by measuring the change in absorbance of the assay mixture at an appropriate wavelength. The amount of glycated protein converted may therefore be calculated by stoichiometric equivalence. Glucosone may be determined by means of aldose reagents, such as diphenylamine.
The present invention provides a diagnostic kit for the determination of glycated protein or fructosamine which is comprised of two reagents or reagent groups. One reagent group contains the protease or proteases and the detergent which is used in the pretreatment of the sample. The other reagent group contains the assay components, including the present ketoamine oxidase, which oxidises the glycated amino acids formed during the pretreatment, and the Trinder reagents, such as peroxidase, 4-amino phenazone end a phenolic or anilinic coupler used to produce a colour signal. Typically, an aliquot of the sample to be assayed is added to a suitable volume of the assay reagent. This assay mixture may be incubated at a temperature of from 10° to 60° C., more preferably from 30° to 50° C., at a pH of from 5 to 9.5, more preferably from 6 to 8, for a suitable time, usually from 2 to 20 minutes. The rate of oxidation may be measured by a kinetic or endpoint method.
The present invention provides for a new fructosamine assay which is better than existing fructosamine assays as it is based on the use of a new enzyme specific for ketoamine bonds of the type present in fructosamine. By virtue of this specificity, the present assay is generally less susceptible to interference, possibly by other substances present in blood samples than existing methods. The method may easily be adapted for use on existing automated analysers.
The present invention will be further illustrated by the following Examples:
EXAMPLE 1
Cells of a culture of Fusarium oxysporum (IMI 353436) were inoculated into 500ml Ehrlenmeyer flasks containing 100 ml of a medium composed of the following: glycerol (10 g/l), Na 2 HPO b .2H 2 O(14 g/l), KCl (0.5 g/l), MgSO 4 (0.5 g/l), CaCl 2 (0.02 g/l) and fructosyl valine (2 g/l). The shakeflask cultures were incubated at 30° C. on an orbital shaker for 4 days. After this time, the cells were harvested by centrifugation at 3500 rpm for 15 minutes. The cells were washed in 0:1 M phosphate buffer, pH 8.0, and re-centrifuged as before. The pellet was then resuspended in 0.1M phosphate buffer, pH 8.0, to 20% of the volume of the original harvest volume. Since the enzyme is located intra-cellularly in this organism, 20 ml aliquots of the cell suspension were each sonicated for 15 minutes to release the enzyme into solution. The sonicate was then centrifuged at 3500 rpm for 30 minutes to remove cell debris. The resulting enzyme solution was dialysed for 20 hours at 4° C. against two changes of 3 liters of 0.1M phosphate buffer, pH 8.0.
The activity of the preparation was assayed using the model substrate BADF. The assay mixture was prepared as follows:
200 μl enzyme preparation
40 μl horseradish Feroxidase (1.45 mg/ml)
60 μl phenol (5.5 mg/ml)
60 μl 4-aminophenazone (2 mg/ml)
720 μl 0.1M phosphate buffer, pH 7.9
This mixture was pre-incubated in a 1 ml cuvette at 37° C. and any blankrate measured by following the change in absorbance at 505 nm. 120 μl of BADF (3 mg/ml) was then added to the cuvette and the ketoamine oxidase activity measured. (One unit of activity is defined as the amount of enzyme that causes the oxidation of one micromole of BADF per minute at 37° C.) By this method, the ketoamine oxidase activity of this preparation was found to be 30 U/l.
EXAMPLE 2
A 250 ml shakeflask containing 50 ml of Tryptone-Soya medium was inoculated with cells from a culture of Acremonium sp (IMI 353437). This shakeflask was incubated at 30° C. on an orbital shaker for 24 hours. A 15 ml aliquot from this culture was then inoculated under aseptic conditions into a 2 liter stirred fermenter containing 1.5 liters of sterile Tryptone-Soya medium. To this fermenter, was added 350 mg/l of a BADF solution through a sterile filter. The medium was agitated at 1000 rpm and 1 l/min of air was sparged through the culture. Temperature was maintained at 28° C. throughout the fermentation.
After 96 hours the absorbance at 470 nm of the culture broth reached 12-15 optical density units and the contents of the fermenter were harvested by centrifugation at 7000 rpm for 15 minutes. The cell pellets were washed in 0.1 M phosphate buffer, pH 8.0, and then re-suspended in 250 ml of the same buffer. The cells were lysed by sonication for 25 minutes and the cell debris was reproved by centrifugation at 7000 rpm for 20 minutes. The supernatant enzyme solution was dialysed against two changes of 5 l of the phosphate buffer. Using the assay described in Example 1, this preparation was found to contain 10 U/l ketoamine oxidase.
EXAMPLE 3
A 250 ml shakeflask containing 50 ml of Malt Extract Broth was inoculated with cells from a culture of Debaryomyces vanrijiae var. vanrijiae (NCYC 2386) . The shakeflask was inoculated under aseptic conditions into a stirred fermenter containing 1.5 liters of sterile Malt Extract Broth. 0.5 g/l of BADF was added as inducer to the fermenter through a sterile filter. The medium was agitated at 1000 rpm and 1 l/minute of air was sparged through the culture. The termperature was maintained at 28° C. throughout the fermentation and the pH was controlled at 6.0.
After 24 hours growth the cells were harvested by centrifugation, washed in 50 mM phosphate buffer, pH 7.5, and then collected again by centrifugation. The cell pellet was resuspended in the same buffer to a volume of 250 ml and the slurry was sonicated to lyse the cells.
The flocculating agent, "Magnafloc LT31" (0.1%) was added to the suspension and the cell debris was removed by centrifugation. An ammonium sulphate frontcut was performed on the solution by adding solid ammonium sulphate to 40% saturation. The precipitate thus formed was removed by centrifugation and discarded. A backcut was performed by raising the ammonium sulphate concentration to 65% saturation and the precipitate was harvested. The precipitate was resuspended in 50 ml of 20 mM piperazine buffer, pH 5.5, and this solution was diafiltered on an Amicon Centriprep 30 module against the same buffer containing 0.1 mM EDTA, 0.1 mM PMSF and 0.2 mM benzamidine. After diafiltration the solution was centrifuged at 3000 rpm for 20 minutes to remove precipitate. 6 ml of the supernatant was loaded onto a Pharmacia Mono S HR5/5 column which had previously been equilibrated with the 20 mM piperazine, pH 5.5, buffer, and the ketoamine oxidase enzyme was removed from the column by isocratic elution in 15 column volumes. The fractions containing ketoamine oxidase were pooled to yield a preparation which contained 0.8 U/ml ketoamine oxidase and 83 μg/ml protein.
The Km of the enzyme prepared in this manner was determined for BADF and was found to be 80 μmolar. Accompanying FIGS. 4 and 5 show the pH/activity and pH/stability profiles of the ketoamine oxidase prepared in the above manner. The pH optimum for activity is in the range cf from 7.0 to 8.5, while the enzyme is most stable in the range of from 5 to 7.5.
EXAMPLE 4
4 g of Sigma human albumin and 5 g of glucose were dissolved in 80 ml of 50 mM phosphate buffer, pH 7.4, containing 150 mM sodium chloride. The mixture was sterile filtered into a sterile flask and incubated at 37° C. for 21 days. After this time, the solution was dialysed against 50 mM Tris/HCl buffer, pH 7.9, and then centrifuged at 3500 rpm for 20 minutes to remove any precipitate. The solution was then assayed using the Roche NBT assay and was found to contain 3880 μmol/l fructosamine.
Aliquots of this solution were diluted with 50 mM Tris/HCl buffer, pH 7.9, to produce a range of samples varying in fructosamine concentration from 0 to 1940 μmol/l. Pretreatment incubation mixtures were made up as follows for each fructosamine dilution.
190 μl Fructosamine solution
20 μl Genzyme Proteinase K (6 mg/ml)
20 μl Sigma Pronase E (6 mg/ml)
20 μl SDS (1.25%)
These mixtures were incubated at 55° C. for 30 minutes. After this time, aliquots were withdrawn from each pretreatment tube and added to the microtitre plate assay mixture as follows:
25 μl Digestion Sample
20 μl 4-amino phenazone solution (2 mg/ml)
20 μl TOOS Solution (I5.5 mg/ml)
10 μl Signma Horseradish Peroxidase (1.45 mg/ml)
150 μl 50 mM Tris/HCl buffer, pH 7.9
Duplicate assays were performed for each concentration of fructosamine.
The microtitre plate was incubated at 37° C. and 25 μl of a ketoamine oxidase solution prepared as described in Example 3, with an activity of 1 U/ml, was added to each assay well. The initial rate of reaction was measured for each well for 5 minutes by absorbance charge at 560 nm. The relationship between initial rate of reaction and fructosamine concentration is shown in accompanying FIG. 6.
EXAMPLE 5
The procedure described in Example 4 was repeated, except that the ketoamine oxidase assay reaction was allowed to run to completion by incubating the microtitre plate reaction mixtures at 37° C. for 20 minutes. After this time, the absorbance of each well was measured at 560 nm. The relationship between the mean absorbance and the fructosamine concentrations obtained for this method is shown in accompanying FIG. 7. | A method for the determination of glycated protein in a sample characterised in that it comprises treating the sample with a protease and treating the protease-treated sample with a ketoamine oxidase, a product of this reaction being measured is disclosed. | 2 |
This application claims benefit of Provisional Application 60/359,967 filed Feb. 27, 2002.
FIELD OF THE INVENTION
The present invention relates generally to visualization of geographically related information, and more particularly, to a method of automatically or semi-automatically generating a cartogram based on an input set of contiguous polygons and an input data vector.
BACKGROUND OF THE INVENTION
Cartograms are a well-known technique for showing geography-related statistical information, such as population demographics, election results and epidemiological data. The basic idea is to distort a map by resizing its regions according to some geographically related statistical parameter, but in a way that keeps the map recognizable. Cartographers and geographers have used cartograms since long before computers were available to make displays. Because cartograms are difficult to make by hand, the study of programs to draw them is of interest.
Other visualization techniques include the conventional choropleth map. A choropleth map is a map divided into regions that are shaded according to the value of a variable for that region. High values are often concentrated in highly populated areas, and low values may be spread out across sparsely populated areas. Such maps therefore tend to highlight patterns in less dense areas where few people live. In contrast, cartograms display areas in relation to an additional parameter, such as population. Patterns may then be displayed in proportion to that parameter (e.g. the number of people involved) instead of the raw size of the area involved. A population-based cartogram is presented in FIG. 1 B. The cartogram gives a much different impression of overall trends, as compared with the original map (FIG. 1 A).
For a cartogram to be recognizable it is important to preserve the global shape or outline of the input map, a requirement that has been overlooked in the past. To address this, the inventors' objective function for cartogram drawing includes both global and local shape preservation. To measure the degree of shape preservation, a shape similarity function is proposed. The function is based on a Fourier transformation of the polygons' curvatures. Also, because the application goal is visualization of dynamic network behavior, an algorithm is needed that recalculates a cartogram in a few seconds. No previous algorithm known to the inventors provides adequate performance with an acceptable level of quality for that application.
In the present application, the inventors formally define a family of cartogram drawing problems, and show that even simple variants are unsolvable in the general case. The feasible variants are NP-complete; i.e., the problem is both NP (verifiable in nondeterministic polynomial time) and NP hard (any other NP problem can be translated into this problem). Heuristics are therefore needed to solve the problem. Previously proposed solutions suffer from problems with the quality of the generated drawings.
The present application describes an efficient iterative scanline algorithm to reposition edges while preserving local and global shapes. Scanlines may be generated automatically, or entered interactively to guide the optimization process more closely. The algorithm is applied to a number of example data sets, providing a detailed comparison of the two variants of our algorithm and previous approaches.
A cartogram can be seen as a generalization of an ordinary map. In that interpretation, an arbitrary parameter vector gives the intended sizes of the cartogram's regions, so an ordinary map is simply a cartogram with sizes proportional to land area. In addition to the classical applications mentioned above, a key motivation for cartograms as a general information visualization technique is to have a method for trading off shape and area adjustments.
For a cartogram to be effective, a human must be able to quickly understand the displayed data and relate it to the original geographical model. Recognition, in turn, depends on preserving basic properties, such as shape, orientation, and contiguity. That, however, is difficult to achieve in the general case because it is impossible to retain even the original map's topology. Because the generation of contiguous cartograms by simultaneous optimization of those objectives is difficult, most currently available algorithms are very time-consuming.
Cartograms may be made by contiguous or non-contiguous distortions. The non-contiguous case is much simpler because the input map topology does not have to be preserved. As seen in FIGS. 2A-2H , hand-made non-contiguous cartograms have been made with overlapping or touching circles (FIG. 2 D), by eliminating some of the original map's adjacencies (FIG. 2 C), or even by drawing disconnected shapes over the original regions (FIG. 2 B).
Previous attempts to automate the drawing of contiguous cartograms do not yield results comparable to good hand-made drawings. One reason is that straight lines, right angles and other features considered important in human recognition of cartograms are obliterated. Methods that are radial in nature such as the conformal maps proposed by W. R. Tobler, “Cartograms and Cartosplines,” Proceedings of the 1976 Workshop on Automated Cartography and Epidemiology, 53-58 (1976) (FIG. 2 A), the radial expansion method of S. Selvin, D. Merrill, J. Schulman, S. Sacks, L. Bedell, and L. Wong, “Transformations of Maps to Investigate Clusters of Disease,” Social Science and Medicine, V. 26, no. 2, at 215-221 (1988) ( FIG. 2F ) and the line integral method of Sabir Gusein-Zade and Vladimir Tikunov, “A New Technique for Constructing Continuous Cartograms,” Cartography and Geographic Information Systems, V. 20, no. 3 at 66-85 (1993) ( FIG. 2G ) do not provide acceptable results, since the shapes of the polygons are heavily deformed. Likewise, the pseudo-cartograms described by W. R. Tobler, “Pseudo-Cartograms,” The American Cartographer, V. 13, no. 1 at 43-40 (1986) ( FIG. 2E ) expand the lines of longitude and latitude to achieve a least root mean square area error. Very similar drawings have been made by approaching the problem as distortion viewing by nonlinear magnification. Radial forces are applied by Charles B. Jackel, “Using Arcview to Create Contiguous and Noncontiguous Area Cartograms,” Cartography and Geographic Information Systems, V. 24, no. 2 at 101-109 (1997) to change the size of polygons, moving the sides of each polygon relative to its centroid. That solver, however, runs slowly (e.g., taking 90 minutes to perform 8 iterations on a map of 6 New England states of the U.S.) and seems to have problems with non-convex input polygons and with self-intersections in the output.
Another family of approaches operates on a grid or mesh imposed on the input map. The “piezopleth” method of C. Cauvin, C. Schneider, and G. Cherrier, “Cartographic Transformations and the Piezopleth Method,” The Cartographic Journal, V. 26, no. 2 at 96-104 (December 1989) transforms the grid by a physical pressure load model. The cellular automaton approach of Daniel Dorling, Area Cartograms: Their Use and Creation, Department of Geography (U. Bristol, England, 1 st ed. 1996) trades grid cells until each region achieves the desired number of cells. The combinatorial approach of Herbert Edelsbrunner and Roman Waupotitsch, “A Combinatorial Approach to Cartograms,” Computational Geometry 343-360 (1997) computes a sequence of piecewise linear homeomorphisms of the mesh that preserve its topology. While the first method is good at preserving the shape of the polygons, the other two methods allow a very good fit for area but only poor shape preservation.
A synthesis of both approaches was recently described in Christopher J. Kocmoud and Donald H. House, “Continuous Cartogram Construction,” Proceedings IEEE Visualization 197-204 (1998) (FIG. 2 H). A force-based model is proposed that alternately optimizes the shape and the area error. Although the results are better than most other methods, the complex optimization algorithm has a prohibitively high execution time. For example, 18 hours is required for a modest-sized map with 744 vertices.
The currently available solutions have two major problems: first, the high time complexity of the algorithms restricts their use to static applications with a small number of polygons and vertices. Second, they have very limited shape preservation. Although the recent work by Kocmoud and House provides nice results, some effectiveness problems remain. One problem is the significant deformation of the global shape. In evaluating the different heuristic solutions which have been proposed so far, the present inventors have found that the insufficient preservation of the global shape is one of the most important factors for cartograms to be effective, and it is certainly at least as important as the preservation of interior polygon shapes.
There is presently a need to make dynamic cartograms for on-line network monitoring, such as display of traffic or transaction event levels by country, state, and local regions. That application requires cartogram generation on the fly, and further requires generation of cartograms with maximum preservation of the global shape as well as preservation of the shapes of the interior polygons. To the inventors' knowledge, there is currently no currently available algorithm with adequate speed to perform that function.
SUMMARY OF THE INVENTION
The present invention addresses the needs described above by providing a method for generating a cartogram from a plurality of contiguous polygons having vertices, and from a vector containing values corresponding to the polygons. The method includes the steps of determining a first curvature function of a first polygon, performing a Fourier transform of the first curvature function to calculate a first shape value, repositioning one of the vertices of the polygon to produce an altered polygon, determining an altered curvature function of the altered polygon, performing a Fourier transform of the altered curvature function to calculate an altered shape value, calculating a shape distortion by comparing the first and the altered shape values, and deciding whether to accept the altered polygon based on the shape distortion.
The steps of determining curvature functions of the polygons may include approximating a region surrounding each vertex with a circular arc. The perimeter length may be normalized to 2π for each polygon, using a radius of π/50 for the circular arcs. The radius may alternatively be established as smaller than one-half a length of a shortest edge of the polygon.
Each polygon may be represented by a series of concatenated straight lines and radii, the curvature function being a square wave. The steps of determining curvature functions may include normalizing a perimeter length for each polygon. That normalized perimeter length may be 2π.
The steps of performing Fourier transforms may include computing coefficients of Fourier sums analytically. The step of repositioning one of the vertices of the polygon may include selecting the vertices from a set of vertices in a region of the contiguous polygons having two edges orthogonal to a preselected scan line. Each step of the method may then be performed on all vertices within the region.
The vector values may define target area values of the corresponding polygons. In that case, the method further includes the steps of calculating a relative area error of the first polygon by comparing an actual area value of the first polygon with a corresponding target area value, calculating a relative area error of the altered polygon by comparing an actual area value of the altered polygon with the corresponding target area value, and determining whether to revert to the first polygon by comparing the relative area error of the altered polygon and the relative area error of the first polygon. The relative area error of a j th polygon may be defined as
A desire j - A actual j A desire j + A actual j ,
wherein A desire j is a target area value for the j th polygon and A actual j is an actual area value for that polygon.
The method may further include an initial step of selectively removing at least one vertex from the plurality of contiguous polygons. The vertices may be selected based on a proximity to 180 degrees of an angle formed by adjacent edges, or may be selected based on a length of an adjacent edge. All interior vertices not common to more than two polygons may be removed. The interior vertices may be removed based on criteria different from those used to remove vertices on a global polygon.
In another embodiment of the invention, a cartogram is generated from a map having a plurality of contiguous map polygons with vertices. The cartogram has a plurality of cartogram polygons corresponding to the map polygons, the cartogram polygons having areas proportional to values contained in a data vector. That method includes the steps of selecting a vertex for repositioning, the vertex having adjacent polygons, repositioning the selected vertex, determining an area error of the adjacent polygons based on corresponding data vector values, determining a shape error of the adjacent polygons based on a Fourier transformation of a curvature function of a perimeter of each polygon, and deciding whether to accept or reject the repositioning step based on the shape error and the area error.
The curvature function may include circular arcs approximating regions surrounding each vertex of the polygons. In that case, a perimeter length of 2π may be normalized for each polygon, in which case a radius of the circular arcs is π/50. Alternatively, the radius may be smaller than one half a length of a shortest edge of the polygon.
Each polygon may be represented by a series of concatenated straight lines and radii, in which case the curvature function is a square wave. The curvature function may be normalized to a predetermined perimeter length, which may be 2π.
Fourier sums may be analytically computed from the Fourier transforms. The step of selecting a vertex may include selecting the vertex from a set of vertices in a region of the contiguous polygons having two edges orthogonal to a preselected scan line. Each of the steps may be performed on all vertices within the region.
The area error of a j th polygon may be defined as
A desire j - A actual j A desire j + A actual j ,
wherein A desire j is a target area value proportional to values contained in the data vector for the j th polygon and A actual j is an actual area value for that polygon.
As with the previous embodiment, the method may further include the initial step of selectively removing at least one vertex from the plurality of contiguous polygons.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a traditional map of the United States.
FIG. 1B is a population cartogram of the United States generated using the method of the invention.
FIGS. 2A-2H are views of cartograms and pseudo-cartograms generated by prior art methods.
FIG. 3 is a partial map of the United States illustrating a vertex/edge notation convention.
FIGS. 4A-4G are sample polygons illustrating shape and topology distortion.
FIG. 5 is a table showing possible constraints for cartogram drawing.
FIGS. 6A & 6B are sample polygons showing shape and topology properties.
FIG. 7 is a table showing possible global polygon constraints for cartogram drawing.
FIG. 8 is a plot of a significance function used in the present invention.
FIG. 9 is an algorithm for reducing global vertices according to the invention.
FIG. 10 is an algorithm for reducing interior vertices according to the invention.
FIGS. 11A-11C are maps of the United States showing reduction in vertices according to the invention.
FIGS. 12A & 12B are sample polygons showing geometry simplification according to the invention; FIG. 12C is a curvature plot of the polygon of FIG. 12 B.
FIGS. 13A & 13B show polygons and corresponding curvature plots according to the invention.
FIG. 14 is a scanline algorithm according to the invention.
FIGS. 15A & 15B show sample scanlines and associated parameters according to the invention.
FIG. 16 is an algorithm for drawing cartograms according to the invention.
FIGS. 17A & 17B show a map of the United States with scanlines placed according to two embodiments of the invention.
FIGS. 18A , 18 B & 18 C show cartograms of the United States produced by three different methods.
FIGS. 19A , 19 B & 19 C show plots of data used to evaluate the methods that produced the cartograms of FIG. 18 .
FIG. 20A is a map of the United States showing area error; FIGS. 20B & 20C show cartograms produced by the method of the invention showing area error.
FIGS. 21A & 21B are plots showing shape versus area error for cartograms produced at stages of an algorithm using interactive scanlines.
FIG. 22 shows plots of shape versus area error for cartograms produced using interactive and automatic scanlines.
FIGS. 23A , 23 B & 23 C are plots for evaluating the efficiency of the method of the invention.
DESCRIPTION OF THE INVENTION
The contiguous cartogram problem may be defined in terms of an ideal solution and topology preservation. It is assumed that the input to the method of the invention is a map defined by a set of connected simple polygons (a polygonal mesh) P, and a parameter vector {right arrow over (X)} that gives the desired values for the proportional area of each polygon. The goal is to generate contiguous cartograms and therefore, the desired output also is a set of connected simple polygons {overscore (P)}. Let |p| denote the number of vertices, A(p) the area, and S(p) the shape of a polygon p, and T(P) the topology of a set of polygons. Then, the ideal solution of the Contiguous Cartogram Drawing problem can be defined as follows.
A contiguous Cartogram of a set of connected polygons P={p 1 , . . . , p k } with respect to the parameter vector. {right arrow over (X)}={x 1 , . . . , x k },(∀jx j >0), is a visualization of the transformed set of polygons {overscore (P)}, where
T({right arrow over (P)})=T(P) (Topology Preservation), S({overscore (p)} j )=S(p),∀j=1, . . . , k (Shape Preservation), A({overscore (p)} j )={tilde over (x)} j , ∀j=1 . . . , k (Area Resizing).
The desired area {tilde over (x)} j of a polygon p j is defined as
x ~ j = x j · ∑ i = 1 k A ( p j ) ∑ j = 1 k x j .
To simplify the description, the following assumes that there is only one set of connected polygons (such as the continental United States) and not multiple unconnected sets (such as a world map). The definitions, however, may easily be extended to multiple polygonal meshes. The heuristic herein described operates on arbitrary maps.
Let ν j i denote the i-th vertex of polygon p j , a i j the angle at the i-th vertex, e j i the i-th edge, |e j i | the length of edge e j i , and CE(ν) the cyclic order of edges at vertex ν, as defined by the notation shown in FIG. 3 .
If it is assumed that the transformed polygons have the same number of vertices (i.e., |{overscore (p)} i |=|p i |), then one way of formalizing the topology and shape preservation constraints is to formalize the preservation of connecting vertices and the preservation of edge length ratios and angles.
As to the preservation of connecting vertices, the topology preservation T({overscore (P)})=T(P) means that for each vertex νεE {overscore (P)} the cyclic order of edges remains the same as in P. More formally,
∀ν j i εP, j=1, . . . , k;i=1, . . . , |p j |: ∃{overscore (ν)} j i ε{overscore (P)}, j=1, . . . , k; i=1, . . . , |{overscore (p)} j |: CE(ν j i )=CE({overscore (ν)} i j )
If the cartogram construction algorithm does not provide a mapping to the original polygon set, topology preservation is difficult to test, because as a first step, the isomorphism problem between the two corresponding graphs must be solved. Graph isomorphism is a difficult problem and, therefore, efficient solutions have to maintain the topology of the original polygon mesh or provide a mapping to the original polygon mesh.
As to the preservation of edge length ratios and angles, shape preservation S({overscore (p)} i )=S({overscore (p)} i ) means that the edge length ratios of the polygons and the angles are preserved
∀ j =1 , . . . , k∃c j εR:|ē j i |=c j |e j i |,i =1 , . . . ,|p j |,e j i εP,ē j i ε{overscore (P)}, ( i )
∀ j =1 , . . . , k∀i =1 , . . . , |p j |:ā j i =a i j . ( ii )
As a simple example, a map with the topology of a checkerboard ( FIGS. 4A & 4D ) is resized according to the color of the fields, scaling white fields by a factor of 1.5 and black fields by a factor of 0.5. That rescaling is impossible without changing the topology or shapes. In the case of the 2×2 grid, FIG. 4B shows solutions in which shape was maintained but topology was relaxed; FIG. 4C shows relaxed shape. In the case of the 3×3 grid, FIG. 4E shows relaxed topology, FIG. 4G shows relaxed shape and FIG. 4F shows both characteristics relaxed. In general, it is impossible to achieve the ideal solution. That observation may be stated as follows: the above-described cartogram drawing problem is unsolvable in the general case; i.e., there exist sets of polygons and parameter vectors such that it is impossible to obtain an ideal solution. The checkerboard topology of FIG. 3 provides an example of such a set of polygons for which there is no ideal cartogram solution.
To derive feasible variants of the problem, some of the feature preservation conditions must be relaxed. If topology is the most important property to maintain, the only other conditions left to relax are the shape and area constraints. Those are explored in terms of two distance functions —an area distance function (which measures the distance of the area of a polygon from the desired size, typically, difference in area in the Euclidean plane) and a shape distance function (which measures the similarity of two shapes). FIG. 5 is a table containing an enumeration of possible constraints. The first column 51 lists constraints that require a maximum distance for each polygon, the second column 52 lists constraints that require a maximum distance for the sum of the distances of all polygons, and the third column 53 lists minimum constraints for the sum of distances. By combining the different area and shape constraints shown in FIG. 5 , variants of the cartogram drawing problem may be constructed. A useful combination would be, for example, a restriction of the solution space to solutions where the shape of each polygon has at least a certain similarity to its original shape and the sum of all area differences is minimal. The following discussion relates to the different variants of the problem and their complexity.
As noted above, in general it is impossible to find an ideal solution of the cartogram drawing problem. It is furthermore noted that any variant of the cartogram drawing problem that involves the single-polygon area constraint or the all-polygon area constraint, as tabulated in FIG. 5 , is also unsolvable in the general case, i.e. there exist sets of polygons P and parameter vectors {overscore (X)}, such that for any ε the problem variants do not have a valid, topology-preserving solution.
FIG. 6A is an example of a symmetric cartogram consisting of seven polygons. If the parameter vector for scaling the polygons requires the light polygons to become larger and the dark ones to become smaller, an impossible case can easily be constructed. Due to the symmetric construction of the polygons, without loss of generality we can assume that one angle
γ ≤ π 3 .
Thus,
α = 2 π - 2 β - γ ≥ 2 π - 2 β - π 3
For the above mentioned resize requirements (triangle A very large and triangles B very small), β→0 and therefore
α ≥ 2 π - π 3 = 5 3 π ⇒ α > π
and thus the topology cannot be preserved, as shown in FIG. 6 B.
That means that only variants of the problem that use the minimum-area condition are solvable, and that is true for any combination with a shape constraint. The solvability is trivial to see since there is at least the identity solution, which yields a perfect shape preservation but a rather bad value for the area difference. As the following shows, the determination of the actual solution with the minimum area difference, however, is a computationally hard problem.
Any variant of the cartogram drawing problem that involves the minimum-area condition is NP-complete. That may be shown using a constrained, simplified version of the cartogram problem called the “integer cartogram problem.” The proof shows that a solution to the integer cartogram problem would imply a solution of the planar 3-SAT problem which is known to be NP-hard.
In using the integer cartogram variant of the problem one easily observes that there is little freedom to improve the second important parameter, namely the shape. In most cases, the minimum area condition will provide some solution that is best optimized according to the area condition but does not take the shape similarity into account. There might be, for example, a solution that much better preserves the shape but is a little bit worse in area. To allow the shape constraint to have an impact on the solution, the constraints must be adapted. In principle, there are two possibilities. The first is to determine the minimum area difference possible and then allow a certain maximum deviation from this minimum difference for finding the best shape. More formally, this may be defined by defining two variants of the contiguous cartogram problem.
First, given a set of polygons P, a parameter vector {right arrow over (X)}, and an error value ε, the contiguous cartogram problem may be defined as a transformed set of polygons {overscore (P)} for which the following two conditions hold:
∑ j = 1 k d A ( x ~ j , A ( p _ j ) ) ≤ MIN ?? ( d A ( x ~ j , A ( p _ j ) ) + ɛ ( 1 ) ∑ j = 1 k d S ( S ( p j ) , S ( p _ j ) ) → ! min ( 2 )
Alternatively, the area and shape distances may be normalized and a weighted mean of the normalized distances may be used as a combined optimization criterion.
Second, given a set of polygons P, a parameter vector {right arrow over (X)}, and importance factors for the area and shape distances, the contiguous cartogram problem may be defined as the transformed set of polygons P for which
a · ∑ j = 1 k d A ( x ~ j , A ( p _ j ) ) + b · ∑ j = 1 n d S ( S ( p j ) , S ( p _ j ) ) → ! min a , b ≥ 0 .
There are other meaningful and solvable variants of the problem that, for example, also include the single-polygon constraints, as demonstrated by the table of FIG. 5 . Most currently available algorithms try to solve the problem according to one of the two variants above. While that seems sufficient for some applications, there are others where additional constraints seem necessary.
In addition to the shape and area constraints discussed above with reference to FIG. 5 , the inventors have found that the global shape is one of the most important factors for cartograms to be effective, and it is certainly at least as important as the preservation of interior polygon shapes. In the definition of the cartogram drawing problem, besides the shape and area constraints discussed above, the inventors therefore explicitly include a global shape constraint which may be again either a single-polygon, all-polygon, or minimum constraint for the global shape(s) (note that there may be multiple global shapes as they occur, for example, on a world map). If G r (P)(r=1 . . . l,l<k) denotes the set of global polygons that may be derived from the set of polygons P, the global shape constraints may formally be described as given in the table of FIG. 7 . The final definition of the cartogram drawing problem below uses a weighted minimum of area, shape, and global shape constraints.
Given a set of polygons P, a parameter vector {right arrow over (X)}, and importance factors for the area, shape, and global shape constraints a, b, and c, the contiguous cartogram problem may be defined as a transformed set of polygons {overscore (P)} for which
a · ∑ j = 1 k d A ( x ~ j , A ( p _ j ) ) + b · ∑ j = 1 n d S ( S ( p j ) , S ( p _ j ) ) + c · ∑ r d S ( S ( G r ( ?? ) ) , S ( G r ( ?? _ ) ) ) → ! min a , b , c ≥ 0
Turning to some observations crucial for an efficient solution of the problem, one important observation is that in practice, only very few vertices are actually important for defining the shapes of the polygons. In considering the U.S. map, for example, the inventors found that in addition to a restricted number of outer vertices, only a limited number of interior vertices are actually relevant. Note also that the importance of polygons and their vertices largely depends on their size (which is directly related to the parameter vector) and on the length of the edges and the angles between them. In the inventive algorithm, special consideration is given to those facts and the importance of vertices is determined based on those observations. A second observation is that, in order to obtain good results, the shape error has to be controlled explicitly. A last observation is that the high time complexity of most algorithms proposed previously is due to a complex and time-consuming optimization. In most cases, however, it is possible to locally reposition vertices and improve the area error while retaining the shape. To obtain good solutions, the algorithm of the present invention iteratively repositions vertices based on scanline-defined locality measures with an explicit shape error control function.
The objective of the cartogram drawing algorithm of the invention is a fast generation of cartograms of acceptable quality. Because input maps often have far more vertices than are needed to compute good cartograms, the first step is an intelligent decimation. That is followed by the central heuristic, scanline-based repositioning of vertices. Vertices of the global polygon(s) are first repositioned, followed by interior vertices. Scanlines can be restricted to vertical and horizontal lines determined automatically, or may be arbitrarily positioned line segments of any length, entered interactively. In each step, the shape of the modified polygon mesh is controlled by the shape error function. The last step is fitting the undecimated polygons to the decimated mesh to obtain the output cartogram. By exploiting the potential for pre-computation and fast local optimization, the inventive algorithm runs quickly enough to support dynamic displays with high update rates on maps having dozens of polygonal regions.
Edge reduction algorithms used in the inventive method will now be discussed. As noted, preserving the global shape is very important in making recognizable cartograms. Decimation algorithm of the invention takes that into account by simplifying the global and inner polygons differently.
Regarding reduction of the global polygon, a key observation is that the importance of the vertices of a polygon can vary greatly. Vertices on angles near 180 degrees and those with short edges make almost no noticeable difference in the shape of a polygon, while others with sharp angles or long edges have a significant effect. The basic idea of the global polygon reduction algorithm is to rate the importance of each vertex according to those criteria. Then, iteratively, the least important vertices are removed. To maintain the topology, only vertices that do not belong to multiple polygons are removed. To formalize the global reduction algorithm, the notion of a vertex's importance is first defined as
I (ν)= Sig ( a ν )· |e 1 ν |·|e 2 ν |
where e 1 ν and e 2 ν are the two edges of vertex νand Sig(a ν ) is a function denoting the significance of the angle α ν at vertex ν. The significance function Sig(a) is important because different angles have a specific impact on the shape of the polygons. Sharp angles and angles close to 90 degrees are more important than obtuse angles and the significance function therefore assigns higher values to sharp angles and lower values for obtuse angles. For our algorithm, we use
Sig ( α ) = ∑ μ ∈ { 0 , 90 , 270 , 360 } exp ( α - μ ) 2 2 σ 2
as the significance function. That function has peaks for α=0, 90, 270, 360 degrees and is close to zero for α=180 degrees. The function is defined for α=]0°, 360°[ and σ is chosen to be 0.2 π. FIG. 8 shows a plot of that function.
To formalize the global reduction algorithm, the global polygon is first defined as a subset of the vertices of P. For each polygon p j , I=1 . . . k, the portion gp j of the global polygon GP can be defined as
gp j ={νεp j : |edges(ν)|>|polygons(ν)|}
The global polygon is defined as GP=
GP = ⋃ j = 1 … k gp j .
The algorithm for the reduction of the global polygon is shown in FIG. 9 . The algorithm initializes V(step 91 ) so that vertices are only considered for removal if they do not belong to multiple polygons. Vertices are removed if the induced area difference is smaller than a given constant MaxAreaDiff (step 92 ). Note also that the area A s (p) of a polygon p is determined as if the polygon is perfectly scaled according to the parameter vector X and the area difference ∥A s (p 1 )−A s (p 2 )∥— the subscript s of A s stands for scaled—is defined as
∥ A s ( p 2 )− A s ( p 2 )∥:=( A s ( p 1 )∪ A s ( p 2 ))\( A s ( p 1 )∪ A s ( p 2 ))
To position interior vertices, an iterative vertex removal may again be used. A more efficient alternative is based on the observation that for most maps only the connecting interior vertices are important. In the preferred embodiment, instead of iteratively removing unimportant interior vertices, a more direct approach is taken by removing all vertices not common to more than two polygons (non-connecting vertices). In some cases, the shape deformation and area error introduced by that reduction is unacceptably high. A few additional vertices are therefore re-introduced. The complete algorithm is shown in FIG. 10 .
As an example of the reduction technique of the invention, the interior vertices of a polygon mesh containing 743 interior vertices ( FIG. 11A ) are reduced to only the 204 interior vertices common to more than two polygons (FIG. 11 B). A few additional vertices are re-introduced in the final polygon containing 343 interior vertices (FIG. 11 C). In practice, only a few polygons need the additional vertices, so the likelihood of re-introducing vertices that were removed is low.
The main cartogram drawing algorithm will now be discussed. The algorithm incrementally repositions the vertices along a series of scanlines. A scanline is a line segment of arbitrary length and position. Each scanline defines a scan section, orthogonal to the scanline. All points within a scan section are repositioned in a single step. For each section on a scanline, a target scaling factor for each of its polygons is determined according to their area error factors. Vertices are then repositioned according to the polygon scaling factors and distances to the scanline. The repositioning may be parallel or orthogonal to the scanlines. If the shape error introduced by applying a scanline exceeds some threshold, its candidate vertex repositionings are discarded.
Scanlines should be applied to parts of the map where the area error is large and there is still potential for improvement. A simple approach to scanline generation is to use horizontal and vertical line segments positioned on a regular grid. Significantly better results can be obtained by a manual scanline placement, guided by the shape of the input polygons and the local potential for improvement. Note that the incremental repositioning of vertices per scanline application is intentionally small, compared to the expected change in area. That means the same scanline may need to be applied many times to make large adjustments in an area.
Before describing the main algorithm, its three main components will be introduced: the area error function, the shape similarity function, and the scanline algorithm.
The area error function is directly related to the objective of cartogram generation; i.e., to obtain a set of polygons where the area of the polygons corresponds to values given in a data vector X. In each step of the algorithm, the area error function is needed to determine the reduction of the area error achieved by applying a given
E rel j = A desire j - A actual j A desire j + A actual j
Hence, the area error for the set of polygons P is defined as
E rel ?? = ∑ j = 1 k ( E rel j · A desire j ∑ j = 1 k A desire j )
In addition to reducing area error, the cartogram generation process also employs a shape similarity function that aims at retaining the original shapes. To assess shape preservation, a shape similarity function is needed that compares the new shape of a polygon with its original shape. Defining a useful shape similarity function is in itself a difficult problem, since the similarity measure should be translation-invariant, scale-invariant, and at least partially rotation-invariant. From CAD research it is known that the Euclidean distance in Fourier space is useful for measuring shape similarity. To gain invariance against translation, rotation, and scaling, the algorithm uses the Fourier transformation of the differential geometric curvature of the polygons, instead of the polygons themselves, and normalizes the arc length of the polygons to 2π. Using the curvature guarantees translation- and rotation-invariance, and normalizing the arc length guarantees scale-invariance.
In the following, it is assumed that the polygons are transformed into a normalized parameterized polygon contour function p:[0,2π]→R 2 . Then, curvature C of the polygons may be defined as
C:(R→R 2 )→(R→R 2 ).
The Fourier transformation F is a transformation
F:(R→R 2 )→R d ,
determining the Fourier coefficients for a given curvature function in d-dimensional Fourier space. The shape similarity of two polygons p and {overscore (p)} can then be defined as
d S ( S ( p ), S ( {overscore (p)} ))= d Euclid ( F ( C ( p )), F ( C ( {overscore (p)} ))).
In the following, the curvature transformation C and the Fourier transformation F are described in more detail.
In general, the curvature of a polygon defined as a parameterized function is mathematically undefined because the second derivative is not continuous. That problem can be avoided by approximating a polygon 120 ( FIG. 12A ) by replacing each vertex 121 , 122 , 123 with a very small circular arc 125 , 126 , 127 , shown in FIG. 11 B. That yields a new geometric object 128 of which the first derivative is continuous. The curvature of that object is defined in sections; concatenating those sections yields the curvature as square wave function 129 (FIG. 12 C).
To describe the curvature transformation in more detail, this discussion will focus on two adjacent edges e i-1 and e i . Those edges coincide in vertex ν i with an angle α i . For the polygon containing ν i , the curvature function c i (t), describing the differential geometric curvature of the approximated polygon, may be easily computed, because the curvature of a circle segment with radius r is a constant function 1/r and the curvature of a straight line is a constant zero function. The arc length of the circle segment may be calculated by substituting vertex ν i by b i =|α i |·r. For c i (t), we therefore obtain
c i ( t ) = { 1 / r if ( t v t - b i / 2 > t > t v t + b i / 2 ) 0 otherwise
The curvature of an arbitrary polygon p is
c ( t ) = ∑ k = 0 p - 1 c k ( t ) .
An example of a graph of the curvature function c(t) for the approximation of the polygon section of FIG. 12A is shown in FIG. 12 C. In another example, the curvature function 135 of FIG. 13B is identical for two polygons p 1 and p 2 shown in FIG. 13A under translation-invariance, rotation-invariance, and scale-invariance.
The approximation of the original polygon, and in particular the choice of r, influences the curvature function. If the radius r of the circle segment is reduced, 1/r will be increased while b i will be decreased. That causes c(t) to become narrower and the amplitude of square waves to become higher, while the approximation of the polygon converges against the polygon itself. On the other hand, c(t) becomes difficult to handle numerically. An adequate value for r that has proven useful for our application is π/50 for polygons with a normalized length of 2π. The inventors have found that the similarity function is quite robust against a sub optimal choice of r, as long as r is smaller than half of the length of the shortest edge since otherwise individual square wave functions may overlap.
The next step is computing the Fourier transformation F of the curvature. The principle of the Fourier transformation is to approximate a function by summing up sine and cosine functions with certain parameters. The quality of the approximation is improved by increasing the degree d of the Fourier approximation, which means to successively sum up cos(x), sin(x), cos(2x), sin(2x), . . . , cos(kx), sin(kx). More formally, the Fourier approximation of a function ƒ with a period of 2π is defined as
F ( x ) = a 0 2 ∑ k = 1 n ( a k cos ( kx ) + b k sin ( kx ) )
where the coefficients a k and b k are defined as
a k = 1 π ∫ 0 2 π f ( x ) cos ( kx ) ⅆ x and b k = 1 π ∫ 0 2 π f ( x ) sin ( kx ) ⅆ x .
In general, integrals of the form ∫ƒ(x)sin(x)dx are difficult to solve analytically. For the special case where ƒ(x) is a square wave function, however, the integral can be easily determined. Let us assume that ƒ(x) has a value of 1/r in the interval [u, ν] and is zero elsewhere. Since the value of the integral is zero outside of [u, ν] it is necessary to integrate only from u to ν. Therefore, it is possible to calculate a k and b k as
a k = 1 π kr ( sin ( kv ) - sin ( ku ) ) and b k = 1 π kr ( cos ( kv ) - cos ( ku ) ) .
To determine the Fourier coefficients of the curvature function c(t) of the whole polygon p, we only have to sum up the above formula c i (t) for all vertices νi of the polygon. We obtain the following formulas for the Fourier coefficients:
a k = 1 π kr ∑ i = 0 p - 1 α i α i ( sin ( k ( t i + α i r 2 ) ) - sin ( k ( t i + α i r 2 ) ) )
b k = 1 π kr ∑ i = 0 p - 1 α i α i ( cos ( k ( t i + α i r 2 ) ) - cos ( k ( t i + α i r 2 ) ) )
The calculation of a k and b k can be done in O(|p|) time, and the calculation of all coefficients can be done in O(|p|d), where d is the degree of the Fourier sum. Note that it is possible to compute the coefficients of the Fourier sum analytically, and therefore not to run into numerical problems such as finding the right sample rate. Experimental results show that the Fourier transformation provides a good approximation of the polygons and their curvature function even for rather small d.
An important feature of the cartogram drawing algorithm of the present invention is the scanline heuristic, which incrementally repositions vertices along scanlines. A scanline sl is a line segment of arbitrary position and length and is partitioned into n portions of length
sl n .
As shown in FIG. 15A , the scanline section points sp i (i=0 . . . n) define n+1 sections (e.g., sections 150 a , 150 b ) of the polygon mesh 152 , which are orthogonal to the scanline 155 . In one step of the scanline algorithm, all vertices νεV i within a certain distance (distance 157 )
( ξ = sl 2 n )
of I i are considered for incremental repositioning. Let SF i be the set of polygons (by index number) that have at least one vertex in scanline section i (i=0 . . . n). Then, the scaling factor SF i is determined according to the area error of all polygons p in section i:
SF i = const · ∑ r ∈ S i ( x ~ r - A ( p r ) x ~ r + A ( p r ) · x ~ r ∑ l ∈ S i n x ~ l ) .
Next, the direction o(ν) of a vertex ν is determined and the scaling factor SF i is applied to reposition the vertex. The repositioning can be done either in the direction of the scanline (direction=scanline) or in the direction of the section line l i (FIG. 15 A). The algorithm is shown in FIG. 14 . In a preferred embodiment, the scanline sections span the full range orthogonal to the scanline of the polygon net. Alternatively, the changes may be restricted to be local in both directions by limiting the considered polygons to those close to the scanline, for example, within a circle 159 ( FIG. 15B ) of radius ξ. That option is not reflected in the algorithm shown in FIG. 14 .
Having defined the components of the cartogram drawing algorithm, the main procedure is now described. The algorithm assumes as input a set of polygons P, a scaling vector of the desired statistical parameter {tilde over (X)} and a set of scanlines SL, which can be determined automatically or manually as described below. Output is the modified set of polygons P that describes the cartogram. The algorithm is shown in FIG. 16 and works as follows. For each scanline (step 160 ), the algorithm applies the scanline transformation (step 161 ) and checks the results (step 162 ). If the area difference E rel introduced by the scanline transformation is below a certain threshold ε A and the shape distortion is below a certain threshold ε s , then the changes are retained and otherwise discarded. Then, the algorithm proceeds with the next scanline until all scanlines are applied in the same way. At that point, the algorithm checks whether in applying all scanlines an improvement of the area error has been obtained. If that is the case, the algorithm applies all scanlines again and repeats the entire procedure until no further improvement is reached (step 165 ) (area improvement below 68). Since the area error improvement must be positive and above the threshold e in each iteration, the area error is monotonously decreasing and termination of the algorithm is guaranteed. Note that in applying an individual scanline, the algorithm is allowed to potentially increase the area error, to allow escaping local optima. Also, notice that after applying a scanline, all the other ones remaining to be processed must be transformed as well, so that they correspond properly to the transformed map.
The set of scanlines SL used by the algorithm may be defined either automatically or interactively. The automatic generation of scanlines uses a fixed grid of horizontal and vertical scanlines. An example of an automatically generated scanline grid 171 generated to cover a polygon grid 172 representing the continental United States is shown in FIG. 17 A. The grid's resolution may be varied, but within reason that has only a minor influence on the result. Because only those scanlines that do not induce a higher shape and area error are applied, generating many useless scanlines causes a potential loss in efficiency, but does not affect the quality of the result.
The inventors have found that the best cartograms seem to be obtained when the scanlines are well adapted to the shape of the input polygons and are placed in areas with a high potential for improvement. Automatic placement based on those criteria is difficult to achieve so, in a preferred embodiment of the invention, the user is allowed to interactively position the scanlines depending on the results of the previous steps. The user usually starts with scanlines in regions with a high area error. The scanlines seem to work best if they are positioned such that they are either parallel or orthogonal to the contour of the global polygon. An example a scanline 175 is shown in FIG. 17 B.
Once the scanlines are specified for a given polygon mesh, they may be stored and re-applied later to different data on the same map. That makes it practical to generate a continuous time series of cartograms, without user interaction in each step. While the generated cartogram may not be as good as if the scanlines were specified anew, the results seem sufficient for many applications. In the inventors' experience, manual positioning of scanlines is not difficult and can be done quickly. For example, the scanlines shown in FIG. 17B took about 5 minutes to enter. Note that parts of the map such as region 176 that need large changes have many scanlines of varying lengths, while other parts have very few scanlines.
The inventors have implemented the algorithm described above in C using the LEDA library described in Kurt Mehlhom and Stefan Naher, “The LEDA Platform of Combinatorial and Geometric Computing,” Cambridge University Press (1st ed. 1999), http://www.mpi-sb.mpg.de/-˜mehlhorn/LEDAbook.html. The algorithm was run on a number of different example applications. Unless noted otherwise, the tests were performed on a 1 GHz Pentium computer with 128 Mbytes of main memory. The results of several different approaches are compared below. Although the focus is on efficiency, the examples show that the algorithm of the inventions also provides results of very high quality. For most of the examples, a state map of the continental U.S. serves as a running example.
For purposes of comparison, FIG. 18A shows a population cartogram generated by the technique of Tobler (supra), 18 B shows a cartogram generated by Kocmoud & House (supra) and 18 C show population cartograms generated by the algorithm of the present invention. A visual comparison shows that the presently-described approach offers comparable if not better visual results, with the geography of the United States being clearly perceivable.
To evaluate the results analytically, a total area error Ere, is compared for all three approaches. As can be seen in FIG. 19A , the presently described algorithm 191 provides better results 191 than those of Tobler 193 and even improves upon the results 192 of the complex optimization-based approach of Kocmoud and House. Since the total area error is basically an average over the state-wise area error, the area error is shown state by state in FIG. 19B , sorted according to the area error. The resulting plot 194 reveals that for most states the present approach 197 provides a much better area error than that of the Tobler cartogram 195 and a slightly better area error than that of the Kocmoud & House cartogram 196 , with very few exceptions. Note that the Tobler cartogram was not optimized according to the error measure described herein, which puts higher weights on polygons that should become large. Since many of the polygons with large weights still have a large area error in the Tobler cartogram, the overall improvement of E rel by the Tobler cartogram is low.
In terms of efficiency, the present approach is faster than existing techniques. While previous approaches need hours or even days to compute a solution, an implementation of the presently described algorithm runs in a matter of seconds. A comparison is shown in FIG. 19C , which assumes that both algorithms run on a 120 MHz computer with 32 MByte RAM. A scanline-based heuristic 198 needs about 25 seconds while the Kocmoud & House approach 199 needs about 16 hours, making the present approach about 2000 times faster.
One important aspect of the cartogram drawing algorithm of the invention is the specification of the scanlines. As mentioned previously, the present algorithm allows scanlines to be determined automatically or interactively. Those two approaches are now compared with respect to effectiveness (quality of the results) and efficiency (time needed to produce the results).
An original US map 200 ( FIG. 20A ) is distorted in this example using automatically generated scanlines ( FIG. 20B ) and interactively generated scanlines (FIG. 20 C). Both approaches provide high quality cartograms. The area error E rel is 0.36 for the original map; is 0.21 for the cartogram generated with automatically placed scanlines and is 0.10 for the cartogram generated with interactively placed scanlines. Shape distortion, however, appears to be higher for the interactively placed scanlines. To measure shape distortion, the inventors use the Fourier-based shape similarity function described above. The results, shown in FIGS. 21A and 21B , show a tradeoff between area and shape error. Those errors are shown for each incremental step of the algorithm, for the interior state polygons ( FIG. 21A ) and the global polygon (FIG. 21 B). Each point corresponds to one intermediate result of the algorithm (with interactive scanlines). In the beginning, there is a large area error E rel =0.36. By applying a scanline, the area error is improved but the shape becomes more distorted. It is therefore natural that the curve goes from the lower right to the upper left until the area error is small enough or the shape distortion reaches some threshold. A similar behavior can be observed for the global shape. There is however a slight difference: while the area error still improves from one step to the next, the distortion global shape in some cases even gets better.
Comparing the area-shape error tradeoff of interactive versus automatic scanlines reveals some interesting properties of the algorithm. As can be seen in FIG. 22 , early in the run, both approaches have a similar trend in shape-area error tradeoff. At a certain point, however, the automatically generated scanlines lead to a deterioration in area error that subsequent scanlines are not able to improve. In case of interactively generated scanlines, the area error continues to improve by smaller and smaller increments. Note the jump in shape error for an area error of about E rel =0.15. At that point, the direction was switched from scanline to section line as described above, which leads to a continued improvement of the area error but a considerable deterioration of the shape error.
The inventors also performed extensive experiments to evaluate the efficiency of the inventive algorithm. The time needed to run the algorithm on the U.S. population data is about 2 seconds. If the parameter vector is changed, the time needed for the reduction step versus the scanline execution varies slightly between 40% and 60%. FIG. 23A shows the percentages needed for the two steps of the algorithm for nine different parameter vectors, namely long-distance telephone call volume data by state for nine time steps during a day. Note that the reduction step can be precomputed so that it does not have to be re-run each time the algorithm is executed.
The effect of changing the length of scanlines was also analyzed. FIG. 23B shows the results for the 144 interactively defined scanlines for the US population data. The time needed to process a scanline depends only on the number of scanline sections, which in turn depends only on the length of the scanlines. That means that a steep increase corresponds to long scanlines and a shallow increase corresponds to short scanlines. The figure reveals that shorter scanlines are more likely toward the end of the process and are used for fine tuning some portions of the polygon. Nevertheless, some shorter scanlines are applied regularly in the process as indicated by the irregularities in the curve.
Another efficiency analysis was aimed at testing the dependency of the algorithm on the number of polygons. Since there are not many different real data sets with a widely varying number of polygons, the inventors generated synthetic data sets, namely checker boards with an increasing number of rectangular polygons. Random numbers were then used for initializing the parameter vectors. FIG. 23C shows the results of those tests, revealing a clear linear dependency on the number of polygons. The algorithm requires about 16 seconds for a polygon net consisting of 90,000 polygons. Note, however, that in this case the number of vertices per polygon is very low (four) and a reduction of vertices is not necessary.
The foregoing Detailed Description 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. For example, while the measurement of shape error using a Fourier transform of a curvature function is described in combination with a scanline algorithm for vertex placement, that shape error technique may be used with other vertex placement methods while remaining within the scope of the invention. It is to be understood that the embodiments shown and described herein are only illustrative of the principles of the present invention and that various modifications may be implemented by those skilled in the art without departing from the scope and spirit of the invention. | The present invention is a method for generating cartograms using a base map of contiguous polygons and a vector containing values to which areas of corresponding polygons are scaled. The general problem is intractable, so an iterative heuristic is proposed. The heuristic is based on “scanlines.” The scanlines may be defined automatically (typically, by placing a grid over the map) or entered manually (to provide finer control over the results). At each step, one scanline is chosen and a new candidate map is made by adjusting the vertices of polygons intersected by the scanline, moving them orthogonally to the scanline. A candidate solution is accepted if it improves the solution and preserves the input mesh's topology. Improvement depends on metrics for area and shape error. The solver is run until the improvement falls below some threshold, or a time limit or maximum number of iterations is reached
The method determines shape error created by a candidate iterative step by first estimating a curvature function of the polygon and then performing a Fourier transform on the function to yield a shape representation that is relatively independent of scale, translation and rotation of the polygon. The proposed iterative step is accepted or discarded based in part on the magnitude of the resulting shape error. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 08/904,009, titled Method For Thin Film Deposition On Single-Crystal Semiconductor Substrates, filed Jul. 31, 1997 now U.S. Pat. No. 6,020,247. This application claims the benefit of priority from U.S. provisional application 60/063,010, titled Low Temperature Method for Forming a Thin, Uniform Oxide, filed Oct. 23, 1997.
FIELD OF THE INVENTION
This invention pertains generally to forming thin oxides at low temperatures, and more particularly to forming thin, uniform oxides.
BACKGROUND OF THE INVENTION
Semiconductors are widely used in integrated circuits for electronic devices such as computers and televisions. These integrated circuits typically combine many transistors on a single crystal silicon chip to perform complex functions and store data. Semiconductor and electronics manufacturers, as well as end users, desire integrated circuits that can accomplish more functions in less time in a smaller package while consuming less power. Miniaturization is a common approach to help meet these goals.
With increasing miniaturization, one concern is the thickness of the gate dielectric used in conventional CMOS circuits. The current drive in a CMOS transistor is directly proportional to the gate capacitance. Since capacitance scales inversely with gate dielectric thickness, higher current drive requires continual reductions in thickness for conventional dielectrics. Present technology uses silicon dioxide (SiO 2 ) based films with thicknesses near 5 nm. However, projections suggest the need for 2 nm ( 20 Å) films for future small geometry devices.
SUMMARY OF THE INVENTION
SiO 2 gate dielectrics in this thickness regime pose considerable challenges from a manufacturing perspective. Process control of the growth of a 2 nm film requires unprecedented thickness control. At these thicknesses direct tunneling through the SiO 2 may occur, although the effect of tunneling current on device performance may not preclude operation. Since the tunnel current depends exponentially on the dielectric thickness, small variations in process control may result in large variations in the tunnel current, possibly leading to reliability problems.
Another area of concern is the interface between the gate oxide and the channel region of the substrate. This silicon dioxide/silicon interface should be very flat and uniform to help limit interface scattering of electrons in the channel region.
Rapid thermal oxidation and furnace annealing are two current methods for forming gate oxides. However, current methods do not reliably produce gate oxides with the thickness uniformity and interface smoothness that will be needed to make devices with approximately 1.5 nm, 2 nm, or 2.5 nm gate oxides practical.
We disclose a low temperature method for forming a thin gate oxide on a silicon surface. This method comprises providing a partially completed integrated circuit on a semiconductor substrate with a clean silicon surface; and stabilizing the substrate at a first temperature. The method further includes exposing the silicon surface to an atmosphere containing ozone, while maintaining the substrate at the first temperature. In this method, the exposing step creates a first, uniformly thick, gate oxide film.
Preferably, exposing the silicon surface to an atmosphere containing ozone includes exposing the silicon surface to an atmosphere containing molecular oxygen, while irradiating at least a portion of the atmosphere with ultraviolet light, where the light transforms some of the oxygen to ozone. In some embodiments, the atmosphere further includes an inert gas, such as argon. Preferably, the ozone at the silicon surface is not in an excited energy state, such as a plasma. However, a plasma kept away from the wafer may be more acceptable.
In some embodiments, the clean silicon surface is atomically flat. Typically, the semiconductor substrate contains some areas that already have some structure, such as a field oxide. In some embodiments, the substrate has a plurality of clean, atomically flat, silicon surfaces. This might occur when the gate oxide is applied to surfaces exposed by etching “windows” in a layer overlying a silicon surface; or when overlying layers are added to the silicon surface, except where “islands” have been masked off.
In some embodiments, the first temperature is about 25 degrees C. and the oxide film has a thickness of about 10 angstroms. In other embodiments, the first temperature may be up to about 200 degrees C., or even up to 600 degrees C. These temperatures will grow thicker oxides (up to about 35 angstroms) as shown in FIG. 3 .
In another aspect of this method, the method further includes depositing a uniformly thick layer of silicon on the first oxide film to form a temporary silicon layer, the temporary silicon layer having a thickness no greater than the potential thickness of oxidizable silicon. This potential thickness is found by determining a planned substrate temperature for a second oxide film formation, the planned temperature no greater than about 200 degrees C. This planned temperature substantially determines the potential thickness of oxidizable silicon. After depositing the silicon, the method further includes exposing the temporary silicon layer to a second atmosphere containing ozone, while the substrate is at the planned substrate temperature. This exposing step oxidizes the temporary silicon layer to form a second, uniformly thick, oxide film extending to the first oxide film; thereby creating a single (combined), uniformly thick, oxide film.
In some embodiments, the method further includes stabilizing the substrate at the planned substrate temperature before the exposing step.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a low temperature method for forming a very thin, uniform oxide layer.
FIG. 2 shows a low temperature method for forming a very thin, uniform oxide layer.
FIG. 3 shows a relationship between time, oxide thickness, and temperature.
FIG. 4 shows a field-effect transistor using a thin, uniform oxide layer as the gate dielectric.
DETAILED DESCRIPTION
FIG. 1 outlines a method of using this invention to form a very thin, uniform SiO 2 gate dielectric on a silicon substrate. Initially, Si substrate 10 with a clean surface 12 is provided. Typically, this substrate 10 will include a partially completed integrated circuit with part of the surface 12 being either bare or hydrogen passivated silicon. This surface 12 may already have structures, such as field oxide regions, already formed upon it, and other structures, such as diffusion regions formed in the substrate beneath it.
We have found that a smooth, flat silicon surface tends to grow a more uniform oxide (particularly for very thin oxides) with this method. Thus, although a hydrogen terminated silicon surface usually produces acceptable results, many very thin, highly uniform silicon dioxide gate dielectrics prefer a silicon underlayer that approaches an atomically flat or atomically stepped surface. For our purposes, an atomically stepped surface will have a very low rms surface roughness, comparable to an atomically flat surface, in most areas. A wafer with an atomically stepped surface may have a series of adjacent flat surfaces (terraces). These terraces typically do not extend across a substrate wafer, and are not required to extend across a single device on a wafer. With very thin gate dielectrics, we sometimes prefer that adjacent terraces be connected by well-defined single- or double-atomic-height steps.
After the surface 12 is clean, but before exposure to an oxygen source, the substrate 10 temperature is stabilized at the oxidation temperature. This oxidation temperature substantially depends upon the thickness of the ozone-base oxide desired as shown in FIG. 3 . This figure shows that for 1.0 nm oxides, the temperature should be near 25 degrees C. For a 2.0 nm oxide, the temperature should be approximately 500 degrees C. Similarly, 530 degrees C. forms an approximately 2.5 nm oxide, while 550 degrees C. forms an approximately 3.5 nm, high quality oxide. FIG. 3 was generated for UV-generated ozone in substantially pure oxygen at a 400 Torr O 2 pressure. Other ozone generation methods, or different oxygen pressures and/or concentrations may require adjustment of the temperature to yield a desired, precise oxide thicknesses.
This ability to grow precise, repeatable, usefully thick oxides at low temperatures greatly simplifies the temperature control problems. The ability to stabilize the whole wafer at the oxidation temperature allows for excellent process control, thus giving a uniform, repeatable oxidation thickness. Useful thermal oxides can be grown on wafers sitting in easily controlled furnaces. We have also found that this method is capable of producing oxides with good electrical properties. This ozone-based method can routinely achieve breakdown voltages above 10 MV/cm, such as 12 to 13 MV/cm.
The clean, temperature stabilized wafer with surface 12 is exposed to ozone 14 . We have found that introducing molecular oxygen to the reaction chamber and exposing the oxygen to a mercury lamp (particular with 183 nm and 253 nm emission lines), generates sufficient quantities of ozone. Other ultraviolet sources or other non-energetic ozone sources can be substituted for the mercury lamp generated ozone. One example of a suitable commercial ozone generator is a barrier discharge ozonizer. Energetic ozone sources including commercial ozone generators can be used, but it is preferable to keep the any excited ozone species from contacting the wafer. We have found that methods that allow an ozone plasma to contact the wafer form oxides with poor electrical properties, such as a significantly lower breakdown voltage. The ozone plasma methods also tend to exhibit poor uniformity and have repeatability problems. In our non-plasma ozone-based method, the oxygen/ozone 14 pressure can be varied from below a microtorr to several atmospheres. We have found that pressures between several hundred torr and one atmosphere provide a simple method to provide good results. If desired, the oxygen/ozone 14 can be mixed with an inert gas, such as argon.
This ozone-based process forms a very uniform, substantially thick silicon dioxide layer 16 on the exposed silicon surface 12 . This oxide layer 16 is much thicker than a conventional thermal oxide formed from exposing silicon to O 2 at the same temperature and time. Of even more importance, this oxide 16 is very repeatable and very uniform, primarily due to its self-limiting nature. When applied to a substantially flat silicon surface, this method repeatably produces SiO 2 layers with thickness uniformities better than 3% (better than 0.1 nm uniformity of an 3.0 nm thick oxide) across a 4 inch test wafer. Better heating uniformity can allow thickness uniformities below 1%. In fact, this method's oxide thickness uniformity will likely be limited in practice only by the heating uniformity, as opposed to the oxidation method itself. A typical transistor or capacitor layout will include a gate (or capacitor) electrode 21 superadjacent to the oxide 16 .
FIG. 3 shows that this method has a very slight time dependent component. However, for most temperature/thickness combinations, the oxidation rate has already slowed dramatically after 30 to 60 minutes. Thus, this process is nearly self terminating with reasonable reaction times. As such, this method can be relatively insensitive to large variations in oxidation time.
As the chart shows, higher temperatures will produce thicker oxides with this method. We have found that, if the thermal budget allows, we can easily produce high quality, 3.5 nm thermal oxides at only 550° C. Sometimes an artisan may prefer to use lower temperatures, but grow substantially thicker layers than shown in FIG. 3 . For this case, we add extra steps as shown in FIG. 2 , but still obtain a highly uniform oxide.
This variation involves first forming a highly uniform silicon dioxide layer 16 on a silicon surface 12 as described above. Next, a uniform silicon layer 18 is deposited on the silicon dioxide layer 16 . The thickness and uniformity of the final oxide layer will depend upon the thickness of the silicon layer 18 . Thus, silicon layer 18 should be formed with a well-controlled method, such as chemical vapor deposition or molecular beam epitaxy. This new silicon surface is then exposed to another ozone/oxygen atmosphere 14 , forming a single SiO 2 layer 20 . In this step, the total thickness of oxide layer 20 is determined by the thickness of the silicon 18 and the underlying SiO 2 layer 16 . However, the ozone allows complete oxidation of much thicker silicon layers than a straight oxygen atmosphere. If necessary, this silicon deposition and oxidation can be repeated to form thicker layers.
FIG. 4 shows a metal-oxide-silicon field-effect transistor (MOSFET) embodiment of this invention. Field-effect transistor 22 has four principal parts: a substrate 24 , a source 26 , a drain 28 , and a gate, where the gate includes the gate electrode 30 and thin silicon dioxide gate dielectric 32 . For an NMOS transistor 22 , p-type silicon substrate 24 includes n+ source 26 and n+drain 28 regions. Gate dielectric 32 is a very thin, very uniform, silicon dioxide film, formed by using ozone to oxidize the cleaned silicon substrate 24 . MOSFET transistor 22 also includes sidewall spacers 34 , lightly doped drain (LDD) region 36 , and isolation region 38 . Those skilled in the art will recognize that these and other features may be used or left out, depending upon the particular function of the device and the intended processing flow.
These examples have shown NMOS transistors. Since the ozone-based thin gate oxide method is substantially insensitive to the doping profile of Si, no special modifications are required to implement this invention in PMOS devices or CMOS devices; or into SiO 2 based capacitors, which require a thin, very uniform dielectric with low electrical leakage and a high breakdown voltage.
Although this method provides substantial benefits when used to form thin oxide layers, it can also offer an improvement over typical methods for forming thicker high-quality oxide layers, such as a dielectric around the floating gate in a flash memory cell. If the thermal budget permits, this ozone-based method can be used to form relatively thick SiO 2 layers in a single pass, or even thicker layers in a layered approach like that described above. Although these thicker layers may require temperature of 600 or 700 degrees C., this variation of the ozone-based method allows lower temperature processing than conventional oxidation processes. Not only do these lower temperatures help the thermal budget, but the self-limiting nature of a ozone-based process improves process repeatability and oxide thickness uniformity, without sacrificing the oxide's electrical quality.
The present invention has been described with several sample embodiments. However, various changes and modifications may be suggested to one skilled in the art. It is intended that the present invention encompass such changes and modifications as fall within the scope of the appended claims. | This invention pertains generally to forming thin oxides at low temperatures, and more particularly to forming uniformly thick, thin oxides. We disclose a low temperature method for forming a thin, uniform oxide 16 on a silicon surface 12 . This method includes providing a partially completed integrated circuit on a semiconductor substrate 10 with a clean, hydrogen terminated or atomically flat, silicon surface 12 ; and stabilizing the substrate at a first temperature. The method further includes exposing the silicon surface to an atmosphere 14 including ozone, while maintaining the substrate 10 at the first temperature. In this method, the exposing step creates a uniformly thick, oxide film 16 . This method is suitable for room temperature processing. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority under 35 U.S.C. §119 of Japanese Application No. 2005-062218, filed on Mar. 7, 2005, the entire content of which is expressly incorporated by reference herein.
FIELD
The present invention pertains to a fuel cell system having a fuel cell stack where a plurality of fuel cells are stacked to generate electricity by receiving a supply of fuel gas and oxidant gas, respectfully, by a fuel electrode (anode) and oxidation electrode (cathode).
BACKGROUND
One example of a conventionally known fuel cell system (see Japanese Laid Open Patent Publication 2002-313396) provides a voltage detection device in at least one location in the vicinity of the hydrogen exit or in the vicinity of the air exit of the fuel cell that has the greatest tendency for reduction in cell voltage due to water blockage, and detects water blockage in the fuel cell by determining whether the cell voltage detected by the voltage detection device is lower than a predetermined voltage.
SUMMARY
Conventional fuel cell systems determined that decreases in voltage were all caused by water blockage.
Due to this, decreases in voltage caused by something other than water blockage were determined to be due to water blockage.
Therefore, a purpose of the present invention is to properly detect the cause of decreases in voltage.
According to the fuel cell systems and methods that pertain to the present invention causes of changes in voltage can be detected.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a block diagram showing the composition of the fuel cell system comprising a first embodiment of the present invention;
FIG. 2 is a schematic diagram showing the composition of the fuel cell comprising the first embodiment of the present invention;
FIG. 3 is a flowchart showing the drive control process flow comprising the first embodiment of the present invention; and
FIG. 4 is a block diagram showing the composition of the fuel cell system according to another embodiment of the present invention.
DETAILED DESCRIPTION
A description of the composition of the fuel cell system comprising the embodiments of the present invention is given below, with reference to drawings.
Composition of the Fuel Cell System
The fuel cell system of embodiments of the present invention is mounted in a vehicle and comprises, as shown in FIG. 1 , fuel cell stack 1 where a plurality of fuel cells are stacked to generate electricity by receiving a supply of fuel gas and oxidant gas, respectfully, by a fuel electrode (anode) and oxidation electrode (cathode). Moreover, the fuel cell in this embodiment is composed of a proton-exchange membrane fuel cell holding a solid electrolyte membrane between a fuel electrode and oxidant electrode, and the electro-chemical reactions occurring in the fuel electrode and oxidant electrode as well as the electro-chemical reaction encompassing the entire fuel cell stack 1 are according to the formulae (1)-(3) shown below.
Chemical 1
Fuel Electrode H 2 →2H + +2 e − (1)
Oxidant Electrode ½O 2 +2H + +2 e − →H 2 O (2)
Overall H 2 +½O 2 →H 2 O (3)
Fuel cell stack 1 , as shown in FIG. 2 , interposes fuel cell 2 and comprises cell voltage measuring terminals 4 a , 4 b at the gas exit portions of separators 3 a , 3 b that supply hydrogen and air, respectfully, to the fuel electrode and oxidant electrode. Cell voltage measuring terminals 4 a , 4 b are connected to voltage detection device 5 , shown in FIG. 1 . Voltage detection device 5 (a first voltage sensor and second voltage sensor) detects the hydrogen exit side voltage of fuel cell 2 , the air exit side voltage, cell in-plane electric potential (the difference between the hydrogen exit side voltage and the air exit side voltage) and the total voltage of fuel cell stack 1 via cell voltage measuring terminals 4 a , 4 b . Cell voltage can be detected for each individual cell or for each plurality of cells.
Hydrogen supply device 6 (for example, a high-pressure hydrogen tank) and air supply device 7 (for example, a compressor) in this fuel cell system shown in FIG. 1 , supply hydrogen and air, respectively, to fuel cell stack 1 while fuel cell stack 1 is kept in a humid state suitable for generating electricity by humidifying device 8 (for example, a device that jet-sprays water into gas). Further, the pressure of the gas supplied to fuel cell stack 1 by hydrogen supply device 6 and air supply device 7 is regulated by pressure regulator 9 (for example, a pressure regulator valve), the amount of flow is regulated by flow volume regulating device 20 (for example a variable valve or a compressor), and the operating temperature of fuel cell stack 1 is controlled by temperature regulator 10 (for example, a cooling channel equipped with a radiator or a circulation pump).
Further, control system 11 in this fuel cell system controls the overall operation of the fuel cell system. More specifically, control system 11 controls hydrogen supply device 6 , air supply device 7 , humidifying device 8 , pressure regulator 9 , and temperature regulator 10 , based on the result detected by voltage detection device 5 . Control system 11 additionally controls the drive current of motor 13 that drives the vehicle, by controlling inverter 12 that converts direct current generated by fuel cell stack 1 into alternating current. Control system 11 also controls the operation of DC/DC converter 15 in order to control the charging and discharging of secondary cell 14 mounted in the vehicle.
Moreover, the fuel cell system having the composition described above, accurately determines in which side of fuel cell 2 , the fuel electrode side or the oxidation electrode side, water blockage has occurred, by implementing the drive control process indicated hereinafter by control system 11 . Water blockage is a phenomenon that occurs when a proton-exchange membrane, for example, is in an overly-humidified state or when the channel(s) provided on the separator(s) and through which gas flows, is blocked with water. An explanation is provided below, with reference to the flowchart shown in FIG. 3 , of the operation of control system 11 when implementing this drive control process.
Referring now to FIG. 4 , another embodiment of the fuel cell system is shown. In FIG. 4 , hydrogen supply device 6 , for example, a high-pressure hydrogen tank, and air supply device 7 , for example, a compressor, in the fuel cell system, supply hydrogen and air, respectively, to fuel cell stack 1 while fuel cell stack 1 is kept in a humid state suitable for generating electricity by humidifying device 8 , for example a device that jet-sprays water into gas. Further, the pressure of the gas supplied to fuel cell stack 1 by hydrogen supply device 6 and air supply device 7 is regulated by pressure regulators 9 , for example, pressure regulator valves; the amount of flow is regulated by flow volume regulating device 20 , for example, a variable valve or a compressor; and the operating temperature of fuel cell stack 1 is controlled by temperature regulator 10 , for example, a cooling channel equipped with a radiator or a circulation pump 21 .
Drive Control Process
The flowchart shown in FIG. 3 begins accordingly with initiating the generation of electricity by fuel cell stack 1 according to the hydrogen flow amount, air flow amount, current, operating pressure, and operating temperature that are set based on the information of the accelerator opening or the like, and the drive control process advances to the process in step S 1 .
At the process in step S 1 , control system 11 detects the output voltage (cell voltage) of each of fuel cell 2 comprising fuel cell stack 1 by means of voltage detection device 5 . In this manner, the process in step S 1 is completed, and the control process advances to the process in step S 2 .
At the process in step S 2 , control system 11 determines whether there is a fuel cell 2 in which the cell voltage is below a predetermined voltage (the voltage of the cell in which water blockage occurs is set according to known or observed properties of the system). If the result of the determination is that there is not a fuel cell 2 in which the cell voltage is below a predetermined voltage, then the control process returns to the process in step S 1 ; however, if there is a fuel cell 2 in which the cell voltage is below a predetermined voltage, control system 11 advances the control process to the process in step S 3 .
At the process in step S 3 , control system 11 detects the hydrogen exit side voltage of the fuel cell 2 in which the cell voltage is below the predetermined voltage by means of voltage detection device 5 and determines whether the hydrogen exit side voltage is below a predetermined voltage. If the result of the determination is that the hydrogen exit side voltage is not below a predetermined voltage, control system 11 advances the control process to the process in step S 5 . Meanwhile, if the hydrogen exit side voltage is below a predetermined voltage, control system 11 determines that water blockage has occurred at the fuel electrode side and after controlling the hydrogen exit side voltage to be above a predetermined voltage by increasing the hydrogen flow amount (for example, by expanding the opening of the variable valve 20 ) by controlling hydrogen supply device 6 in the process in step S 4 , the control process advances to the process in step S 5 . Moreover, control system 11 detects the cell in-plane electric potential and if the electric potential of the hydrogen side exit of fuel cell 2 is lower than the electric potential of the air side exit, then a determination may also be made that water blockage has occurred at the fuel electrode side.
At the process in step S 5 , control system 11 detects the air exit side voltage of the fuel cell 2 in which the cell voltage is below a predetermined voltage by means of voltage detection device 5 and determines whether the air exit side voltage is below a predetermined voltage. Further, if the result of the determination is that the air exit side voltage is not below a predetermined voltage, control system 11 advances the control process to the process in step S 7 . Meanwhile, if the air exit side voltage is below a predetermined voltage, control system 11 determines that water blockage has occurred at the oxidation electrode side, and after controlling the air exit side voltage to be above a predetermined voltage by increasing the air flow amount (for example, by increasing the number of rotations of the compressor) by controlling air supply device 7 in the process in step S 6 , the control process advances to the process in step S 7 .
Moreover, control system 11 detects the cell in-plane electric potential, and if the electric potential of the air side exit is lower than the electric potential of the hydrogen side exit, then a determination may also be made that water blockage has occurred at the oxidation electrode side. Further, for the processes in steps S 4 and S 5 , if a decreasing voltage that pulsates across the threshold of a predetermined voltage (the output that should be generated when in a steady state (voltage)) is detected, control system 11 preferably stabilizes the cell voltage by either lowering the operating pressure (to the atmospheric pressure) of fuel cell stack 1 by controlling pressure regulator 9 (for example, by closing the opening of the pressure regulator valve), or by raising the operating temperature of fuel cell stack 1 by controlling temperature regulator 10 (for example, by stopping the rotation of the circulating pump). A steady state is a state in which the electric current value is steady and the temperature distribution calculated from the amount of colling water flow is steady, or, in other words, when the target temperature has been reached.
At the process in step S 7 , control system 11 determines whether the total voltage of fuel cell stack 1 has fallen below a predetermined voltage (the voltage for when the proton-exchange membrane is in a dry state is set according to known or observed properties of the system) with the passage of time. Further, if the result of the determination is that the total voltage has not fallen below a predetermined voltage, control system 11 returns the control process to the process in step S 1 . Meanwhile, if the total voltage has fallen below a predetermined voltage, control system 11 determines that the solid electrolyte membrane that comprises fuel cell 2 is in a dry state, and advances the control process to the process in step S 8 .
At the process in step S 8 , control system 11 performs control so that the total voltage rises above a predetermined voltage by: lowering the air flow amount by controlling air supply device 7 (for example, by lowering the number of rotations of the compressor); raising the relative humidity at the gas entry side of fuel cell 2 by controlling humidifying device 8 (for example, by increasing the amount of water that is jet-sprayed); lowering the operating temperature of fuel cell stack 1 by controlling temperature regulator 10 (for example, by increasing the number of rotations of the circulation pump); or raising the operating pressure of fuel cell stack 1 by controlling pressure regulator 9 (for example, by closing the opening of the pressure regulator valve). Therefore, in this manner, the process in step S 8 is completed, and the control process returns to the process in step S 1 .
For purposes of the present embodiment, lowering the predetermined voltage means lowering it when the current is constant. In other words, the voltage detected is lower than the target voltage in relation to the current.
As is evident from the explanation provided above, the fuel cell system embodiments of the present invention have the ability to accurately determine in which side of fuel cell 2 , the fuel electrode (anode) side or the oxidation electrode (cathode) side, water blockage occurs, because cell voltage measuring terminals 4 a , 4 b are provided at the hydrogen exit and air exit of each fuel cell, and voltage detection device 5 detects the hydrogen exit side voltage of fuel cell 2 , the air exit side voltage, the cell in-plane electric potential, and the total voltage of fuel cell stack 1 by means of cell voltage measuring terminals 4 a and 4 b.
Further, the fuel cell system comprising the embodiments of the present invention has the ability to demonstrate stable output performance by keeping deterioration of the sold electrolyte membrane to a minimum by using the result detected to quickly execute return processing because control system 11 detects water blockage in each fuel cell, or a dry state of the solid electrolyte membrane comprising the fuel cell, based on the result detected by voltage detection device 5 , so that the reciprocating dry state and water blockage can be detected.
Further, the fuel cell system embodiments of the present invention have the ability to rapidly and accurately determine in which side of fuel cell 2 , the fuel electrode side or the oxidation electrode side, water blockage occurs because, if the cell voltage is below a predetermined voltage, control system 11 detects water blockage of either the fuel electrode side or the oxidation electrode side by determining in which location, the hydrogen exit or the air exit, cell voltage has fallen below a predetermined voltage.
Further, the fuel cell system embodiments of the present invention have the ability to rapidly and accurately determine in which side of fuel cell 2 , the fuel electrode side or the oxidation electrode side, water blockage occurs because, if the cell voltage is below a predetermined voltage, control system 11 detects the in-plane electrical potential of the fuel cell, and if the electric potential of the hydrogen exit side is lower than the electric potential of the air exit side, water blockage is determined to be on the fuel electrode side, and if the electric potential of the air exit side is lower than the electric potential of the hydrogen exit side, water blockage is determined to be on the oxidation electrode side.
Further, the fuel cell system embodiments of the present invention have the ability to rapidly and accurately return and stabilize cell voltage because control system 11 controls cell voltage of the fuel cell to be above a predetermined voltage by increasing the amount of gas flow supplied to the electrode at which water blockage occurs.
Further, the fuel cell system embodiments of the present invention have the ability to rapidly and accurately return and stabilize cell voltage because control system 11 increases the output voltage of the fuel cell by lowering the operating pressure or raising the operating temperature of the fuel cell when there is a fuel cell in which the cell voltage pulsates across the threshold of a predetermined voltage.
Further, the fuel cell system embodiments of the present invention have the ability to simultaneously detect a dry state of the solid electrolyte membrane together with water blockage because control system 11 determines that the solid electrolyte membrane that comprises the fuel cell is in a dry state when the output voltage of fuel cell stack 1 reduces with the passage of time.
Further, the fuel cell system embodiments of the present invention have the ability to eliminate a dry state of the solid electrolyte membrane at the same time as water blockage because control system 11 increases the output voltage of the fuel cell in which the solid electrolyte membrane is in a dry state by lowering the operating temperature of the fuel cell, reducing the gas supplied to at least one side of the fuel electrode side or the oxidation electrode side of the fuel cell, raising the operating pressure of the fuel cell, or raising the relative humidity of the air electrode side of the fuel cell.
Further, for the fuel cell system embodiments of the present invention, control system 11 makes the determination as to whether there is a water blockage after it determines whether there is a dry state, so the voltage for an ordinary dry state is higher than the voltage for water blockage, thus allowing for an efficient determination. In addition, giving precedence to determinations pertaining to the failure of the fuel cell itself, which is a dry state, can prolong the life of the fuel cell.
Further, the fuel cell system embodiments of the present invention provide an understanding of the phenomenon whereby the flow of gas gets obstructed, the distribution of the gas becomes disturbed, the channel gets blocked with water, and the voltage for the cell alone falls when water blockage is determined using the cell voltage. It also provides an accurate understanding of the fall in voltage due to a disturbance of temperature distribution when determining a dry state using the total voltage.
Further, the fuel cell system embodiments of the present invention can also detect when water gets blocked inside of a porous body such as a gas dispersion layer. That is, even though sufficient gas has been supplied to the gas channel, the water blocked in the porous body prevents the dispersion of gas to the catalyst layer. Accordingly, water blockage takes place when the total voltage has fallen with the passage of time and when there is a decline in the voltage that pulsates across the threshold of a predetermined voltage.
An explanation was provided hereinabove of embodiments that apply the invention conceived by the inventors; however, the present invention is not limited to the description or drawings in any part of the disclosure of the present invention according to the embodiments. In other words, it is obvious that any other embodiment, form of implementation, or operating technology conceived by a person skilled in the art based on the above embodiments are all included within the scope of the present invention.
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement, which is calculated to achieve the same purpose, may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof. | A fuel cell system determines a water blockage or a dry state of the system using voltage sensors that determine anode and cathode voltages of single fuel cells as well as a total voltage for the fuel cell system. The system also compensates for water blockages or dry states by adjusting supplies of fuel and oxidation gases to the system. | 7 |
FIELD OF THE INVENTION
[0001] The present invention generally relates to the field of system for facilitating financial transactions, and in particular, to a system for facilitating foreign currency exchange transactions over a network.
BACKGROUND OF THE INVENTION
[0002] Billions of dollars worth of currencies are bought and sold everyday. The buying and selling of currencies, commonly known as foreign exchange (or “forex”), is an activity which is integral to the financial industry. Despite the high volumes, currencies are bought and sold in a manner which is different than many of the other financial products. For instance, stocks are sold in an open market with an open bidding system. Virtually anyone (with some restrictions) can purchase a stock at the posted price so long as a proper protocol is followed and sufficient funding can be shown to exist. In other words, the price of the stock does not depend on the status of the purchaser, and the seller cannot discriminate among the buyers.
[0003] Currencies, on the other hand, are not traded on an open market. Traditionally, the forex market has always been a closed system where one institution would trade with another institution whom it considers to be credit worthy. Indeed, an institution always needs to establish a credit line with the institution whom it is trading with before a trade can be executed. The credit line can vary from one institution to another. Obviously, a large institution having a large pool of funds and good credit rating will generally be given a higher credit line than a smaller institution with limited resources. But because the credit line is given by one institution to another and is not established by a central body, an institution can have a different credit line depending on whom it is trading with. For instance, Bank A may have a credit line of one hundred million dollars with Bank B, but may have only eighty million dollars of credit line with Bank C.
[0004] Similarly, even the exchange rate one institution charges to another institution may vary depending on the status of the institution. While a number of factors are generally involved in determining an exchange rate, it is not uncommon for an institution to give a more favorable rate to an institution whom it considers to be a better customer.
[0005] Because a variety of exchange rates are applied for different institutions and because a credit line must first be established, currencies cannot easily be traded on an open market. Since a credit line is rarely given to any institution without some sufficient level of funding, essentially, forex trading is relegated only to the large institutions with a good credit rating. In addition, since an exchange rate is partially determined by the size of the trade, only trades of sufficient size are made which further limits any small institutions from entering the forex market.
[0006] To a large extent, the forex transactions are still conducted in a manual manner. When an institution such as a bank desires to trade currency with another bank, for instance, a trader representing the bank would manually contact a trader representing the other bank. A standard negotiation ensues and an exchange rate is determined by applying a variety of factors such as inter-bank rates, credit worthiness, stability of the currency being traded, etc, all of which are well know those in the forex market.
[0007] To automate the trade to some degree, a multitude of forex systems have been developed and are currently being used. One such system is described in the U.S. Pat. Nos. 5,787,402, 5,978,485, and 5,508,913. Other systems can be found on the Internet such as www.forextrading.com while some are proprietary systems available for only a small selected group of banks. One such proprietary system is known as the Electronic Broking System or EBS which generally accepts only the largest of the banks.
[0008] Most of the currently available systems relating to forex trading generally fall under two distinct categories. The first type is a system that allows one institution to trade with another institution. Basically, this type of system allows one to enter the particulars of a trade and execute the trade on-line. This type of system is basically one-to-one, that is, one can only submit a forex order to a single financial institution. While the system makes it easier to conduct a trade, all of the necessary protocols such as establishment of credit line, etc., still must be met.
[0009] The second type is a system that provides a network of institutions to create a marketplace for forex trading. While a credit line still needs to be established before a trade can be made, once the credit lines have been established, an institution may have access to several exchange rates posted by different institutions. One may think of such a system as a sort of a quasi- open marketplace for currencies. Currently, this system of the second type is available as a proprietary system which limits participation to only a selected group of banks which are typically banks with very large capital.
[0010] Although these systems in general do automate many of the conventional manual steps involved in forex trading, they are essentially that: a system for making a conventional forex trading easier. They do not change the fundamental nature of the forex trading itself. For instance, in all of these systems, an entity must still establish a credit line before a trade can b e executed. If a low net worth individual, for instance, wishes to conduct a forex trade, he/she would not be able to do so because no institution would give a credit line to such a person. Same is true for small to medium-sized companies that may need to trade relatively small amounts of currencies. In essence, the current automated systems, while more efficient, is still a closed system.
[0011] Yet there are legitimate reasons for smaller institutions and individuals trade currencies. The needs of these players are currently not being met with the existing system (whether it be the traditional manual system or the automated one). While it of course currently possible for the small entities to buy and purchase currencies, they must either purchase them directly from a bank or other financial institutions who will charge a rate which is relatively much higher than those charged in the inter-bank market. This may not b e acceptable, and certainly not optimal, for many of the smaller institutions. Therefore, what is needed is a new way of trading currencies which does not limit the participants to just the large banks or other large institutions while still preserving the basic economic fundamentals of the forex market.
OBJECT OF THE INVENTION
[0012] It is therefore an object of the present invention to provide a method and system for facilitating an exchange of currencies that overcome the shortcomings of the prior art systems described above.
SUMMARY OF THE INVENTION
[0013] The present system has two layers of transaction. The first layer comprises a Web-based foreign exchange (“forex”) market where financial institutions and other business entities can trade currencies. These transactions conducted in the forex market will generally be referred to as B2B (business-to-business) transactions. Although typically these business entities will be banks, present system can accomodate other entities such as corporations, public institutions, and even individuals. To participate in the forex market, there no special software is required; all the business entities need is an internet browser like Internet Explorer or Netscape. The business entities, such as a bank, are able to trade on current credit line structure that currently exists among banks The second layer of the present system facilitates a B2C (business-to-client) transaction, where the business can provide forex trading capability for the business entities' own clients. This B2C feature allows each business entity to take the forex orders from each of their respective clients through the Internet. The system provides online checking of collateral and deposit before accepting the placement of orders. Each business entity can choose to work on the orders they receive from their client by hitting on the clients orders or, strictly at the discretion of each business entity, pass the orders into forex market in the names of the respective business entities (possibly adding a spread first) and using the credit lines of the respective business entities. It is in this way that the business entities' clients are linked up to the forex market. With the ability of straight through processing of clients' orders, business entities can accept clients orders more freely.
[0014] The present system includes a central server system 20 system which comprises a Web server engine 22 , databases and application managers 24 , and a plurality of Web pages 26 . The central server system 20 establishes the Web based forex market to facilitate the trading of the currencies among the business entities by providing the necessary interfaces via the Web pages. The central server system is linked via the Internet to a business entity's server system. The business entity's server system comprises a Web server, B2C engine, the PCs of the business entity's various representatives, and the business entity's legacy forex system. The business entity's server system is linked via the Internet to the business entity's client's PCs. The business entity's system, through its Web server and B2C facilitates both the B2B and the B2C transactions. The clients' PCs basically only requires an Internet browser and the appropriate Internet connection.
[0015] In one embodiment of the present invention, a method facilitated by a computer network to accomplish a foreign currency exchange transaction between business entities includes providing a central server system having a communication channel for electronically communicating with the business entities, whereby a representative of a first business entity that is registered is allowed access to the central server system. The representative is then allowed to select a currency pair to be transacted. The system then displays at least one rate for the selected currency pair posted by a representative from a second business entity which is registered with the central server system, the second business entity having established a mutual credit line with the first business entity. Lastly, representative of the first business entity is allowed to place an order on the currency pair, whereby the order is matched against the posted rates, a match resulting in a trade, and a non-match resulting in a posting of the order.
[0016] In another embodiment, a method facilitated by a computer network to accomplish a foreign currency exchange transaction between business entities includes providing a central server system having a communication channel for electronically communicating with the business entities and registering a first business entity whereby a representative is assigned a role of an administrator, credit officer, and a trader, each role requiring a proper login ID and a password to access the central server system. The trader is then allowed to select a currency pair to be transacted, and the system displays at least one rate for the selected currency pair posted by a trader from a second business entity which is registered with the central server system, the second business entity having established a mutual credit line with the first business entity. Lastly, the trader of the first business entity is allowed to place an order on the currency pair, whereby the order is matched against the posted rates, a match resulting in a fulfillment of the order, and a non-match resulting in a posting of the order.
[0017] Yet in another method facilitated by a computer network to accomplish a foreign currency exchange transaction between clients having an account with a business entity includes providing a business entity's system having a communication channel for electronically communicating with the clients and registering the clients with the business entity's system whereby the registered clients are allowed access to the business entity's system and whereby the registered clients place a collateral with the business entity. The clients are then allowed to select a currency pair to be transacted, and the system displays at least one rate for the selected currency pair posted by a registered client. The registered clients are then allowed to place an order on the currency pair, whereby the order is matched against the posted rates, a match resulting in a trade, and a non-match resulting in a posting of the order. The trades are then settled.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a symbolic diagram illustrating the general concept of the present invention.
[0019] [0019]FIG. 2 illustrates the physical architecture of the present system.
[0020] [0020]FIG. 3 illustrates in detail the databases and application managers of the central server system.
[0021] [0021]FIG. 4 illustrates the components of the B2C engine.
[0022] [0022]FIG. 5 is a flow diagram illustrating the overall process flow for a business entity to conduct a B2B transaction using the present system.
[0023] [0023]FIGS. 6 and 6 A are flow diagrams illustrating the process flow for a trader to conduct a trade, step 108 of FIG. 5, using the present system.
[0024] [0024]FIG. 7 flow diagram illustrating the overall process flow for a client to conduct a B2C transaction using the present system.
[0025] [0025]FIG. 8 is a Web interface representing a dealing room where a trader conducts foreign exchange trades.
[0026] [0026]FIG. 9 is a Web interface where credit groups are formed and credit lines are assigned.
[0027] [0027]FIG. 10 is a Web interface where business entities are placed into a credit group.
[0028] [0028]FIG. 11 is a Web interface where a client places a foreign exchange order.
[0029] [0029]FIG. 12 is a Web interface where a trader can view a list of orders placed by clients.
[0030] [0030]FIG. 13 is a Web interface where a trader can execute a clients order “in house”.
[0031] [0031]FIG. 14 illustrates the physical architecture for another embodiment of the present invention.
[0032] [0032]FIG. 15 illustrates in detail the databases and application managers of the business entity's system of FIG. 14.
[0033] [0033]FIG. 16 is a flow diagram illustrating the overall process flow for conducting a C2C transaction.
[0034] [0034]FIGS. 17 and 17A are flow diagrams illustrating the process flow for a client to conduct a trade using the system shown in FIG. 14.
[0035] [0035]FIG. 18 is a Web interface representing a dealing room where a client conducts foreign exchange trades.
DETAILED DESCRIPTION OF THE INVENTION
[0036] [0036]FIG. 1 is a symbolic diagram illustrating the general concept for the present invention. In the preferred embodiment, the present system has two layers of transaction. The first layer comprises a Web-based foreign exchange (“FOREX”) market 10 where financial institutions and other business entities 12 can trade currencies. These transactions conducted in the forex market 10 will generally be referred to as B2B (business-to-business) transactions. Although typically these business entities will be banks, present system can accomodate other entities such as corporations, public institutions, and even individuals. However, because banks will be the most prolific users of the present system, frequent references will be made to banks as an illustrative example. It should be understood, however, that users can encompass a wide range of entities other than just banks.
[0037] To participate in the forex market 10 , there no special software is required; all the business entities 12 need is an internet browser like Internet Explorer or Netscape. The business entities, such as a bank, are able to trade on current credit line structure that currently exists among banks. In the preferred embodiment, the forex market 10 is available free to these entities 12 on a subscription basis where each participating entity undertakes the legal obligation to settle each trade done on using the present system. The B2B layer can operate independently from the B2C layer of the system.
[0038] Still referring to FIG. 1, the second layer of the present system facilitates a B2C (business-to-client) transaction, where the business can provide forex trading capability for the business entity's 12 own clients 14 . Most typically, clients will be account holders of a bank, and therefore this business relationship shall frequently be used as an illustrative example, though clearly other scenarios are possible. For instance, the client may also be an employee of a corporation.
[0039] This B2C feature allows each business entity to take the forex orders from each of their respective clients through the Internet. The system provides online checking of collateral and deposit before accepting the placement of orders. Each business entity can choose to work on the orders they receive from their client by hitting on the clients orders or, strictly at the discretion of each business entity, pass the orders into forex market 10 in the names of the respective business entities (possibly adding a spread first) and using the credit lines of the respective business entities. It is in this way that the business entities' clients 14 are linked up to the forex market 10 . With the ability of straight through processing of clients' orders, business entities can accept clients orders more freely. On the one hand, the present system protects the business entities by giving them the administrative controls like accepting, rejecting, or “transferring” the orders. What spreads being charged to the clients' are entirely the decision of the business entities.
[0040] [0040]FIG. 2 illustrates the preferred overall architecture of the present financial system. Referring both to FIGS. 1 and 2, the central server system 20 system comprises a Web server engine 22 , databases and application managers 24 , and a plurality of Web pages 26 . The central server system 20 establishes the Web based forex market 10 to facilitate the trading of the currencies among the business entities 12 by providing the necessary interfaces via the Web pages 26 . The central server system 20 is linked via the Internet 39 to a business entity's server system 30 . The business entity's server system 30 comprises a Web server 32 , B2C engine 34 , the PCs 36 of the business entity's various 5 representatives, and the business entity's legacy forex system 38 . The business entity's server system 30 is linked via the Internet 39 to the business entity's client's PCs 40 . The business entity's system 30 , through its Web server 32 and B2C 34 facilitates both the B2B and the B2C transactions. The clients' PCs 40 basically only requires an Internet browser 42 and the appropriate Internet connection.
[0041] To participate in the forex market 10 using the preferred embodiment of the present system, the business entity's representatives need to be assigned three different roles: a trader, a credit officer, and an administrator. A user representing each role will be assigned a unique login ID and password, and the system will only give access to the interfaces appropriate for the role. The trader's main function is to conduct forex trades on the Web-based B2B dealing room as represented by the interface shown in FIG. 8. The credit officer's main function, among others, is to assign credit limits to parties involved in a trade and to form credit groups. The administrator's main function, among others, is to handle a multitude of administrative duties such as updating user roles, e.g., changing a user from a trader to an administrator, updating trading limit for an individual trader, and defining the preferred settlement method. Each of these representatives can access the central server system 20 via the Internet using a PC from any location. Although generally the PC may be physically located at the business entity's site and may go through the business entity's Web server 32 , it should be understood that a PC residing outside of the business entity's system 30 may also be used.
[0042] [0042]FIG. 3 illustrates in detail the databases and application managers 24 . The User Profile Manager 51 facilitates the interfacing between the central server system 24 and the various representatives of the business entities 30 who will be accessing the central server system 24 . The user particulars, e.g., user names, login ID, encrypted password, etc., are stored in the User Profile database 52 . The Authentication Manager 53 co-operates with the User Profile Manager 51 and User Profile database 52 , and authenticates the users by, for instance, matching the user's user ID with a corresponding password. The Authorization Manager 55 co-operates with the User Profile Manager 51 and authorizes the appropriate activities depending on the role assigned for the user. For instance, a user who is designated as a trader would be authorized to trade currencies on behalf of a business entity, but would not be authorized to assign or change credit limits, an activity which is reserved only to a user designated as the credit officer.
[0043] The Order Manager 57 handles the administration of the orders (placed by the traders) such as the input and cancellation of the orders. Orders which are placed but not executed (i.e. not traded yet) are stored in the Pending Order database 56 . The executed orders are stored in the Executed Order database 58 . The Settlement Manager 59 manages the handling of settlement information, e.g., settlement method and settlement account information, and stores the information in the Settlement database 60 .
[0044] The Currency Manager 61 handles, among others, administration of the currency pairs, the particulars of which are stored in the currency pair database 62 . The particulars can include information such as a list of authorized currency pairs, e.g., US$/Yen, currency multiplier, and minimum/maximum trading range.
[0045] The Holiday Manager 63 keeps track of holidays and off hours and stores all relevant information in- the Holiday/Off-Hours database 64 . The NewsFeed Manager 65 receives news feeds from various sources and stores pertinent information in the news feed database 66 and displays the news on one of the Web pages. The Rates Manager 67 is mainly responsible for the displaying of indicative exchange rates of the various currency pairs which are obtained from public sources. The indicative rates are stored in the Rate database 68 . The News Manager 69 handles the display of news relating the present system and the News database 70 stores the news information.
[0046] The Credit Manager 71 manages the giving and receiving of credits among the business entities 30 that trade in the forex market 10 provided by the present system. Before a currency can be traded, the business entities must first establish a credit group and provide a credit line to all parties with whom a trade will be made. The information relating to the credit groups is stored in the Credit Group database 76 . The credit limits given to the various trading parties are stored in the Credit Limits database 74 . The particulars of the business entities such as name, address, etc., are stored in the Business Entity database 72 . The Collateral Manager 73 keeps track of the collateral received by the business entity from its clients and stores the information in the Collateral database 78 .
[0047] [0047]FIG. 4 illustrates the components of the B2C engine 34 of the business entity's system 30 . The User Manager 84 facilitates the interfacing between the business entities' system 30 and the clients 40 of the business entities who will be accessing the system 30 , including authenticating the users. The user particulars, e.g., user name, address, etc., are stored in the User Accounts database 82 . The User Profile database 80 , on the other hand, stores user information such as user ID, password, collateral (type and amount), etc.
[0048] The Order Manager 90 handles the administration of the orders placed by the clients such as the input and cancellation of the orders. Orders which are placed but not executed (i.e. not traded yet) are stored in the Orders database 86 . The executed orders are stored in the Trades database 88 . The Collateral database 92 stores the details of the collateral. For instance, the database 92 stores the type and amount of collateral placed by each client and the amount of collateral remaining after assessing the profit and loss of the trades executed by the client. The collateral information is dynamically updated as the client executes a trade.
[0049] The Margin Rates database 94 contains three main types of margin rates information. The first type is the spread margin which is the commission the business entity such as a bank charges for each transaction of a currency pair. The second type is the initial margin which is used to calculate the maximum amount a client can trade based on the amount of collateral placed by the client with business entity. The third type is the maintenance margin which is the percentage of the collateral used up by losses in trades before the client needs to top up the collateral. The administration of the collateral and margin rates information is handled by the Collateral Manager 96 .
[0050] The B2C engine may optionally include a settlement database 98 and a settlement manager 99 . Depending on the needs of a particular business entity, the settlement database may simply include information such as settlement method (similar to the central server system's settlement database 60 ) if the settlement is handled by the business entity's legacy system most commonly found in banks. In the alternative, the settlement database 98 and settlement manager 99 may play a more active role in the settlement process by incorporating all of the account data for each business entity's client.
[0051] [0051]FIG. 5 illustrates the overview process flow for the business-to-business or B2B transaction. In step 100 , the business entity that wishes to trade currencies using the present system must first register itself and its representatives with the central server system 20 such that each of the representatives may properly access the system. The representatives must be assigned the roles of administrator, credit officer, and a trader. Once properly registered, in step 102 , the administrator performs various administrative activities before a forex order can be placed by a trader. In step 104 , the credit officer of a business entity establishes a credit line with one or more other business entities. In step 106 , the credit officer accesses the central server system 20 and forms credit groups and allocates a credit line for each group. In step 108 , the trader accesses the dealing room and conducts the trades. In step 110 , the system settles the executed trades.
[0052] The registration of the business entity and its representatives performed in step 100 , may be performed on-line or off-line, but it is generally preferred that it be performed off-line to ensure security. The registration process basically entails obtaining the particulars of the registering business entity such as its business name, address, contact person, and in the case where the business is a bank, its dealing code. The business entity also specifies the particulars of the users who will play the role of the administrator, credit officer, and a trader. Of course, it is possible for a single representative to play multiple roles, if need be. Each of the role players will be assigned a unique login ID and a password. Only the user with the proper login ID and password will be able to perform the duties authorized for that particular role. All of the information is stored in the user profile database 52 of FIG. 3. Although in the preferred embodiment multiple roles are defined, it should be understood that it is possible to have a scheme where no formal separation of the roles is made.
[0053] The administration duties of step 102 are performed by the administrator. The functions of the administrator are, among other, to update user roles in case there is a change in the role played by a particular user; update trading limit, i.e., a limit to the amount a trader can trade in a given day, for a particular trader; update trading balance, i.e., adjust the balance of the trades made by a particular trader in order to allow a trader to trade beyond the trading limit; update trading time, i.e., the range of time when the trades can b e made by the traders; activate/deactivate a trader's account; create preferred settlement method, e.g., defining which accounts the traded currencies will be drawn from; etc.
[0054] In step 104 , the business entity such as a bank contacts another business entity, e.g., bank and establishes a mutual credit line with each other. Various means of contact are possible such as communicating over a phone, e-mail, faxes, etc. Although the concept of a credit line is well understood in certain industries such as the banking industry, it should be understood that the term “credit line” as used herein is more general to mean any mechanism or rules of engagement which facilitate an understanding between the trading parties such that an exchange of currency can be accomplished.
[0055] Once a credit has been established with one or more business entities, in step 106 , by accessing the central server system 20 , the credit officer forms credit groups and allocates a credit line to each of the groups. Each credit group represents a single trading entity which may consist of one or more business entities. The credit group allows small institutions to participate in the forex market by aggregating multiple institutions (usually affiliated) so that as a group a sufficient credit line can be established even if as individual entities, sufficient credit line would not be available. For instance, a single banking institutions may have multiple branches in several countries. The branches may decide to trade as a credit group rather than trading individually.
[0056] The formation of the credit groups and allocation of credit lines are performed by accessing the interface shown in FIG. 9. The credit officer first enters the name of the credit group 240 in the field provided. Any name is possible. The Daily Credit Limit 242 is then entered which is the daily credit line which was established in step 104 in FIG. 5. The Warning Percentage 244 , percentage of credit available before a warning is given, is then entered. If a credit limit has been previously established, it will be shown under Current Credit Limit 248 . The Available Balance 250 indicates how much of the credit is remaining. The list of the existing credit groups is shown in a display box 252 .
[0057] Once the credit groups have been formed and the credit lines have been allocated, the credit officer assigns the trading floors which is a process for assigning the business entities to a credit group. The assignment of trading floor is accomplished via the interface shown in FIG. 10. As shown, the names of the credit groups which were formed using the interface of FIG. 9 are shown in the box 260 . In the box 262 is the list of business entities which have been properly registered and which are properly entered into the system 20 . The credit officer first selects the credit group in box 260 , then selects the names of the business entities from box 262 that it wishes to add to the selected business group. The added business entity is shown in box 264 . The process is repeated until all of the business entities listed in box 262 have been assigned to a credit group. Although the formation of a credit group provides the flexibility for business entities to group multiple entities together and thus the feature is highly desirable, it should be understood that the present system may operate without such a feature where each business entity trades under its own name and credit line.
[0058] The details of how a trader conduct a trade of currencies using the present system in step 108 shall be explained in reference to the flow diagrams shown in FIGS. 6 and 6 A and the interface 200 shown in FIG. 8. Referring now to FIG. 6, in step 120 the trader accesses the dealing room as represented by the Web interface 200 shown in FIG. 8. The trader then, in step 122 , chooses a currency pair from the drop-down menu 210 . Note that each interface 200 can show up to two currency pairs, in this case, US dollar against the Japanese Yen (USD/JPY) 202 and European Euro against the U S dollar (EUR/USD) 204 . For the purposes of describing the trading process, however, only the USD/JPY will be used as an illustrative example since identical set of steps will apply to all currency pairs.
[0059] In step 124 , the system displays the best three rates for each currency pair. The rates posted are from those business entities whom the current trader's business entity has established a credit line with and who have been entered into the system. Here, the best three rates for the USD/JPY are listed on the display board 206 . Note that the last two digits of the exchange rate are shown in the larger box 208 in bold and the remaining digits are shown in the smaller box 210 . The rates on the left side 212 indicate a rate at which the US dollar is being offered to be bought, and therefore the rate most favoring the US dollar will be considered the “best” rate from the viewpoint of the trader looking at the display board 206 . The best rate from the viewpoint of the trader is listed first. The rates on the right side 214 indicate a rate at which the US dollar is being offered to be sold, and therefore the rate least favoring the US dollar will be considered the “best” rate from viewpoint of the trader, and will be listed first. The number 216 immediately below the smaller box 210 indicates the number of units of the currency being offered at the rate shown without the multiplier. The multiplier factor 228 is indicated on the left side of the interface. Although here the multiplier is 100,000, other multipliers, e.g., 1,000,000, are clearly possible. Thus here, the number “55” indicates 55×100,000 or US$5,500,000. It should be noted that the amount 55 need not have been placed by a single business entity. Where several business entities place an order for the same rate, the amount is aggregated. Hence the amount 55 may have come from a single business entity, or it may be an aggregation of several orders placed by plurality of business entities. The interface, 200 , however does not indicate whether the posted amount comes from a single business entity or is an aggregation of multiple postings.
[0060] In step 126 , the trader chooses either a “Bid” 218 or “Ask” 220 under “Type” 217 . Choosing “Bid” would indicate that the trader wishes to buy US dollar against the Japanese Yen; choosing “Ask” would indicate that the trader wishes to sell US dollar against Japanese Yen. In this case, for illustrative purposes only, “Ask” is selected which indicates that the trader wishes to buy US dollars against the Japanese Yen. In step 128 , the trader enters the amount in the amount field 222 that the trader wishes to sell or buy. Note that the multiplier 223 is 100,000, so an entry of 10, for instance, is equaled to 1,000,000 units of currency, and in this case, US dollars.
[0061] In step 130 , the trader decides whether to buy or sell at the “best” rate posted on the display board 206 . If yes, the trader chooses “Hit at Market Rate” 226 , step 132 , and the system automatically assumes that the trader wishes to trade on the best rate displayed on the display board 206 . If the trader has chosen “Bid”, then the “best” rate would be the first rate listed on the right side (“Ask” or “sell” side) of the display board 206 . But if the trader has chosen “Ask”, then the “best” rate would be the first rate listed on the left side (“Bid” or “buy” side) of the display board 206 . The amount entered in the amount field 222 will then be deducted from the amount 216 shown for the best rate in step 134 . Here, because “Ask” was chosen under “Type”, the entered amount “10” will be deducted from the amount “55” 216 . If the amount 55 is an aggregation of orders placed by several business entities, the amount 10 will be deducted first from the “Bid” order which was placed first in time. So for instance, if a Business Entity A placed an order for 8 units first and a Business Entity B placed an order for 47 (hence a total of 55) second, then the 8 of the entered amount 10 will be deducted first from Business Entity A's order of 8, and then the remaining 2 units will be deducted from Business Entity B's order of 47. The amount remaining after the deduction, 45, will now be displayed. In the event that the entered amount is larger than what is available on display board, then all of the available amount is deducted from the posting and the remaining amount is posted. Once the deduction is made, the transaction is considered a “done deal” and the system displays the transaction in the “Deal Done” section 226 . It should be noted that this section only shows the transactions performed by the current trader; it does not list all of the transactions performed using the system 20 .
[0062] Now referring to FIG. 6A, if in step 130 of FIG. 6 the trader decides not to take the best rate, then the trader enters the desired rate in the rate field 224 in step 140 . In step 142 , the system tries to match the rate against posted rates. In this case, the entered rate was 116.70 and the transaction is “Ask” (sell). Therefore, the system 20 looks to the postings on the “Bid” side 212 of the display board 206 to see if there are any buyers who has posted a bid rate which either matches that entered by the trader or is better. Since there is no buyer who is willing to buy US dollars at the rate entered by the trader, the answer to the question in step 144 is “No”, and the system moves to step 146 . If, on the other hand, the system determines that there is a match in step 144 , then the system deducts the entered amount from the posted rate which either matches or surpasses the entered rate in step 156 , and displays the transaction in 158 under section entitled “Deal Done” 226 . In step 146 , the entered order is queued among other orders. If the order entered is within the three best rates, it is posted on the display board 206 in step 148 . The system then waits for a matching order to be placed by traders of other business entities who are using the system in step 150 . If a matching order is found, then the system deducts the amount from the posted amount in step 152 , and displays the transaction in step 154 .
[0063] The settlement process of step 110 is performed by the system per the method defined by the administrator. In the preferred embodiment, the settlement process is performed by the business entities off-line using the existing settlement processes.
[0064] [0064]FIG. 7 illustrates the overview process flow for the business-to-client (B2C) transaction. In step 160 , the client wishing to conduct a forex trade first registers with the business entity to obtain a login ID and a password. In step 162 , the client logs onto the B2C system and places an order. In step 163 , the client's order is sent to the order monitor so that a trader can make a decision as to how best to fulfill the order. In step 164 , the trader for the business entity decides whether to send the order to the B2B system. If the trader decides to fulfill the order “in-house”, then in step 166 , the trader executes the client's order. If, however, the trader decides to fulfill the client's order via the B2B system, then the order is “transferred” to the B2B system and the particulars of the client's order is displayed in the B2B dealing room interface 200 (FIG. 8) in step 168 . The trade is then executed in the dealing room in step 170 . The business entity then settles the trade with the business entity with whom the trade was made in step 172 (“B2B settlement”). The business entity then settles the trade with the client in step 174 (“B2C settlement”).
[0065] The registration of the client performed in step 160 , may be performed on-line or off-line, but it is generally preferred that it be performed off-line to ensure security. The registration process basically entails obtaining the particulars of the client such as the name, address, etc. The registration process also entails determining the credit worthiness of the client by obtaining the necessary financial information and conducting a credit analysis of the client. The client also needs to place a collateral with the business entity. Although the collateral will generally be cash, it may be other financial instruments or even goods. For instance, the collateral may be stocks, bonds, or real property.
[0066] Based on the amount of collateral placed by the client, and a credit analysis performed on the client by the business entity, the business entity determines the initial margin rate which is used to calculate maximum amount the client can trade. In the preferred embodiment, the maximum amount is calculated using the following formula:
100 IM × C = MaxAmount
[0067] where
[0068] IM=Initial Margin Rate
[0069] C=collateral amount in US$.
[0070] So for instance, an initial margin rate of 20% with a collateral amount of US$10,000 would sets the maximum amount to be traded at US$50,000. It should be understood that many variations of the above formula are possible depending on the needs of the users, and therefore, the above formula should be taken as illustrative only.
[0071] The business entity also sets the maintenance margin rate which is the percentage of the collateral amount which is remaining after offsetting losses in trades before a warning is given to the client to “top up” the collateral. For instance, using the above example where a collateral of US$10,000 was placed by a client, a maintenance margin rate of 5% means that a warning will be given when the total losses reach US$45,000. Once all of the information has been received and the proper financial analysis has been conducted, the client is assigned a login ID and a password which are necessary to make an order entry.
[0072] Once a proper login ID and a password are obtained, the client is able to make an order entry The order entry of step 162 of FIG. 7 is performed via the interface shown in FIG. 11. Using the login ID and password, the client first accesses the B2C system via the Internet. The client first chooses the Order Type 270 . In the preferred embodiment, the Order Type 270 can be Take Profit, Stop Loss, or Call. Choosing “Take Profit” means that the client's order is executed when the entered rate is met or exceeded. “Stop Loss”, on the other hand, is the price level at which further losses are limited by the act of terminating an open position when the stop loss limit is reached. Choosing “Call” means that the trader needs to call the client for confirmation before a trade on the client's order is executed.
[0073] After making a selection under Order Type 270 , the client chooses the currency pair 272 , e.g., US$Yen. The client chooses whether to sell or buy a currency under Buy/Sell 274 . If US$Yen was selected as the currency pair, for instance, choosing “Buy” would indicate that the client wishes to purchase US$ against the Yen; choosing “Sell” would indicate that the client wishes to sell US$ against the Yen. The client then enters the Currency 1 Amount 276 , or the currency listed first in the currency pair. For example, if the currency pair US$/Yen was chosen, the “first” currency would be the US$. Once the amount Currency 1 Amount 276 is entered, the Currency 2 Amount 280 is automatically calculated. The client next enters the Rate 278 at which the client wishes to buy or sell the currency. Some of the other particulars submitted the client are Expiry City 282 (time zone where the client is located for time zone determination purposes), Expiry Date 284 (the date when the order is to expire), and Expiry Time 286 (the time when the order is to expire).
[0074] Once all of the information is entered, the client hits “Execute” 290 . This prompts the system to check to see if all of entered data is valid and calculates currency amount (either 276 or 280 ) for the currency pair using the entered rate 278 , and also calculates the expiry date of the order taking into account any time zone differences. The calculated values are then displayed in the corresponding fields. After observing the calculated numbers, the client can choose to amend the entered data by hitting Amend 292 . If the client is satisfied with the order, then he may hit Confirm 296 which sends the order to the Order Monitor (explained below). Hitting the Reset 292 clears all of the fields and returns them to default values, but this option is only available before the order is executed.
[0075] When the client's order is sent to the Order Monitor in step 163 , the order can be viewed by a trader through a B2C desktop application which can reside on a business entity's trader's PC. Using this application, the trader can perform various functions such as view the clients' orders, execute the orders, cancel or assign the orders, etc. provided that the trader has properly been assigned a login ID and a password which are needed to access the B2C desktop application.
[0076] The client's orders which have been confirmed are displayed on an Order Monitor display. FIG. 12 illustrates the Order Monitor display 300 showing a list of the outstanding orders 302 which are orders which are unexecuted or partially executed. For each order, the Order Monitor 300 displays the following (corresponding part numbers in parenthesis):
Order ID (310): a unique identifier for the order B/S (312): Buy/Sell User ID(314): a unique identifier for the client placing the order CcyPair(316): currency pair Currency 1 Amount(318): Amount of the first currency Rate(320): exchange rate for the currency pair Currency 2 Amount(322) Amount of the second currency Order Status(324): Status of the order, e.g., partially executed Executed Amount(326): Amount of order executed Assigned To(328): Name of trader to whom the order is assigned Accepted By(330): Name of trader accepting the order Assigned By(332): Name of trader assigning the order Last Modified By(334): Name of trader last modifying the order
[0077] When an order is first received, the trader must first “Accept” the order by highlighting the order and pressing the “Accept” button 304 to indicate that the trader is accepting the order. If, however, the trader does not wish to accept the order, he may “assign” the order by highlighting the order and pressing the “Assign” button 308 . Moreover, the order may also be canceled by highlighting the order and pressing the “cancel” button. Pressing on the “collateral” button allows the trader to see the client's collateral information.
[0078] The critical decision the trader must make in step 164 (FIG. 7), is whether to “transfer” the order to the B2B system or to execute the order “in house”, i.e., execute the order by the business entity. To execute an order per step 166 , the trader highlights an order and presses the “Execute” button 306 at which time the Execute Order interface 330 of FIG. 13 appears. All of the relevant particulars of the highlighted order are imported into the relevant fields of the Execute Order interface 330 under Order Information 331 . In particular, the imported information is the following: Order ID 332, User ID 334, Buy/Sell 336 , Order Type 338 , Ccy Pair 340 , Target Rate 342 , Ccyl Amount 344 . The Balance To Execute 348 is calculated by subtracting the Executed Amount 346 from the Ccl Amount 344 .
[0079] Based on the Order Information 331 given, the trader enters the Dealt Rate 350 and Amount 352 . The trader may choose to enter the entire amount of the Balance to Execute 348 , or choose to only partially execute the order by entering an amount which is less than the Balance to Execute 348 . The trader executes the order by pressing the “Execute” button 354 which freezes all of the data in the fields which can be amended only by pressing the “Amend” button 356 . Once everything is confirmed, the trader presses the “Confirm” button 358 . Once the order has been properly fulfilled, the business entity settles the trade with the client in step 174 .
[0080] If, in step 164 , the trader decides to transfer an order to the B2B system, the trader highlights the order on the Order Monitor 300 and presses the “transfer” button 311 . The selected order is then sent to the B2B dealing room 200 of FIG. 8 and particulars of the order are entered into the appropriate fields in a manner similar to how a trader would enter the data using the same interface 200 . The order is then executed per the usual B2B trading process where the clients order has essentially been “white labeled” by the business entity. In other words, the other business entities using the B2B system is unaware that the order has originated from a business entity's client. Once the trade has been executed in step 170 , the trade is first settled at the B2B stage, and then subsequently settled at the B2C stage with the business entity's client.
[0081] [0081]FIG. 14 illustrates an another embodiment of the present invention where the business entity essentially plays the role of the Central Server System 20 (FIG. 2) and allows its clients 382 to trade currencies amongst each other in a manner which is substantially similar to the B2B system described above. This type of transaction is called the client-to-client, or C2C, transaction. The embodiment of FIG. 14 includes a business entity system 370 which is accessible via the Internet by the business entity's clients PCs 382 having an Internet browser 384 . The business entity's system 370 includes a Web server engine 374 , business entity's legacy system 376 , databases and application managers 378 , and Web pages 380 .
[0082] [0082]FIG. 15 illustrates the databases and application managers 378 in detail. The User Manager 390 facilitates the interfacing between the business entity's system 370 and the clients 382 of the business entity who will be accessing the system 370 . The user particulars, e.g., user name, address, etc., are stored in the User Accounts database 394 . The User Profile database 392 , on the other hand, stores user information such as user ID, password, collateral (type and amount), etc.
[0083] The collateral database 398 stores the details of the collateral. For instance, the database 398 stores the type and amount of collateral placed by each client and amount of collateral remaining after assessing the profit and loss of the trades executed by the client. The collateral information is dynamically updated as the client executes a trade.
[0084] The Margin Rates database 400 contains three main types of margin rates information. The first type is the spread margin which is the commission the business entity such as a bank charges for each transaction of a currency pair. The second type is the initial margin which is used to calculate the maximum amount a client can trade based on the amount collateral placed by the client with business entity. The third type is the maintenance margin which is the percentage of the collateral used up by losses in trades before the client needs to top up the collateral. The administration of the collateral and margin rates information is handled by the collateral manager 396 .
[0085] The Order Manager 408 handles the administration of the orders such as the input and cancellation of the orders. Orders which are placed but not executed (i.e. not traded yet) are stored in the Pending Order database 402 . The executed orders are stored in the Executed Order database 404 . The Settlement Manager 410 manages the handling of settlement information, e.g., settlement method and settlement account information, and stores the information in the Settlement database 406 .
[0086] The Currency Manager 414 handles, among others, administration of the currency pairs, the particulars of which are stored in the currency pair database 412 . The particulars can include information such as a list of authorized currency pairs, e.g., US$Yen, currency multiplier, and minimum/maximum trading range. The Holiday Manager keeps track of holidays and off hours and stores all relevant information in the Holiday/Off-Hours database 416 . The News Feed Manager 422 receives news feeds from various sources and stores pertinent information in the news feed database 420 and displays the news on one of the Web pages. The Rates Manager 426 is mainly responsible for the displaying of indicative exchange rates of the various currency pairs which are obtained from public sources. The indicative rates are stored in the Indicative Rate database 424 . The News Manager 430 handles the display of news relating the present system and the News database 428 stores the news information.
[0087] [0087]FIG. 16 illustrates the overview process flow for the client-to-client or C2C transaction. In step 450 , the client wishing to conduct a forex trade first registers with the business entity to obtain a login ID and a password. In step 452 the client logs into the business entity's system via the Web pages 380 and trades on-line. In step 454 , the executed trades are settled.
[0088] The registration of the client performed in step 450 , may be performed on-line or off-line, but it is generally preferred that it be performed off-line to ensure security. The registration process basically entails obtaining the particulars of the client such as the name, address, etc. The registration process also entails determining the credit worthiness of the client by obtaining the necessary financial information and conducting a credit analysis of the client. The client also needs to place a collateral with the business entity. Although the collateral will generally be cash, it may be other financial instruments or even goods. For instance, the collateral may be stocks, bonds, or real property. Based on the amount of collateral placed by the client, and a credit analysis performed on the client by the business entity, the business determines the initial margin rate which is used to calculate maximum amount the client can trade. In the preferred embodiment, the maximum amount is calculated using the following formula:
100 IM × C = MaxAmount
[0089] where
[0090] IM=Initial Margin Rate
[0091] C=collateral amount in US$.
[0092] So for instance, an initial margin rate of 20% with a collateral amount of US$10,000 would sets the maximum amount to be traded at US$50,000. It should be understood that many variations of the above formula are possible depending on the needs of the users, and therefore, the above formula should be taken as illustrative only.
[0093] The business also sets the maintenance margin rate which is the percentage of the collateral amount which is remaining after offsetting losses in trades before a warning is given to the client to “top up” the collateral. For instance, using the above example where a collateral of US$10,000 was placed by a client, a maintenance margin rate of 5% means that a warning will be given when the total losses reach US$45,000. Once all of the information has been received and the proper financial analysis has been conducted, the client is assigned a login ID and a password which are necessary to make an order entry.
[0094] Once a proper login ID and a password are obtained, the client is able to trade currencies online using the dealing room Web interface 600 shown in FIG. 18. The details of how a client conducts a trade of currencies using the present system in step 452 shall be explained in reference to the flow diagram shown in FIGS. 17, 17A and 18 . Referring now to FIG. 17, in step 470 the client accesses the dealing room as represented by the Web interface 600 shown in FIG. 18. The client then, in step 472 , chooses a currency pair from the drop-down menu 610 . Note that the interface 600 can show up to two currency pairs, in this case, US dollar against the Japanese Yen (USD/JPY) 602 and European Euro against the US dollar (EUR/USD) 604 . For the purposes of describing the trading process, however, only the USD/JPY will be used as an illustrative example since the same steps will apply to all currency pairs.
[0095] In step 474 , the system displays the best three rates for each currency pair. The rates posted are from all of those clients who are currently using the dealing room interface 600 . Here, the best three rates for the USD/JPY are listed on the display board 606 . Note that the last two digits of the exchange rate are shown in the larger box 608 in bold and the remaining digits are shown in the smaller box 610 . The rates on the left side 612 indicate a rate at which the US dollar is being offered to be bought, and therefore the rate most favoring the US dollar will be considered the “best” rate from the viewpoint of the client looking at the display board 606 . The best rate from the viewpoint of the client is listed first. The rates on the right side 614 indicate a rate at which the US dollar is being offered to be sold, and therefore the rate least favoring the US dollar will be considered the “best” rate from viewpoint of the client, and will be listed first The number 616 immediately below the smaller box 610 indicates the number of units of the currency being offered at the rate shown without the multiplier. The multiplier factor 628 is indicated on the left side of the interface. Although here the multiplier is 1000, other multipliers, e.g., 10,000, are clearly possible. Thus here, the number “55” indicates 55×1000 or US$55,000. It should be noted that the amount 55 need not have been placed by a single client. Where several clients place an order for the same rate, the amount is aggregated. Hence the amount 55 may have come from a single client, or it may be an aggregation of several orders placed by plurality of clients. The interface, 600 , however does not indicate whether the posted amount comes from a single client or is an aggregation of multiple postings.
[0096] In step 476 , the client chooses either a “Bid” 618 or “Ask” 620 under “Type” 617 . Choosing “Bid” would indicate that the client wishes to buy US dollar against the Japanese Yen; choosing “Ask” would indicate that the client wishes to sell US dollar against Japanese Yen. In this case, for illustrative purposes only, “Ask” is selected which indicates that the client wishes to buy US dollars against the Japanese Yen. In step 478 , the client enters the amount in the amount field 622 that the client wishes to sell or buy. Note that the multiplier 623 is 1000, so an entry of 10, for instance, is equaled to 10,000 units of currency, and in this case, US dollars.
[0097] In step 480 , the client decides whether to buy or sell at the “best” rate posted on the display board 606 . If yes, the client chooses “Hit at Market Rate” 626 , step 482 , and the system automatically assumes that the client wishes to trade on the best rate displayed on the display board 606 . If the client has chosen “Bid”, then the “best” rate would be the first rate listed on the right side (“Ask” or “sell” side) of the display board 606 . But if the client has chosen “Ask”, then the “best” rate would be the first rate listed on the left side (“Bid” or “buy” side) of the display board 606 . The amount entered in amount field 622 will then be deducted from the amount 616 shown for the best rate in step 484 . Here, because “Ask” was chosen under “Type”, the entered amount “10” will be deducted from the amount “55” 616 . If the amount 55 is an aggregation of orders placed by several clients, the amount 10 will be deducted first from the “Bid” order which was placed first in time. So for instance, if a Client A placed an order for 8 units first and a Client B placed an order for 47 (hence a total of 55) second, then the 8 of the entered amount 10 will be deducted first from Client A's order of 8, and then the remaining 2 units will be deducted from Client B's order of 47. The amount remaining after the deduction, 45, will now be displayed. In the event that the entered amount is larger than what is available on display board, then all of the available amount is deducted from the posting and the remaining amount is posted. Once the deduction is made, the transaction is considered a “done deal” and the system displays the transaction in the “Deal Done” section 626 . It should be noted that this section only shows the transactions performed by the current client; it does not list all of the transactions performed using the system.
[0098] Now referring to FIG. 17A, if in step 480 of FIG. 17 the client decides not to take the best rate, then the client enters the desired rate in the rate field 624 in step 488 . In step 490 , the system tries to match the rate against posted rates. In this case, the entered rate was 116.70 and the transaction is “Ask” (sell). Therefore, the system looks to the postings on the “Bid” side 612 of the display board 606 to see if there are any buyers who has posted a bid rate which either matches that entered by the client or is better. Since there is no buyer who is willing to buy US dollars at the rate entered by the client, the answer to the question in step 492 is “No”, and the system moves to step 494 . If, on the other hand, the system determines that there is a match in step 492 , then the system deducts the entered amount from the posted rate which either matches or surpasses the entered rate in step 504 , and displays the transaction in step 506 under section entitled “Deal Done” 626 .
[0099] In step 494 , the entered order is queued among other orders. If the order entered is within the three best rates, it is posted on the display board 606 in step 496 . The system then waits for a matching order to be placed by clients of other business entities who are using the system in step 498 . If a matching order is found, then the system deducts the amount from the posted amount in step 500 , and displays the transaction in step 502 .
[0100] The settlement process of step 454 is performed by the system per the method defined by the administrator. In the preferred embodiment, the settlement process is performed by the business entity off-line using the existing settlement processes.
[0101] The present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The presently disclosed embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims and all changes which come within the meaning and range of equivalency of the claims are, therefore, to be embraced therein. | A method facilitated by a computer network to accomplish a foreign currency exchange transaction between business entities includes providing a central server system having a communication channel for electronically communicating with the business entities, whereby a representative of a first business entity that is registered is allowed access to the central server system. The representative is then allowed to select a currency pair to be transacted. The system then displays at least one rate for the selected currency pair posted by a representative from a second business entity which is registered with the central server system, the second business entity having established a mutual credit line with the first business entity. Lastly, representative of the first business entity is allowed to place an order on the currency pair, whereby the order is matched against the posted rates, a match resulting in a trade, and a non-match resulting in a posting of the order. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to apparatus and methods for recording, computing and billing the long-distance or toll calls made by various persons (guests or patients and staff) in an institution having a transient population, such as a hospital, hotel, motel, or company corporate headquarters.
2. Description of the Prior Art
Forty or fifty years ago, what is accomplished with the present invention was done, if at all, by the personal attention of one of the institution's switchboard operators and the bookkeeping personnel of the institution. Initially, we had neither telephone equipment that would produce the sort of signals required for this sort of system, nor the electronic computers to receive, store, and manipulate (calculate) the signals, nor the output or display systems (printers, CRT screens) that make such a system practical. When computers were first invented, they were for many years too large, cumbersome, expensive, difficult to program and/or unreliable for any system such as that herein disclosed to be practical.
The basic problem of recording data concerning toll calls made from different identifiable stations of a telephone system, and computing bills for each station, is one that is faced not only by a hospital or hotel but also by the telephone company itself, and it is not surprising that, because of the greater volume of calls to be handled and bills to be calculated and prepared, the principal early advances towards solving the problem of generating proper statements were made by the telephone company. As any telephone customer knows, there are now prepared monthly statements of long-distance calls which are to a great extent, if not always entirely, generated by automatic computer equipment. This implies that the telephone company has, some time ago, solved the problem of connecting individual stations to a call-pricing computer and a backup memory, and connecting the computer to appropriate printer means.
This all does not solve the problems which confront the administrator of a hospital or hotel with respect to providing individual statements for patients or guests. It does not provide any sort of record independent of that made by the telephone company, so that any telephone-company errors in billing could be detected. It also does not give the administrator what he needs in terms of prompt statements and useful reports, because he has patients or guests leaving the premises who should be required to pay before they depart, and he also wishes to be alerted promptly if there is any instance of heavy use or of the making of unauthorized calls. Moreover, especially in hospitals, a given patient is not infrequently moved from one room to another during his stay, so that what the telephone company wants to produce (a month-end statement of all calls from a given extension) is not useful to the administrator, because it comes too late and does not break down the charges into the ones attributable to the individuals who have used that extension during that month, and it also does not assemble into one statement the calls made by a patient from the various rooms that he occupied during his stay. The alternative of having all long-distance calls routed to a telephone-company human operator who makes the necessary records is available, but it is more costly for the patient or guest, depriving him of any chance to take advantage of the lowest rates for direct-dial, non-operator-assisted calls.
It needs to be admitted that at least some of the individual components which are required for the functioning of a system according to the present invention have, per se, been known before now.
For example, there are about fifty known, commercially available systems known as "Call Detail Recording" or "Station Message Detail Reporting," and any of these may be added as a feature to an existing institution PBX.
Another component of this apparatus of the present invention which may be taken as already known per se is a suitable call-record storing system, such as the known COM DEV Model STU-4 pollable call-record storage device. It is known in the art to use such a device in store-and-forward applications which enable remote batch processing of stored call-detail-recording (CDR) records; it is believed to be novel to use such a device as a back-up memory system which is activated if a call-pricing computer is not operating.
It can also be taken as known that there is existing computer equipment which is suitable for use as a call-pricing computer in a system such that proposed in accordance with the present invention. For example, there exists a computer known as a Zilog Series 8000 Model 11 mini-computer, which features a Z 8000 CPU, a random-access memory of 512,000 bytes, a 19 MB hard disc, a 17 MB streaming tape cartridge, and 8 input-output terminal ports. This or any other computer of substantially equivalent or greater capabilities of speed, storage, and input-output could be used. The existence of such commercially available hardware does not, it must be understood, imply that it would be obvious to surround it with the other means taught and disclosed herein to arrive at an apparatus which serves the purposes of the present invention.
The prior art has been such that
(1) there are no interim reports about heavy or expensive usage of long-distance facilities unless a human operator is used,
(2) there are no immediate reports about placing of unauthorized calls, and
(3) previous systems have not provided for the possibility of having the equipment locally present at a hospital or hotel connected telephonically to a remote location which has "Reset After Malfunction" capabilities, i.e., the existing equipment utilized at hotels and hospitals does not provide for a telephone link which will make it possible to perform remotely the diagnosis and the correction, by reprogramming or otherwise, of existing problems. It is believed that in the hospital industry, a two-way link between the institution's computer for generating patient bills and a telephone-call-pricing computer also is novel and unique.
SUMMARY OF THE INVENTION
A data-collection and -processing system is integrated with an existing Private Branch Exchange (PBX) telephone system to provide a highly automated telephone-usage accounting and billing tool for use in hospitals and other similar institutions having a large and transient clientele base. The system consists of four separate computer systems connected together (and the required applications software which enables them to function as an integrated system) and miscellaneous peripheral hardware.
Working together, the system components provide a detailed accounting of long-distance calls placed by guests and staff personnel. A very high degree of reliability is achieved by the use of redundant and self-checking components. This reliability is further enhanced by the provision for remote software maintenance and hardware diagnosis.
An extensive set of reports and transactions provide for correct handling of many difficult but typical health-care-related needs which have been lacking in previous offerings addressed to this market.
DESCRIPTION OF THE DRAWING
The above and other objects and features of the invention will become apparent from the following detailed description taken in connection with the accompanying drawings which form a part of this specification, and in which:
the sole FIGURE is a schematic block diagram showing the interconnection of the four computer systems discussed above.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
PRIVATE BRANCH EXCHANGE 10
Please refer to the FIGURE. A number of individual stations, such as those indicated at 2 to 9, inclusive, are connected to a PBX 10. The Private Branch Exchange (PBX) telephone system 10 is a computer whose primary responsibility is to route telephone calls. Such a system is a requirement for hospitals and other institutions providing telephone service to a large client population. Such a system is, therefore, always provided in a site which would have need of the invention under discussion, and is the focal point for the incorporation of the institution's existing telephone system in the invention.
There are only two special requirements for the PBX 10 which might not be implemented prior to the installation of this invention. First, each patient (or guest) must have his own Main Station telephone instrument to allow calls to be billed to the single responsible party. Some hospitals have both of the patients in a semi-private room share one telephone instrument, but for this system to work correctly, such sharing must be first be eliminated. This feature may be easily provided by adding telephone instruments in semi-private rooms, unless the PBX is already configured at its capacity.
Second, the PBX 10 (or an accessory) must provide a stream of special data records which relate the details of every call handled by the system. This feature is known variously as Call Detail Recording (CDR) or Station Message Detail Reporting, depending on the manufacturer. CDR may be added to virtually any PBX now in use. Software provided with the invention allows it to accept any of the roughly 50 different CDR record formats in use today.
The CDR record provides the following details: digits dialed, trunk group used, originating Main Station number (extension number), the time the call was initiated (or alternatively, finished), and the duration of the call, for each call originated within the building(s) served. The PBX may optionally be programmed to report only certain calls which are of interest for resale purposes; however, this is not a requirement. The format of the call records conforms to the RS-232C standard for asynchronous data transmission.
BACK-UP MEMORY SYSTEM 12
The CDR records are first routed to a COM DEV Model STU-4 pollable call-record storage device 12, which accomplishes three functions. First, it converts each call record received from the data format appropriate for the generating PBX to a standard format known as the COM DEV record format. Second, it passes a copy of the translated record on to the Call-Pricing Computer 14. Finally, it stores a copy of the translated call record in its own internal random-access memory banks. This internal random-access memory has a capacity of 7,000 call records and is erased every 24 hours as long as the Call-Pricing Computer 14 is functioning. If the Call-Pricing Computer 14 should fail, then the call records saved here would be retrieved automatically when the Call-Pricing Computer 14 has recovered. The call records stored in the memory of the Back-up Memory System 12 are protected from power failure by a built-in battery which insures that there would never be an interruption to the internal RAM memory which would cause erasure. A remote alarm unit (not shown) for the Back-up Memory System warns the operator of a power failure or memory-overflow condition.
All of the features described above are features normally provided in the COM DEV STU-4 unit; however, the use of the system in this configuration as a back-up memory system is a novel concept. The STU-4's intended application is in store-and-forward applications which enable remote batch processing of stored CDR records.
BACK-UP MEMORY BYPASS SWITCH 16
In the event of a failure of the Memory unit 12, the unit 12 may be bypassed by a bypass switch 16 which effectively removes the Memory unit 12 from the link between the PBX 10 and the Call-Pricing Computer 14. This action also eliminates the translation feature of the Memory unit 12; however, software in the Call-Pricing Computer 14 automatically detects the change in format and performs the necessary translation internally. This component 16 provides additional reliability to the system. Hence, either the Memory unit 12 or the Call-Pricing Computer 14 may be out of service for up to several days without the loss of any significant amount of data.
CALL-PRICING COMPUTER 14
The heart of the system is the Call-Pricing Computer 14. This unit 14 is preferably implemented with a Zilog Series 8000 Model 11 mini-computer. It features a Z 8000 CPU, 512 K RAM, 19 MB hard disc, a 17 MB streaming tape cartridge, and 8 terminal ports. Any computer offering comparable storage and speed capabilities could conceivably be used for this application. Of the eight input-output ports, one is dedicated to the Memory unit 12, one to the institution computer 18, and one to a modem 26. The remaining ports are available to support up to five user terminals.
Stored on hard disc within the computer is the data base, which contains information used in the preparation of all reports furnished by the system. This data base is constantly being updated by the applications software in response to call records received from the PBX and operator input from terminals.
Contained in the memory of the computer 14, there is preferably a program (the PIPE or PBX Input Processing Executive program) which runs continuously, awaiting the receipt of a call record from the PBX unit 10 or the backup Memory unit 12 or directives from an operator of the system. Upon receipt by the computer 14 of a call record, the computer 14 thus substantially immediately determines whether the call requires some particular action. A free call, for example, does not require any action. But this program in the computer 14 does various things. First, it prices the call. Second, it posts the call record and price against the account of the outlet from which the call was made. Third, whenever the number and/or value of calls coming from a particular station exceeds some predetermined threshold amount, it automatically generates a suitable output report or signal. It is within the skill of the art, to generate such a program; indeed, such a program is commercially available. It is thus to be understood that we have had, prior to this invention, a call-pricing computer that has been provided with such a program, but not one that was integrated into a suitable system possessed by a hospital or similar institution and capable of operating to provide the institution with interim billings and the other useful reports and information generated by the system of the present invention.
DATA BASE OF COMPUTER 14
The data base installed on the Call-Pricing Computer 14 consists of a collection of files which fall into one of two basic categories: working files and data-base files. Working files are those containing information which typically is in a state of continuous change. These files reflect the current status of the system at any given moment. For example, the TRUNKS file contains information on the month-to-date usage of each toll-bearing trunk installed in the PBX, including the number of calls handled to date, the dollar volume of the cost of these calls, the dollar volume of the revenue of these calls, the amount of traffic handled on these trunks during their busiest hour this day, and the time of the busiest hour so far this day.
Data-base files, on the other hand, do not typically change during the course of a day, and reflect those parameters unique to the particular installation being serviced. Included in the data-base files is all of the information necessary to price any long-distance call from the client's location to virtually any city in the world over any type of line available to the PBX at that site.
All files in the system are maintained on a hard disc located in the cabinet of the Call-Pricing Computer 14. All data-base files are also copied to a magnetic-tape cartridge every night during a reset procedure to provide a back-up copy of these files in case of disc failure. All parameters unique to a particular site are set forth on the data-base files, rather than the applications software, allowing the operating environment of a particular site to be easily duplicated on another computer by loading these files from tape. This feature allows ease of software maintenance because software failures may be duplicated on a headquarters computer by simply reloading the failing site's files onto the headquarters computer from tape and duplicating the sequence leading to the software failure.
TERMINAL INTERFACE AND REPORT GENERATOR
In order for the system to be kept abreast of events taking place which have an impact on the system operation (such as the admission or discharge of a patient), a special package of software has been provided to allow the system operator to interact with the system. This software package is known as the "Terminal Interface and Report Generator" package.
There is a kind of transaction which may be called an "admission transaction." When a patient or guest is admitted to the institution, the system operator indicates to the system which telephone main station the guest is to be assigned to and also furnishes a 7-digit patient ID number to provide positive identification for billing purposes. The use of the patient ID number by the system allows proper billing of calls, even when a patient is transferred to a new room during his visit.
A similar transaction, called a "discharge transaction," indicates to the system when a patient is being discharged. Immediately upon discharge, the patient's long-distance bill is generated and printed at the system operator's position, so that the institution may collect for the phone calls prior to the patient's departure from the building. The status of the patient's room/bed is also immediately changed to vacant in the system's working files, so that any further calls from the phone by that bed will be identified as possibly unauthorized.
In the event of an unauthorized phone call, an audible warning is sounded and a written record of the call details (including cost) is printed at the system operator's console, so that the system operator may take immediate steps to correct the irregularity. This feature is an important feature which is unique to this invention.
The need for admission and discharge transactions outlined above may be eliminated by having the Hospital Business Computer 18 provide the required information to the Back-up Memory System 12. Such a fully automated system requires the Hospital Business Computer 18 to be linked electronically to the Back-up Memory System 12, and for special admission and discharge records to be forwarded to the Back-up Memory System 12 as soon as received by the Hospital Business Computer 18. Additional information on this approach may be found below under Hospital Business Computer 18.
A third approach for handling admission and discharge transactions is to allow hospital personnel, such as hosts, transportation clerks, or nurses, to accomplish the transaction from the patient's bedside by dialing a special 4-digit code on the patient's phone. In the case of an admission, this 4-digit code would be followed by the 7-digit patient ID.
Because of administrative errors (such as entering an admission transaction late) it may become necessary for the system operator to make adjustments in the patient's bill prior to discharge. The Terminal Interface and Report Generator package also provides for debit, credit and delete-last-call transactions. The credit transaction would also be used when an interim payment was received from a patient prior to discharge.
The results of the transactions described above (admission, discharge, debit, credit, and delete-last-call) is a single record which is passed to PIPE whose form is similar to a call record which would be received from the Back-up Memory System 12. This "dummy call record" contains all of the information necessary for PIPE to bring about the desired changes in the system's working files. There are two important reasons for handling these transactions in this fashion. First, by allowing the PIPE program to be responsible for any actions which write to system working files, the problem of multiple-program contention for the same file is eliminated. This would otherwise be a serious problem for a multi-tasking multi-processing computer system such as this.
The second advantage to the use of "dummy records" is that it allows a very straightforward reconstruction of all or part of a day's worth of processing in a highly automated fashion. For example, in the event of a software failure which caused damage to the working file which contains copies of patient bills, the file could be completely reconstructed by PIPE by having it reprocess all input (call and "dummy") records which had been processed since the last valid copy of the file was archived on tape. This reprocessing ability is a very significant feature of the software which contributes to the system's ability to recover from even the most catastrophic failure with a very minimum of data loss.
RESET
Periodically, the working files of the data base must be "cleaned up." This process is taken care of by a package of programs known as Reset. Actually there are two reset procedures--one nightly and one monthly. The nightly reset is responsible for erasing from the Back-up Memory System 12 all call records which have already been processed by PIPE. This ensures that the Back-up Memory System 12 never exceeds more than about 25% of its capacity unless there is a failure in the Call-Pricing Computer 14. Also, during the nightly reset, the file containing patient's bills is reviewed for any unauthorized calls, and they are printed and then deleted from the file. Additional reports generated at this time include a Daily Trunk Usage Report, which contains information on call volume handled by each trunk group in 24-hour period; a Patient Phone Activity Report, of which shows month-to-date patient-call activity including dollar volume and profits; and a Hospital Census, which lists all patients currently admitted. Finally, a back-up copy of all data-base files is generated and stored on magnetic tape.
Once a month, the file containing administrative longdistance calls is cleared. This is normally scheduled to take place at the same time the local telephone company ends its billing period. Prior to erasure, these files are used to generate a Departmental Long-Distance Usage Report (showing details of every toll call placed during the month by department) and an Administrative Long-Distance Summary Report (summarizing toll usage by department). Finally, all counters reflecting monthly statistics on call volume are reset to zero. Note that the figure contained in the Daily Trunk Usage Report and Patient Phone Activity Report generated at this time should correspond very closely with the bill furnished by the telephone company for the same period. This feature allows the insitution to monitor the entire system's integrity very closely as well as to detect equipment malfunctions and billing errors which are the responsibility of the phone company.
RESET AFTER MALFUNCTION (RAM)
This program is responsible for picking up the pieces after any equipment malfunction or software malfunction, regardless of the cause. The technique used to provide for automatic recovery after malfunction is to have PIPE update a one-record file every time a call record is processed. This file is called LASTREC and always contains a copy of the last call record processed. Since this file resides on hard disc, it is not damaged in the event of a power failure. In the event of a disc failure, all of the data-base file would be restored from tape, including LASTREC, which would still show the exact state of the system the instant the tape was made.
By referring to this file, the RAM program is able to search the contents of the Back-up Memory System 12 and determine exactly which records need to be processed for the system to be caught up. (The records in the Back-up Memory System 12 are stored in chronological order, so all records between the one matching LASTREC and the newest record have yet to be processed.) This searching and catching-up process is accomplished automatically after the operator completes a brief dialogue with the program.
This automatic restart or reset after malfunction capability is a very important feature of this invention not found in competing products.
HOSPITAL BUSINESS COMPUTER 18
In the event that the hospital has a computer in use which handles the billing of patients for services received during their stay in the hospital, a special interface may be provided to interconnect the Hospital Business Computer 18 to the CallPricing Computer. This interface is accomplished through two data links known as Link A 20 and Link B 22.
Link A 20 connected to an input of the Back-up Memory System 12 which was originally provided for a second PBX system. Records transmitted across this link must match the format of a PBX CDR record. They are transmitted in one direction only, that is from the Hospital Business Computer 18 to the Back-up Memory System 12. When received by the Back-up Memory System 12, these records are merged into chronological order with the records coming from the PBX. From here, they are processed by PIPE just like any other call or "dummy" record. The purpose of this link is to allow the Hospital Business Computer 18 to forward the details of admission and discharge transactions to the Call-Pricing Computer 14 and thus eliminate the requirement for redundant data entry on two separate computer systems.
Link B 22 is connected between an input/output port of the Call-Pricing Computer 14 and a similar port on the Hospital Business Computer 18. Its primary purpose is to allow the transmission of line items for posting on a patient's bill from the Call-Pricing Computer 14. These line items would include bills for calls, debit, credit and delete-last-call transactions. It is also possible for the Hospital Business Computer 18 to request any of the system reports over this line, and have them returned almost immediately.
This intercomputer link is a very important feature of the invention and is probably unique in the industry.
REMOTE COMPUTER SUPPORT
By accessing the system over a dial-up telephone line 24 connected to a Modem 26, it becomes possible for service personnel to perform remote software maintenance and remote hardware diagnosis on the entire system. The Call-Pricing Computer 14 can, on demand, provide access to Back-up Memory System 12, terminal equipment, and the Hospital Business Computer Link A 20. The Back-up Memory System 12, in turn, can provide access to the PBX CDR output and the Hospital Business Computer Link B. Thus nearly all functions of the system may be checked remotely, provided the Modem 26 and the Call-Pricing Computer 14 do not fail. This Modem 26 is also used to place nightly calls to company headquarters for the delivery of nightly reports generated during reset.
UNINTERRUPTABLE POWER SUPPLY (UPS) 28
The Call-Pricing Computer 14, the Back-up Memory System 12, the Modem 26, the Control Console CRT 27, and the Console Printer 30 are all powered by an Uninterruptable Power Supply 28 which delivers a carefully filtered and controlled 117 VAC to this equipment, even in the event of a complete loss of conventional power. The UPS 28 is capable of handling the load to about 30 minutes after a power failure. The UPS 28 in turn is connected to the hospital's emergency-power grid where available, which would not normally have a power failure of over 5 minutes duration. Thus the system is essentially immune to power failures and hardware/software problems caused by power-line transients. The key point here is that as long as the telephones in the building are working, there will be a reliable mechanism for recording the details of every toll call, even in the event of equipment-hardware failure and/or software failure. This, in turn, ensures that the institution will not lose revenue or incur unbillable expenses due to equipment problems.
MODIFICATIONS AND EQUIVALENTS
Because of the modular approach utilized in the design of this computer system, a number of the hardware features outlined above are not required for the system to operate. Although each equipment omission involves some obvious tradeoffs in performance, the system is still able to accomplish its intended purpose. Some examples of the optional hardware features are outlined below.
Terminals: The design calls for the use of a CRT Terminal 27 and an associated Hard-Copy Device 30 (RO teletype equivalent). However, a KSR teletype (or equivalent) terminal may be substituted for both terminals above. The trade-off would involve slower printing of bills and waste of paper for transactions which would not normally require a hard copy.
Back-up Memory System 12: The CDR output from the PBX 10 may be connected directly to the Call-Pricing Computer 14, omitting both the Back-up Memory System 12 and A/B Switch 16. This configuration would sacrifice the redundancy feature provided by the Back-up Memory System 12, and hence an increase in the probability of a hardware failure which would cause the loss of call records.
Uninterruptable Power Supply 28: The Uninterruptable Power Supply (UPS) 28 insures the performance of the system in the event of a power failure or other fluctuation in the power furnished to the Call-Pricing Computer 14 which might adversely affect its performance. If the UPS 28 is omitted, then the system would be susceptible to these problems, and hence its overall integrity would be correspondingly sacrificed.
In each case outlined above, the system would continue to function as designed, because of the redundant nature of the design, but some degree of performance would be sacrificed.
While we have shown and described herein certain embodiments of our invention, we intend to cover as well every change or modification therein which may be made without departing from the spirit and scope of the invention. | A data-collection and -processing system is integrated with an existing Private Branch Exchange (PBX) telephone system to provide a highly automated telephone-usage accounting and billing tool for use in hospitals and other similar institutions having a large and transient clientele base. The system consists of four separate computer systems connected together (and the required applications software which enables them to function as an integrated system) and miscellaneous peripheral hardware.
Working together, the system components provide a detailed accounting of long-distance calls placed by guests and staff personnel. A very high degree of reliability is achieved by the use of redundant and self-checking components. This reliability is further enhanced by the provision for remote software maintenance and hardware diagnosis. | 7 |
BACKGROUND OF THE INVENTION
[0001] The subject matter disclosed herein relates to gasification systems and processes. More particularly, the subject matter relates to removal of particulate layers from gasification system components.
[0002] Gasification is a process for the production of power, chemicals, and industrial gases from carbonaceous or hydrocarbon feedstocks such as coal, heavy oil, and petroleum coke. Gasification converts carbonaceous or hydrocarbon feedstocks into synthesis gas, also known as syngas, comprising primarily hydrogen and carbon monoxide. The resultant syngas is a feedstock for making useful organic compounds or can be used as a clean fuel to produce power.
[0003] In a typical gasification plant, a carbonaceous or hydrocarbon feedstock and molecular oxygen are contacted at high pressures within a partial oxidation reactor (gasifier). The feedstock and molecular oxygen react and form syngas. Non-gasifiable ash material and unconverted and/or incompletely converted feedstock are by products of the process and take essentially two forms: molten slag and smaller particles referred to as “fines”. In some gasification plants, a syngas cooler is located downstream of the gasifier. The syngas, ash, slag and fines cool as they travel through the syngas cooler. A quench process cools and saturates the syngas near the exit of the syngas cooler. Alternatively, in gasification plants without syngas coolers, the quench is located near the exit of the gasifier. Further, additional cooling and/or gas clean-up components may be disposed downstream of the quench. During the cooling process, however, deposits of soot and ash, for example, form on interior surfaces of the syngas cooler, and/or the quench and additional cooling components. The deposits in the syngas cooler create many problems. For example, the deposit layer prevents efficient heat transfer from taking place, resulting in a reduction in steam production from the gasification process. Also, deposits may include corrosive species, thus the removal of the corrosive deposits would prolong the life of components of the syngas cooler, for example, heat transfer tubes. Further, deposits often break off from the interior of the syngas cooler under some operating conditions, for example, startup and shutdown. Such spontaneous liberation of large deposits often results in plugging of downstream components of the syngas cooler. Finally, falling deposits create a hazard for workers performing maintenance and/or repairs in the syngas cooler. Therefore it is desirable to remove the deposits at regular intervals prior to the deposits developing into a substantial size.
BRIEF DESCRIPTION OF THE INVENTION
[0004] According to one aspect of the invention, a method of removing a particulate layer from a gasification system component includes locating a shedding apparatus in operable communication with the gasification system component. A force is transmitted from the shedding apparatus into the gasification system component and the particulate layer is shed from the gasification system component as a result of the vibration.
[0005] According to another aspect of the invention, a syngas cooler for a gasification system includes a vessel and a plurality of thermal energy transfer platens located in the vessel. A shedding apparatus is in operable communication with the plurality of platens and is capable of shedding a particulate layer from the plurality of platens by transmitting a force to the plurality of platens.
[0006] These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0008] FIG. 1 is a plan view of an embodiment of a syngas cooler for a gasification system;
[0009] FIG. 2 is a cross-sectional view of the syngas cooler of FIG. 1 ;
[0010] FIG. 3 is a cross-sectional view of another embodiment of a syngas cooler for a gasification system;
[0011] FIG. 4 is a cross-sectional view of another embodiment of the syngas cooler of FIG. 3 ;
[0012] FIG. 5 is a cross-sectional view of an embodiment of a syngas cooler including a single support;
[0013] FIG. 6 is a cross-sectional view of an embodiment of a syngas cooler including a helical manifold;
[0014] FIG. 7 is an alternative embodiment of the syngas cooler of FIG. 5 ;
[0015] FIG. 8 is an alternative embodiment of the syngas cooler of FIG. 6 ;
[0016] FIG. 9 is a cross-sectional view of yet another embodiment of a syngas cooler;
[0017] FIG. 10 is a cross-sectional view of still another embodiment of a syngas cooler;
[0018] FIG. 11 is a detail view of an embodiment of the syngas cooler of FIG. 10 having a mechanical crank;
[0019] FIG. 12 is a detail view of an embodiment of the syngas cooler of FIG. 10 having an electrical or pneumatic actuator;
[0020] FIG. 13 is a detail view of an embodiment of the syngas cooler of FIG. 10 having a hydraulic jet;
[0021] FIG. 14 is a cross-sectional view of an embodiment of a syngas cooler including a shock tube;
[0022] FIG. 15 is a cross-sectional view of another embodiment of the syngas cooler of FIG. 14 ; and
[0023] FIG. 16 is a cross-sectional view of yet another embodiment of the syngas cooler of FIG. 15 .
[0024] The detailed description explains embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Shown in FIG. 1 is an embodiment of a gasification system component, in this case a syngas cooler 10 . The syngas cooler 10 comprises a vessel shell 12 which defines an outer surface of the syngas cooler 10 . A plurality of internal components may be disposed inside of the vessel shell 12 in an interior 14 of the syngas cooler 10 . Many of these components, including a tube cage 16 and one or more sets of platens 18 , are configured and disposed to facilitate transfer of thermal energy from syngas in the syngas cooler 10 to the tube cage 16 and/or the platens 18 . While eight sets of platens 18 are shown in FIG. 1 , it is to be appreciated that other quantities of sets of platens 18 , for example 10 or 12 sets of platens 18 may be arranged in the interior 14 of the syngas cooler 10 . As shown in FIG. 2 , the tube cage 16 comprises a plurality of individual cage tubes 20 and each set of platens 18 comprises a plurality of platen tubes 22 . During operation of the syngas cooler 10 , particulates in the syngas accumulate and build up creating layers 24 of particulates on, for example, heat exchange surface such as the platen tubes 22 and the cage tubes 20 . The deposit layers 24 inhibit efficient thermal energy transfer from the syngas to the platen tubes 22 and the tube cages 20 .
[0026] To periodically remove the layers 24 , in some embodiments the syngas cooler 10 includes one or more sprayers 26 , as shown in FIGS. 1 and 2 . The sprayers 26 are disposed at the interior 14 of the syngas cooler 10 . When the sprayers 26 are activated, a high pressure flow 28 of fluid, in some embodiments, water, is directed from the sprayers 26 toward the platen tubes 22 , thereby removing the layers 24 therefrom. The flow 28 acts to remove the layers 24 by mechanically shearing the layers 24 from the platen tubes 22 and also by chemically dissolving the layers 24 in the flow 28 . Further, because of a temperature differential between the flow 28 and the layers 24 , when it impacts the layers 24 the flow 28 causes thermal contractions in the deposit layers 24 thus causing the layers 24 to fall off of the platen tubes 22 . As shown in FIG. 2 , the sprayers 26 may be arranged around a circumference of the interior 14 , and as shown in FIG. 1 , may also be arranged along a length of the interior 14 . Further, in some embodiments, each sprayer 26 is capable of spraying in a predetermined pattern along the platen tubes 22 to increase the amount of platen tube 22 surface exposed to the flow 28 . Alternatively, in some embodiments, the sprayers 26 are configured and disposed to spray solid projectiles, for example, ball bearings, of a desired size at the platen tubes 22 to remove the layers 24 .
[0027] In some embodiments, the means to remove layers 24 from the sets of platens 18 is a mechanical structure that causes a vibration of the platen tubes 22 sufficient to cause the layers 24 to be liberated from the platen tubes 22 . For example, as shown in FIG. 3 , a vibration manifold 30 is disposed in the interior 14 of the syngas cooler 10 . The vibration manifold 30 is mechanically attached to the sets of platens 18 by one or more struts 32 , which in some embodiments are springs. At least one support 34 extends through the vessel shell 12 from an exterior 36 of the syngas cooler 10 through a support opening 38 . In some embodiments, the support opening 38 includes a ball bearing 40 arrangement at which the support 34 is disposed. In the embodiment of FIG. 3 , the manifold 30 is substantially circular in shape, and two supports 34 are utilized and are disposed at substantially the same circumferential position in the vessel shell 12 . It is to be appreciated that in other embodiments, as shown in FIG. 4 , the supports 34 may be located at other relative circumferential locations, for example 180 degrees apart. Further, as shown in FIG. 5 , a single support 34 may be utilized. Referring again to FIG. 3 , flex hoses 42 are coupled to the supports 34 to provide a conduit for a flow of cooling fluid through the supports 34 and the manifold 30 to extend the useful life of the manifold 30 in the high temperature environment of the interior 14 . In the embodiment of FIG. 3 , a vibratory force is initiated by an activator, such as a mechanical crank 44 . In some embodiments, the mechanical crank 44 is driven by a magnetic actuator comprising members of opposing polarity that urge rotation of the mechanical crank 44 without direct contact with the mechanical crank 44 . Turning of the mechanical crank 44 initiates a rotation of the support 34 , which induces a vibratory force in the manifold 30 . The vibration of the manifold 30 is transmitted to the sets of platens 18 via the one or more struts 32 thus causing the platen tubes 22 to vibrate and cause the layers 24 to be removed from the platen tubes 22 . While the manifold 30 shown in FIG. 3 is substantially circular in shape, as shown in FIG. 6 , the manifold 30 may be helical in shape extending in at least one direction along a manifold axis 46 . A helical manifold 30 allows for greater flexibility to improve the vibratory capacity of the manifold 30 and for the placements of additional struts 32 fixed to the platens 20 along a length of the platens 20 .
[0028] Referring again to FIG. 5 , in some embodiment the manifold 30 may be supported by a single support 34 . The support 34 extends through vessel shell 12 and comprises an outer support 50 that extends through the vessel shell 12 , and an inner support 52 that is affixed to the manifold 30 . The outer support 50 and the inner support 52 are coupled to each other by, for example, a bellows coupling 54 . In another embodiment, as shown in FIG. 7 , the outer support 50 and inner support 52 are coupled to each other by a wound tube 56 . In the embodiment of FIG. 5 , the vibratory force is initiated by one of several means including a mechanical hammer or crank 58 , an electrically or pneumatically-induced vibration, and/or by a fluid pulse through the outer support 50 . The force is transmitted through the outer support 50 and the bellows coupling 54 to the manifold 30 via the inner support 52 . The vibratory force is then transmitted through the one or more struts 32 to the platen tubes 22 to remove the layers 24 . Referring now to FIG. 8 , some embodiments may include a helical manifold 30 together with the bellows coupling 54 . Further, the manifold 30 may be supported by more than one support 34 , for example, two supports 34 , each including a bellows coupling 54 . Use of the bellows couplings 54 allows the outer supports 50 to remain in a fixed position while the inner supports 52 freely vibrate in response to the vibratory force.
[0029] Referring to FIG. 9 , in some embodiments, the one or more struts 32 are coupled directly to the inner support 52 so the vibratory force is transmitted directly from the inner support 52 to the one or more struts 32 . Referring to FIG. 10 , the vibratory force may be initiated internally to the inner support 52 . For example, referring to FIG. 11 , the crank 58 may be disposed inside of the inner support 52 and when activated, initiates vibration of the inner support 52 . As shown in FIG. 12 , an electrical or pneumatic actuator 60 may be similarly disposed in the inner support 52 to initiate vibration thereof. Further, as shown in FIG. 13 , a hydraulic jet 62 or water hammer disposed in the inner support 52 may initiate vibration of the inner support 52 . Initiating the vibratory force in the inner support 52 increases efficient transmission of the vibratory force since it is not necessary to transmit the vibratory force to the inner support 52 via the outer support 50 and the bellows coupling 54 .
[0030] Referring now to FIG. 14 , some embodiments may utilize one or more shock tubes 64 to impart the vibratory force on the platens 20 . Each shock tube 64 includes a shock tube body 66 that extends through an opening 68 in the tube cage 16 . In one embodiment, since syngas is normally present in the shock tube 64 , a quantity of oxygen is injected into the shock tube 64 , which ignites the syngas fuel. The combustion process results in a shock wave 70 which imparts a force on the set of platens 18 . The force initiates vibration of the set of platens 18 which removes the layers 24 from the platen tubes 22 . As shown in FIG. 15 , the one or more shock tubes 64 may be utilized to initiate vibration of a manifold 30 . The manifold 30 is coupled to one or more struts 32 which transmit the vibratory force initiated by the one or more shock tubes 64 to the sets of platens 18 . In this embodiment, flexibility in the manifold 30 design enables high tunability to achieve a desired amount of vibration. Further the manifold 30 serves to isolate the combustion process from the syngas in the syngas cooler 10 . In other embodiments, as shown in FIG. 16 , the shock tube 64 apparatus is isolated from the manifold 30 by a diaphragm 72 disposed in the one or more supports 34 . When initiated, the shock tube 64 causes the diaphragm 72 to vibrate, which in turn transmits the vibration through a gas or fluid, for example, nitrogen, disposed in the support 34 and manifold 30 . The shock tube 64 exhausts through an exhaust tube 74 so that exhaust gases are isolated from the remainder of the system.
[0031] It is to be appreciated that while the description of the embodiments herein are illustration in relation to a syngas cooler 10 , application of the embodiments to other components, for example, a quench or other components of a gasification system, is contemplated within the present scope.
[0032] While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims. | Disclosed is a method of removing a particulate layer from a gasification system component including locating a shedding apparatus in operable communication with the gasification system component. A force is transmitted from the shedding apparatus into the gasification system component and the particulate layer is shed from the gasification system component as a result of the force. Further disclosed is a syngas cooler for a gasification system including a vessel and a plurality of thermal energy transfer platens located in the vessel. A shedding apparatus is in operable communication with the plurality of platens and is capable of shedding a particulate layer from the plurality of platens by transmitting a force to the plurality of platens. | 5 |
RELATED APPLICATION AND CLAIM OF PRIORITY
This application claims domestic priority under 35 U.S.C. §119(e) from prior U.S. provisional application Ser. No. 60/668,351, filed Apr. 5, 2005, entitled “PROBE PAD STRUCTURE IN A MULTILAYER CERAMIC SPACE TRANSFORMER,” the contents of which is hereby incorporated herein by reference in its entirety for all purposes as if fully set forth herein.
FIELD OF THE INVENTION
The present invention generally relates to a probe pad structure in a ceramic device.
BACKGROUND
In recent years, there has been a tremendous push to miniaturize all electrical components, including integrated circuits and other computer chip products. The reduction in the size of ICs has placed a demand on test systems to determine new ways to achieve the tighter spacing needed to test the contact pads of the ICs.
Current processes utilize lithography to produce pad structures of copper and polyimide that have a tight-pitch of 150 μm or less. In these conventional processes, the resulting pads are pliable due to the fact that the pads are routed by copper/polyimide with a flexible polyimide located below the pad. As a result, wire bonding cannot be performed on these pads in a consistent manner.
Recently, a process called Chemical Mechanical Polishing (CMP) was developed to remove material from uneven topography on a wafer surface until a flat (planarized) surface is created. This allows subsequent photolithography to take place with greater accuracy, and enables film layers to be built up with minimal variations in height. CMP combines the chemical removal using a base fluid solution with a mechanical effect provided by abrasive polishing. CMP has particular applicability in the fabrication of copper-based semiconductors, where it is used to define the copper wiring structures.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:
FIG. 1 graphically depicts the performance of steps 1-8 according to an embodiment of the invention;
FIG. 2 graphically depicts the performance of steps 9-15 according to an embodiment of the invention;
FIG. 3 graphically depicts the performance of steps 16-19 according to an embodiment of the invention; and
FIG. 4 graphically depicts the performance of steps 42-43 according to an embodiment of the invention.
DETAILED DESCRIPTION
In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the embodiments of the invention presented herein. It will be apparent, however, that the embodiments of the invention presented herein may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to avoid unnecessarily obscuring the embodiments of the invention presented herein.
Embodiments of the invention relate to a novel manufacturing process for forming probe pads on copper pedestals. Embodiments of the invention have particular application in tight-pitch area arrays ceramics, such as a multilayer ceramic in a space transformer.
An embodiment of the invention is best understood through the following description of process steps that produce a space transformer with improved copper surface planarity. FIGS. 1-4 graphically depict the performance of the following process steps. The process is described as it relates to the formation of three copper layers on a polyimide (PI). The formation of three copper layers is described for purposes of providing a clear example, but any number of copper layers may be used in forming a copper pedestal. As a result, it should be noted that steps 20-41 in the below process correspond to a repetition of steps 9-19 in the illustrations.
PROCESS STEPS TO CONSTRUCTIVE A CERAMIC DEVICE ACCORDING TO AN EMBODIMENT
Step 1. Start with a finished multilayer ceramic (MLC) that has multiple metal vias on the surface. In an embodiment, the via pitch is about 200 μm or larger.
Step 2. Grind the MLC surface to reach a reasonable flatness. In an embodiment, the linear flatness is about 3 μm per linear inch. The surface texture should be such that good adhesion to plated copper can be assured.
Step 3. Deposit a layer of copper over substantially the entire MLC surface. In an embodiment, the layer of copper is a thin layer, e.g., about 1 to 3 μm in thickness.
Step 4. Coat substantially the whole surface with a thick photo resist layer. Any conventional photo resist material can be used. In an embodiment, the photo resist layer may be about 25 or 30 μm in thickness.
Step 5. Define the capture pads openings in the photo resist layer. The capture pad openings are defined by exposing and developing openings in the photo resist layer, thereby forming copper pedestal pads. Underneath some of the copper pedestal pads will be the ends of MLC via metal traces. Underneath the remaining copper pedestal pads, there will be no metal traces of the MLC. Instead, these copper pedestals are sitting directly on the rigid MLC surface. The copper layer that was deposited in step 3 will now be exposed. In an embodiment, the copper layer is not etched.
Step 6. Pattern plate a layer of cooper. In an embodiment, the layer of copper is a thick layer, e.g., about 20 μm thick. Pattern plating involves the electrolytic plating of a thick layer of copper on the portions of the copper layer that were exposed in step 5. In an embodiment, the plating thickness is less than the photo resist thickness. In an embodiment, the copper thickness may be as uniform as possible across the wafer.
Step 7. Remove the photo resist layer, thereby exposing the entire copper surface. At this stage, the copper thickness over the copper pedestal pads may be about 21 to 23 μm. The thickness of the copper over the remaining area may be about 1 to 3 μm.
Step 8. Dip-etch a portion of the thickness of the original copper layer. In an embodiment, the portion of the thickness of the original copper layer dip-etched in step may be about 2 to 4 μm thick. In such an embodiment, this will result in the reduction of about 2 to 4 μm of the copper thickness over the pedestal pads. After performing step 8, the remaining area will have the copper completely removed, leaving the MLC surface visible. At this stage, the copper pedestals are electrically isolated, unless they are connected inside the MLC by internal wirings. The height uniformity of the pedestals across the MLC substrate is primarily determined by the plating uniformity at step 6.
Step 9. Apply a coating of polyimide (PI) to form a layer of PI on the MLC substrate. In an embodiment, the layer of PI is formed with a thickness of about 45 to 55 μm. If application of a single coat of PI is not possible or economical, the PI layer can be formed using more than one coating to obtain the desired thickness.
Step 10. Grind the PI layer to reach a desired degree of flatness. In an embodiment, the thickness of the PI layer over the copper pedestals may be about 20 μm.
Step 11. Apply a photo resist coating on top of the PI layer. Expose and develop openings in the photo resist layer for via holes to access the copper pedestal pads.
Step 12. Etch the via openings in the PI layer, then strip off the remaining photo resist.
Step 13. Pattern plate copper over the via holes. In an embodiment, the thickness of the copper layer slightly over-fills the via holes in the PI layer. For example, the thickness of the copper layer may be about 22 to 25 μm.
Step 14. Grind the surface, such as through a Chemical Mechanical Polishing (CMP) process, to remove excess copper in the via holes plus a small amount of PI so that the whole surface is flat. If the copper layer in Step 13 does not overfill the via holes, then Step 14 would involve removing some PI first, then removing a thin layer of PI and copper using a CMP process.
Step 15. Plate a layer of copper over the entire surface. In an embodiment, the layer of copper plated over the entire surface may be thin, e.g., about 1 to 2 μm.
Step 16. Apply photo resist to the entire surface. In an embodiment, the photo resist layer is about 25 to 30 μm thick. Next, define the metal patterns for accessing the vias as well as for the wirings over the PI layer, including any jump wire patterns.
Step 17. Pattern plate another layer of copper. In an embodiment, the layer of copper may be formed thinner than that of the photo resist, e.g., the layer of copper may be up to 20 μm thick. The resulting layer of copper will cover both the copper wiring and the copper vias.
Step 18. Strip off the photo resist layer using a conventional stripping process.
Step 19. Dip etch the thin copper layer to remove a layer of copper. After the etching step, the PI surface between copper wiring should be visible. For example, the layer of copper removed may be about 2 to 320 μm thick. At this stage, the surface planarity is primarily determined by the thickness control of Step 17.
If only one copper wiring layer is needed, the process can proceed to Step 42. Otherwise, then the following steps are part of the process that may be followed in order to form a second copper wiring layer for wirings.
Step 20. Apply a coating of PI. In an embodiment, the coating of PI added in step 20 may be about 45 to 55 μm thick. If application of a single coat is not possible or economical, the PI layer can be formed using more than one coating to obtain the desired thickness.
Step 21. Grind the surface of the PI layer to achieve the desired flatness. At this point, the thickness of the PI layer over the first copper wiring lines is about 20 μm.
Step 22. Apply photo resist to the entire layer and then define the via openings in the photo resist for accessing the vias.
Step 23. Etch the via openings in the PI layer, then strip off photo resist.
Step 24. Pattern plate another copper layer over the via openings. In an embodiment, the copper layer may have a thickness of about 22 to 25 μm. The copper layer should slightly over-fill the via holes in the PI.
Step 25. Grind the surface to remove excess copper in the via holes plus a small amount of PI so that the whole surface is flat.
Step 26. Apply a layer of copper over the entire surface. In an embodiment, the layer of copper is thin, e.g., about 1 to 2 μm in thickness.
Step 27. Apply photo resist to the entire surface. In an embodiment, the photo resist layer may have a thickness of about 25 to 30 μm. After the photo resist layer is applied, define the metal patterns for accessing the vias as well as for the wirings over the PI, including jump wires patterns.
Step 28. Pattern plate a layer of copper. In an embodiment, the copper layer may have a thickness of up to about 20 μm. This copper layer may have a thickness that is less than the thickness of the photo resist layer.
Step 29. Strip off the photo resist layer.
Step 30. Dip etch the copper layer (for example, about 1 to 2 μm in thickness). At this time, the PI surface between copper wiring should be visible. The surface planarity is primarily determined by the thickness control of Step 28.
If only two copper wiring layers are required, then the process can proceed to Step 42. If an additional copper wiring layer is needed, then the following steps may be followed.
Step 31. Apply a coating of PI. In an embodiment, the coating of PI may have a thickness of about 45 to 55 μm. If application of a single coat is not possible or economical, the PI layer can be formed using more than one coating to obtain the required thickness.
Step 32. Grind the surface of the PI layer to achieve the desired flatness. In an embodiment, the thickness of the PI layer over the second copper wiring lines at this point may be about 20 μm.
Step 33. Apply photo resist to the entire layer and then define the via openings in the photo resist for accessing the vias.
Step 34. Etch the via openings in the PI layer, then strip off photo resist.
Step 35. Pattern plate another copper layer. In an embodiment, the copper layer may have a thickness of about 22 to 25 μm. The copper layer should slightly over-fill the via holes in the PI.
Step 36. Grind the surface to remove excess copper in the via holes plus a small amount of PI so that the whole surface is flat.
Step 37. Apply a layer plating of copper over the entire surface. In an embodiment, the layer of copper applied may be thin, e.g., about 1 to 2 μm in thickness.
Step 38. Apply photo resist to the entire surface. In an embodiment, the photo resist layer may have a thickness of about 25 to 30 μm. After the photo resist layer is applied, define the metal patterns for accessing the vias as well as for the wirings over the PI, including jump wires patterns.
Step 39. Pattern plate a layer of copper. In an embodiment, the copper layer may have a thickness of up to about 20 μm thick. Thus, this copper layer may have a thickness that is less than the thickness of the photo resist layer.
Step 40. Strip off the photo resist layer using a conventional stripping process.
Step 41. Dip etch the copper layer (for example, about 1 to 2 μm in thickness). At this time, the PI surface between copper wiring should be visible. The surface planarity is primarily determined by the thickness control of Step 39.
The following are the finishing steps to promote the planrization of the probing pads.
Step 42. Apply a coating of PI to form a layer that is thicker than the copper wiring. Thereafter, grind the PI layer until the copper metal in the wirings and probing pads are clearly defined. Note that the probing pads and the surrounding PI are at the same height at the completion of this step.
Step 43. Pattern plate the probing pad. For example, the probing pads may be platted with nickel and gold.
Embodiments of the invention have been determined to provide significant advantages over prior approaches. For example, using embodiments of the invention, every MLC via will have a copper pedestal that is fully resting on the MLC surface. Taking into account the MLC shrinkage tolerance, the diameter of such a pedestal should be large enough to cover the MLC vias. Also, it is possible to place copper pedestals in locations where no MLC vias exist. Since there is no MLC via underneath in this case, the diameter of such a pedestal can be smaller, allowing it to be placed in a tight area.
The process, according to embodiments of the invention, result in a vertical arrangement of a copper pedestal, a metal via, and a pad in a stack. As such, it provides the pad with the support necessary for a probing or bonding operation. While the mechanical strength of PI is lower than that of copper, embodiments of the invention alleviate this issue by providing a continuous copper column in each stack, thereby providing greater support than that of the PI layer.
Embodiments of the invention also provide excellent surface planarity for every pad on the space transformer top surface. Good surface planarity is important for whole area array probing. Additionally, embodiments of the invention eliminate the photo resist grinding steps that are part of conventional manufacturing processes. | A method for manufacturing a ceramic device is provided. The ceramic device comprises a ceramic layer. A polyimide layer is on the ceramic layer. The polyimide layer has disposed therein a plurality of copper vias. Each copper via is in physical contact with the ceramic layer. A plurality of pads are formed on the polyimide layer. Each of the plurality of pads is in physical contact with a copper via of the plurality of copper vias. In this way, the pads are supported by a continuous copper arrangement, thereby providing greater support for the probe pads than if the probe pads were supported by the polyimide layer, as the mechanical strength of polyimide layer is lower than the mechanical strength of copper. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to German Patent Application No. 102 47 136.3 filed Oct. 9, 2003, which application is herein expressly incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a protective apparatus for securing to a component movable along a track and for the monitoring of a protected zone to be moved with the component as well as to a method for the monitoring of a protected zone which has to be moved together with a component moved along a path.
BACKGROUND OF THE INVENTION
[0003] Machines are used in many areas which have components moved automatically by a drive device or which are moved themselves. If persons are standing in the movement zone of these components, the persons can be potentially at risk from the movement of the components. For the protection of people, protective apparatuses can therefore be arranged at the moved component at such machines which allow a monitoring of a protected zone moved along with the component. If the presence of a person is detected in the moved along protected zone, the movement of the component can be interrupted.
[0004] An example for such a machine is a bending press which is shown schematically in part in FIG. 1 and which has a bending tool 10 driven by a drive device not shown in FIG. 1 and having, for example, a lower side formed in a V shape and a stationary lower tool 12 whose upper side can, for example, have a V groove corresponding to the shape of the lower side of the bending tool 10 . For the shaping of a workpiece 14 , it is placed by an operator onto the lower tool 12 . To achieve a short cycle time, the bending tool 10 is moved from a starting position at high speed along a direction of movement B toward the workpiece 14 , but is then braked again such that it impacts the workpiece 14 at a lower speed suitable for the bending process and presses said workpiece into the lower tool 12 . The slowing down of the movement of the bending tool 10 can not take place instantaneously due, among other things, to its inertia. The path which is necessary to brake the bending tool 10 down from the fast speed to a standstill is also termed the trailing path N.
[0005] For the protection of a person who places workpieces 14 into the bending press, a light transmitter 20 and a light receiver 22 are attached to two holding arms 16 and 18 and together form a one-way light barrier. The light transmitter 20 , which has a light source 24 and a focusing optical transmitting system 26 , radiates a substantially parallel transmitted light beam 27 at a distance to the trailing path N parallel to the lower side of the bending tool 10 onto the light receiver 22 which has a photo-detection element with evaluation electronics 28 and an optical reception system 30 for the focusing of the received light ray onto the photo-detection element 28 with the evaluation electronics. The evaluation electronics are made such that, when the light path between the light transmitter 20 and the light receiver 22 is interrupted, a signal can be emitted to the drive device so that it brakes the movement of the bending tool 10 as fast as possible. The parallel transmitted light beam emitted by the light transmitter 20 therefore defines a protected zone which prevents injury to a person thanks to its distance from the lower side of the bending tool 10 corresponding to the size of the trailing path N.
[0006] In practice, however, vibrations of the holding arms 16 and 18 occur due to the movement of the bending tool 10 , whereby the light transmitter 20 , and thus also the parallel transmitted light beam 27 emitted by the light transmitter, is, for example, tilted relative to the light transmitter 20 (illustrated in FIG. 1 by short-dotted lines). Due to the long light path, even small angles of tilt can result in large movements of the transmitted light beam 27 in the plane of the light receiver 22 , and in particular in a migration from a reception surface of the light receiver 22 . The transmitted light beam 27 can thereby no longer be received by the light transmitter 22 even without the presence of a body part of a person between the bending tool 10 and the workpiece 14 . The evaluation optics will therefore detect an interruption of the light path such that the bending press is stopped. This increases the downtimes of the bending press in an unnecessary manner.
[0007] To reduce the downtime, a reception surface of the light receiver 22 can alternatively be enlarged such that the transmitted light ray 27 of the light transmitter 20 does not migrate so easily from the light receiver 22 on vibrations. However, the case can then occur that the presence of a body part of a person between the bending tool 10 and the workpiece 14 —in FIG. 1, for example, close to the light receiver 22 —cannot be detected although it is at a distance beneath the bending tool 10 inside the trailing path N. This then means a reduction in labor safety.
[0008] Bending presses secured in this manner therefore have the disadvantage that they either conceal increased safety risks for the operators or have undesirably high downtimes.
SUMMARY OF THE INVENTION
[0009] It is therefore the underlying object of the present invention to provide a protective apparatus for securing to a component movable along a track and for the monitoring of a protected zone to be moved with the component, which has good functional reliability, as well as a method for the monitoring of a protected zone which has to be moved along with a component moved along a track.
[0010] The object is satisfied by a protective apparatus having the features of claim 1.
[0011] The protective apparatus in accordance with the invention for securing to a component movable along a track and for the monitoring of a protected zone to be moved with the component includes a light transmitter for the radiation of a divergent transmitted light beam into a spatial zone containing the protected zone, a light receiver for the reception of at least some of the light of the transmitted light beam of the light transmitter radiated into the spatial zone and for the emitting of corresponding received signals and a restriction device which is arranged after a section of the transmitted light path, which contains the protected zone in the direction of a transmitted light path and by means of which the transmitted light beam can be restricted to a less divergent received light beam defining the width of the protected zone in at least one direction.
[0012] The object is furthermore satisfied by a method for the monitoring of a protected zone having the features of claim 21.
[0013] In the method in accordance with the invention for the monitoring of a protected zone which has to be moved along with a component moved along a track, a divergent transmitted light beam is transmitted and moved along with the component, the divergent transmitted light beam is restricted after covering a light path including the protected zone to a less divergent received light beam moved along with the component and defining the width of the protected zone in at least one direction and the received light beam is received and monitored.
[0014] The component along with which the protected zone is to be moved can principally be any desired component movable along a path, preferably along a fixedly pre-determined path, and in particular movable by an at least semi-automatic drive.
[0015] The protective apparatus in accordance with the invention is provided for securing to this component for the moving along of the protected zone.
[0016] In accordance with the invention, a divergent transmitted light beam is transmitted and moved along with the component. For this purpose, the light transmitter is provided for the radiation of the divergent transmitted light beam into a spatial zone containing the protected zone such that both this spatial zone and the transmitted light beam can be moved along with the component. The light transmitter can include a light source for example for light in the visible or in the infrared wavelength of light and, optionally, an optical transmitter system for the shaping of the divergent transmitted light beam from light emitted by the light source. The transmitted light beam is divergent in at least one direction of divergence, i.e. in particular in a sectional plane through the transmitted light beam along a direction of propagation of the light.
[0017] The restriction of the transmitted light beam in accordance with the invention takes place in the protective apparatus in accordance with the invention by the restriction device which is arranged such that the transmitted light beam is restricted at the earliest after covering a path containing the protected zone in the direction of divergence of the transmitted light beam. The restriction device can therefore also be moved along with the component and can in particular be held at it.
[0018] A part beam of the light of the divergent transmitted light beam determined by the restriction device is furthermore received and monitored after the restriction as a received light beam moved along with the component. In the apparatus in accordance with the invention, the light receiver serves for this purpose which is to be secured to the component, can then be moved along with the component and can, for this purpose, have a photo-detection element for light of the light transmitter and, optionally, an optical reception system for focusing the received light beam onto the photo-detection element.
[0019] The transmitted light beam, which is divergent contrary to the prior art, does not define the protected zone, but only contains it, in accordance with the invention.
[0020] The definition of the protected zone rather takes place in that the divergent transmitted light beam is restricted after covering the light path including the protected zone to a less divergent received light beam determining the width of the protected zone in at least one direction. The received light beam can in particular also be parallel or even convergent. The term of the less divergent received light beam therefore includes these two alternatives in the sense of the present invention. A narrower, that is less divergent, part beam is therefore so-to-say cut out of the divergent, i.e. spread out, transmitted light beam by the restriction, said part beam defining the protected zone and being received and monitored after the restriction or after the restriction device as a received light beam moved along with the component. Only the blocking of the part beam, and thus of the corresponding received light beam, is therefore monitored such that it, and in particular its width, in one direction or the part beam and its corresponding width define the protected zone. The restriction device therefore determines the part beam of the transmitted light beam between the light transmitter and the restriction device which can be received by the light receiver as the received light beam and thus defines the protected zone.
[0021] On a movement of the transmitted light beam by vibrations in a direction in which the transmitted light beam is divergent and in which a restriction takes place, only one other part beam of the transmitted light beam is used as the received light beam. The position of the protected zone, however, remains the same, since the received light beam or the restriction device are moved along with the component and a vibration-determined movement of the restriction device or of the light receiver only results in small displacements of the protected zone, but not in pivot movements with some large deflections of the part beam.
[0022] The protected zone can therefore also be held in a constant position relative to the component on a vibration of the light transmitter by a suitable arrangement of the restriction device.
[0023] A transmitted light beam is expediently used which is divergent at least in a direction tangential to the track of the component, for which purpose the light transmitter has to be aligned correspondingly. The restriction then takes place in the same direction, which can take place by a corresponding arrangement of the restriction device. The protected zone can be moved along in front of the component in this manner.
[0024] A migration of the transmitted light beam from the light receiver is thus largely avoided such that an interruption of the light path caused by a relative movement of the light transmitter and of the light receiver and an incorrect report of an infringement of the protected zone which thus takes place and which can, for example, result in a braking of the component is avoided.
[0025] A particularly large functional reliability of the protective apparatus in accordance with the invention thus also results on vibrations of the component to which the protection device is secured.
[0026] The use of a divergent transmitted light beam furthermore allows a particularly simple adjustment of the light transmitter relative to the restriction device or to the light receiver since, on a tilting of the light transmitter relative to the light receiver, only a different part beam of the transmitted light beam can be received as the received light beam.
[0027] Further developments and preferred embodiments of the invention are described in the description, in the claims and in the drawings.
[0028] An aperture angle of the transmitted light beam which determines the divergence of the transmitted light beam in the direction of divergence can preferably be selected, among other things, in dependence on the spacing between the light transmitter and the restriction device, since this spacing, together with the aperture angle, forms the width of the transmitted light beam at the restriction device. It is preferred for an aperture angle of the transmitted light beam to be selected such that a width of the transmitted light beam in a pre-determined direction orthogonal to the transmitted light path directly in front of the restriction device is larger by a factor of 10 than a corresponding width of the received light beam directly at the restriction device. Such a large divergence of the transmitted light beam relative to that of the received light beam allows a particularly simple adjustment and a high functional reliability, in particular if the pre-determined direction is arranged tangentially to the track of the component after the fitting to the component.
[0029] When the aperture angle of the transmitted light beam is pre-determined independently of the special features of the component, and in particular of its movement, a comparatively large amount of light of the light transmitter can remain unused during the total operation due to the divergence of the transmitted light beam. It is therefore preferred for an aperture angle of the transmitted light beam to be selected such that a width of the transmitted light beam directly at the restriction device is larger in a pre-determined direction orthogonal to the transmitted light path than a mean movement amplitude of the transmitted light beam to be expected caused by a relative movement of the light transmitter and the restriction direction directly at the restriction device. In this manner, with a given functional reliability, as much light as possible of the light transmitter is also actually used for the monitoring of the protected zone on the operation of the protective apparatus.
[0030] The restriction device can generally include any desired means by means of which the divergent transmitted light beam can be restricted in its width to the received light beam in the pre-determined direction. It can, for example, be a restriction of the light-sensitive surface of the photo-detection element. It is, however, preferred for the restriction device to include a diaphragm. Such a restriction device is in particular suitable for use in one-way light barriers, i.e. for the case that the light transmitter and the light receiver are arranged on opposing sides of the protected zone. The protected zone can be defined very easily by the shape and size of the diaphragm restricting the transmitted light beam. The diaphragm can in particular also be made as a part of the light receiver.
[0031] It is furthermore preferred for a reflecting element to be used for the restriction of the transmitted light beam. In particular, it is preferred in the protective device in accordance with the invention for the restriction device to include a reflecting element at which a part beam of the divergent transmitted light beam to be supplied to the light receiver can be reflected. The reflecting element acting in a reflecting manner for light of the light transmitter thus acts in a similar manner to a diaphragm in that only light of the transmitted light beam incident onto the surface of the reflecting element is reflected as the received light beam. The size, shape and alignment of the reflecting surface, which is preferably surrounded by a region reflecting the light of the light transmitter not at all or only a little, determine the width or divergence of the received light beam and the direction in which the transmitted light beam is restricted. Furthermore, it simultaneously allows a deflection of the light path.
[0032] In another embodiment of the invention, it is preferred for a retro-reflective element to be used for the restriction of the transmitted light beam. For this purpose, it is preferred in the protective apparatus in accordance with the invention for the restriction device to include a retro-reflective element at which a part beam of the divergent transmitted light beam to be supplied to the light receiver can be reflected. A retro-reflective element is here understood as an element which reflects back the incident light again in the direction of the incident light. The retro-reflective element can in particular be a 90° prism, a triple reflector or appropriate reflection foils. Even when the retro-reflective element is tilted with respect to the light transmitter, light can thus again be reflected back in the direction of the light transmitter. Analogously to the case of the reflecting element of a restriction device, the size, shape and alignment of the retro-reflective element or of its optically effective surface also determine the effect on the transmitted light beam here. The resulting received light beam can in particular be convergent.
[0033] In the two aforesaid alternatives, it is particularly preferred for the light transmitter and the light receiver to be arranged on the same side of the protected zone. The protective apparatus therefore then includes a special reflection light barrier in which the light transmitter and the light receiver can preferably be arranged in one housing. The arrangement of the light transmitter and the light receiver on the same side of the protected zone in particular allows a particularly simple adjustment of the light transmitter and of the light receiver even before the mounting to the component.
[0034] In this case, it is furthermore particularly preferred for the light transmitter and the light receiver to have a common beam splitter and a common transmission/reception lens arranged after the beam splitter at least in the transmission direction. The beam splitter, which can in particular include a semi-transmitting mirror, allows a spatially separated arrangement of a light source of the light transmitter and of a photo-detection element of the light receiver, although the transmitted light beam and the received light beam overlap at least in the region of the transmission/reception lens. In this manner, an optical transmission system and an optical reception system of the protective apparatus in accordance with the invention are at least partly integrated, which results, in particular in conjunction with a retro-reflective element as the restriction device, in a simple design with a simultaneously high accuracy of the beam guiding.
[0035] It is furthermore preferred for the light receiver to have at least one reception element whose reception surface has a greater extent in a divergence direction of the received light beam which corresponds to the direction in which the divergent transmitted light beam has been restricted by the restriction device than in a direction orthogonally thereto. This reception element can in particular be a photo-detection element. As previously mentioned in connection with the term of the less divergent reception light beam, the received light beam does not necessarily have to be divergent in the direction of divergence, but can also be parallel or convergent. In this manner, a migration of the received light beam from a reception surface of the reception element, which is caused by a tilting of the light transmitter and/or of the light receiver or of the restriction device with a reflecting or retro-reflective element, can be avoided at least with small tilting angles. The extent of the reception element in the direction of divergence of the received light beam is particularly preferably larger by a factor of at least 4 than its extent in a direction orthogonal thereto.
[0036] To achieve a particularly high light intensity on a photo-detection element of the light receiver, the light transmitter preferably has an optical transmission system and/or the light receiver preferably has an optical reception system. To obtain an increased depth of field, it is then preferred for the light receiver to have a slit diaphragm whose slit is arranged parallel to a direction of divergence of the received light beam which corresponds to the direction in which the divergent transmitted light beam can be restricted by the restriction device. The slit is aligned parallel to the direction of divergence of the received light beam at the location of the slit; this means that the direction of divergence is defined with respect to the direction of the received light beam. An increased depth of field is thus achieved in the direction of divergence of the received light beam, but not in a direction orthogonal thereto, which is in particular not necessary when asymmetric reception elements are used. The accuracy requirements for the adjustment of the diaphragm or of the light receiver in the direction of the slit as well as the accuracy requirement on production are hereby reduced.
[0037] In accordance with the invention, the transmitted light beam only needs to be divergent in a direction which is preferably aligned tangentially to the track along which the component is moved. A very narrow, i.e. almost linear, protected zone, can then result. It is, however, desirable for many applications for an a real protected zone to be monitored. It is therefore preferred for the light transmitter to be designed such that a transmitted light beam can be emitted by it which diverges to a different extent in two directions orthogonal to one another. Whereas, for example, an aperture angle selected in accordance with the aforesaid criteria can be provided in a direction in which the restriction device restricts the divergent transmitted light beam, the transmitted light beam can, for example, be selected to substantially diverge less in a direction orthogonal thereto such that an areal protected zone results whose surface normal is preferably tangential to the track of the component.
[0038] It is therefore particularly preferred for the light transmitter and the restriction device to be made for the monitoring of a substantially areal protected zone in a direction orthogonal to a direction of movement of the component. The restriction device can in particular have a greater extent transversely to the direction in which it restricts the transmitted light beam than in the direction orthogonal thereto.
[0039] It is then furthermore preferred for the light receiver to have a diaphragm with a butterfly-shaped diaphragm aperture which includes two wing regions which are arranged transversely to the direction in which the divergent transmitted light beam can be restricted by the restriction device. A minimum width of the diaphragm aperture is particularly preferably approximately as large as the extent of a reflecting or retro-reflective element of the restriction device in the direction in which the restriction device restricts the divergent transmitted light beam. In this manner, a maladjustment between the restriction device and the sensor in the direction of restriction, in which the restriction device restricts the divergent transmitted light beam, can be recognized easily, on the one hand, since the received light beam can no longer pass through the diaphragm aperture on a sufficiently large maladjustment. The position of the protected zone can therefore be kept constant relative to the component in the direction of restriction. On the other hand, however, there is an adjustment tolerance with respect to an inclination of the restriction device transversely to the direction of restriction, since the diaphragm aperture widens toward the outside such that a tilting of the protected zone around the beam direction by correspondingly small angles does not result in an interruption of the received light beam. Furthermore, rotational vibrations of the restriction device which bring about a corresponding inclination do not have a strong effect. Since the marginal region of the protected zone has the function of recognizing an intervention approaching from the side, the difference in the spacing of the protective field from the component which can occur under certain circumstances in the direction of restriction is of less importance.
[0040] It is then furthermore particularly preferred for the restriction device to include at least two reflecting or retro-reflective elements which represent an encoding. In this manner, a lateral resolution of the protected zone into zones is also possible.
[0041] It is furthermore preferred for the reflecting or retro-reflective elements to be inclined with respect to one another such that a drop in intensity of the transmission and/or reception light beam in the direction of a margin of the light beam can substantially be compensated. A uniformly illuminated protected zone thus results for the light receiver. Typically, zones of retro-reflective elements are tilted in the image central region by an angle different from beams incident on them perpendicularly. The magnitude of the tilt of the retro-reflective elements decreases down to zero toward the image margin. Due to the efficiency of the retro-reflection decreasing as the angle of tilt increases, the imaged energy in the image central region can be reduced and the intensity drop toward the image margin typical for images can be compensated. When retro-reflective elements are used, in particular the retro-reflective elements lying in the center of the transmitted light beam can therefore be tilted by a small angle with respect to the retro-reflective elements lying at the margin of the transmitted light beam such that the corresponding received light beam—in contrast to a received light beam of a retro-reflective element at the margin of the transmitted light beam—is only partially incident on the light receiver or on a corresponding light-sensitive element.
[0042] It is in particular preferred for the monitoring of an areal protected zone for the light receiver to have a linear arrangement of photo-detection elements. In this manner, in particular in conjunction with a restriction device having an encoded reflector unit, a resolution is also made possible in a direction perpendicular to the track of the component.
[0043] The protective apparatus in accordance with the invention preferably has an evaluation circuit for the reception of received signals of the light receiver and for the emitting of corresponding monitoring signals. In particular a drive for the moved component can then in particular be controlled using these monitoring signals.
[0044] A further subject of the invention is a component for an apparatus which can be moved on a pre-determined track with a drive device of the apparatus and which is characterized in that a protective apparatus in accordance with the invention is held at the component, with the protected zone including at least some of the track. The protective apparatus is particularly preferably held at the component such that the transmitted light beam diverges in a direction tangential to the track of the component and such that the restriction device likewise restricts the divergent transmitted light beam in a direction substantially tangential to the track. Vibration influences in the direction of the track can thereby be largely suppressed, in particular without any limitation in safety, such that only a few or no infringements of the protected zone caused only by vibrations are recognized with high reliability. Lower downtimes thus result.
[0045] It is preferred for the light transmitter and the restriction device to be held at two holding arms spaced apart spatially transversely to the track of the component. In this manner, a protected zone can be obtained very easily over the total width of the component.
[0046] A further subject of the invention is a shaping apparatus, in particular a bending press, having a component in accordance with the invention made as a shaping tool, in particular as a bending tool, with a protective apparatus in accordance with the invention, with the protected zone including at least some of the track. Large advantages in particular result for such apparatuses, since high safety demands are made, on the one hand, due to the high forces and high tool speeds which occur as a rule in shaping, and since only low downtimes are desired at the same time. The use of the protective apparatus in accordance with the invention therefore allows a particularly safe and efficient manner of operation of the shaping apparatus in accordance with the invention.
[0047] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0049] [0049]FIG. 1 is a schematic, partly side view of a bending press with a conventional protective apparatus;
[0050] [0050]FIG. 2 is a schematic, partly side view of a bending press with a protective apparatus in accordance with a first preferred embodiment of the invention;
[0051] [0051]FIG. 3 is a schematic, partly side view of a bending press with a protective apparatus in accordance with a second preferred embodiment of the invention;
[0052] [0052]FIG. 4 is a schematic, partly side view of two holding arms with a protective apparatus of a bending press in accordance with a third preferred embodiment of the invention;
[0053] [0053]FIG. 5 is a schematic, partly plan view of the protective apparatus in FIG. 4;
[0054] [0054]FIG. 6 is a schematic representation of a restriction device of the protective apparatus in FIG. 4;
[0055] [0055]FIG. 7 is a schematic representation of photo-detection elements in a light receiver of the protective apparatus in FIG. 4;
[0056] [0056]FIG. 8 is a schematic representation of a diaphragm of a protective apparatus of a bending press in accordance with a fourth preferred embodiment of the invention; and
[0057] [0057]FIG. 9 is a schematic representation of a protected zone position in the protective apparatus in FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0058] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0059] In FIG. 2, a bending press includes a bending tool 32 , which can be moved in a direction of movement B along a pre-determined linear path by a drive device not shown in FIG. 2, and a stationary lower tool 34 , on which a workpiece 36 can be stored for working.
[0060] The bending tool 32 has a V-shaped lower side. The upper side of the lower tool 34 is made complementary to this lower side of the bending tool 32 and has a corresponding V-shaped bending groove which is not shown in FIG. 2.
[0061] A protective apparatus of the invention in accordance with a first embodiment of the invention is held at holding arms 38 and 40 secured to the bending tool. It includes a light transmitter 42 held at the holding arm 38 and a light receiver 44 held at the holding arm 40 and connected to the drive device of the bending press by a lead (not shown).
[0062] The light transmitter 42 includes—in a housing—a light source 46 in the form of a red light LED or an infrared light LED and an optical transmission system 48 arranged in front of the light source 46 in the radiation direction.
[0063] The optical transmission system 48 includes at least one lens and is designed such that light of the LED 46 can be radiated as a transmitted light beam 50 which is divergent in a direction parallel to the direction of movement B of the bending tool 32 .
[0064] Furthermore, the light transmitter 42 is held at the holding arm 38 such that the divergent transmitted light beam 50 can be radiated in a direction substantially along the lower side of the bending tool 32 and parallel thereto. A light discharge aperture of the light transmitter 42 has a spacing from a lower edge of the bending tool 32 of the magnitude of a trailing path N, which is defined as above, such that the transmitted light beam 50 also has this spacing from the lower edge of the bending tool 32 on average.
[0065] The light receiver 44 includes—in a housing—a diaphragm 52 as a restriction device, an optical reception system 54 , a photo-detection element 56 for the reception of red light or of infrared light of the light transmitter 42 and for the emitting of corresponding received signals and an evaluation circuit 57 connected to the photo-detection element 56 for the monitoring of the received signals and for the emitting of monitoring signals to the drive device.
[0066] For the monitoring of a protected zone beneath the bending tool 32 , infrared light is emitted by the light emitting diode 46 during a movement of the bending tool 32 and shaped by the optical transmission system 48 into the transmitted light beam 50 which is divergent in a direction parallel to the direction of movement B of the bending tool 32 . The transmitted light beam 50 passes through a corresponding spatial zone moved beneath the bending tool 32 along with the bending tool and is restricted by the diaphragm 52 acting as a restriction device to a received light beam 58 which is substantially less divergent than the transmitted light beam 50 . The received light beam 58 is then focused onto the photo-detection element 56 by the optical reception system 54 . The photo-detection element 56 receives the infrared light and converts it into an electrical signal which is monitored by the evaluation circuit 57 . The evaluation circuit 57 emits an alarm signal to the drive device for the bending tool 32 on the absence of a received signal such that the bending tool's movement is stopped.
[0067] The diaphragm 52 therefore only allows a part beam 60 of the transmitted light beam 58 to pass which is supplied to the photo-detection element 56 as a received light beam 58 via the optical reception system 54 . Only if an object blocks the part beam 60 of the divergent transmitted light beam 50 can no light be received by the light receiver 44 such that the part beam 60 defined by a diaphragm aperture of the diaphragm 52 forms a protected zone 62 of the protective apparatus formed by the light transmitter 42 and by the light receiver 44 shown as hatched.
[0068] As can easily be recognized in FIG. 2, a tilting of the light transmitter 42 admittedly results in a correspondingly pivoted divergent transmitted light beam 50 ′ but another part beam 60 ′ of the divergent transmitted light beam 50 ′ is now transmitted through the diaphragm 52 as the restriction device and has the same position and the same width relative to the bending tool 32 as the part beam 60 . The position of the protected zone 62 relative to the bending tool 32 therefore remains substantially unchanged even on a movement of the light transmitter 42 . A movement of the light receiver 44 also does not substantially change the position of the protected zone 62 relative to the bending tool 32 since, in contrast to movements of the light transmitter 42 , small movements of the light receiver 42 , and thus of the restriction device in the form of the diaphragm 52 , do not result in a pivoting of the part beam 60 , but at most in small displacements.
[0069] To achieve a sufficient insensitivity to the influence of vibrations, an aperture angle α of the divergent transmitted light beam 50 amounts, for example, to approximately 1° with a 2 m long bending tool, with the diaphragm 52 then being able to have a diaphragm aperture with a width of, for example, approximately 5 mm in the direction of restriction parallel to the direction of movement B such that the width of the transmitted light beam 50 at the diaphragm 52 amounts to approximately 3.5 cm. The angles and lengths used in the Figures are, if not otherwise stated, only selected for a better illustration and are therefore not necessarily realistic.
[0070] To allow a stopping of the bending tool 32 in good time, the light transmitter 42 and the light receiver 44 are held at the holding arms 38 or 40 such that the protected zone 62 extends substantially parallel to the lower edge of the bending tool 32 at a spacing from the trailing path N which designates the path which is required to brake the bending tool 32 down to a standstill as quickly as maximally possible.
[0071] In FIG. 3, a bending press is shown with a protective apparatus in accordance with a second preferred embodiment of the invention which only differs from the first embodiment by the design of the protective apparatus. The same statements therefore apply with respect to the same components, in particular to the bending press, as in the preceding embodiment and the same reference numerals are used.
[0072] The protective apparatus now includes a light transmitter and a light receiver which are combined to from one transmission/reception unit 64 and are held at the holding arm 38 . A restriction device in the form of a reflecting element 68 is arranged at a holder 66 at the holding arm 40 .
[0073] The transmission/reception unit 64 includes as a light source for the light transmitter a laser diode 69 for red light, a beam splitter 70 and an optical transmission/reception system 72 and for the light receiver, in addition to the optical transmission/reception system 72 and the beam splitter 70 , a further optical reception system 74 , a photo-detection element 56 and an evaluation circuit 57 . The photo-detection element 56 and the evaluation circuit 57 are made as in the preceding embodiment.
[0074] The beam splitter 70 is formed by a semi-transmitting mirror.
[0075] The reflecting element 68 is formed by a mirror reflective for light of the laser diode 69 , whereas the holder 66 does not reflect the light at all or only weakly.
[0076] For the monitoring light of the laser diode 69 is shaped by the beam splitter 70 and by the optical transmission/reception system 72 to a divergent transmitted light beam 76 which is radiated between the bending tool 32 and the lower tool 34 and which is divergent in a direction parallel to the direction of movement B of the bending tool 32 .
[0077] The transmitted light beam 76 is then incident on the reflecting element 68 and on the holder 66 , with it substantially only being reflected at the reflecting element 68 . A part beam 78 of the transmitted light beam 76 is therefore reflected back to the transmission/reception unit 64 as a received light beam 80 . The width of the part beam 78 and that of the received light beam 80 are defined by the extent of the reflecting element 68 parallel to the track of the bending tool 32 , i.e. to the direction of movement B in the example. The reflecting element 68 therefore represents a restriction device within the sense of the invention.
[0078] The received light beam 80 is focused or deflected onto the photo-detection element 56 by the optical transmission/reception system 72 , by the beam splitter 70 and by the further optical reception system 74 .
[0079] Analog to the part beam 60 of the transmitted light beam 50 in the preceding embodiment, a protected zone 82 is now substantially provided by the part beam 78 since only its blocking results in a change of the received light beam 80 received by the transmission/reception unit 64 .
[0080] The reflecting element 68 and the transmission/reception unit 64 are in turn arranged such that the protected zone 82 is arranged substantially parallel to the lower side of the bending tool 32 at a spacing from the trailing path N.
[0081] To obtain high functional reliability, the optical transmission/reception system 72 is made such that an aperture angle □ of the transmitted light beam 76 is so large that its width in a plane parallel to the reflecting element 68 is approximately ten times larger directly at the reflecting element 68 than the extent of the reflecting element 68 in this direction. The widths of the part beam 78 and of the received light beam 80 directly at the reflecting element are therefore—defined by the corresponding extent of the reflecting element—smaller by a factor of approximately 10 than the width of the transmitted light beam 76 at this point.
[0082] The function of the protective apparatus of the second embodiment, and in particular also the insensitivity to vibrations, result analogously to that of the first embodiment.
[0083] A bending press with a protective apparatus in accordance with a third preferred embodiment of the invention is partly shown in FIGS. 4 to 7 . It differs from the bending press in the second embodiment by the design of the restriction device and by the design of the transmission/reception unit. The same reference numerals are therefore used for the same components and the statements on these components also apply accordingly in this embodiment.
[0084] A transmission/reception unit 84 which includes a light transmitter and a light receiver and is held at the arm 38 has a laser diode 69 for red light, a cylindrical lens 86 , a beam splitter 70 , an aspheric lens 88 , a slit diaphragm 90 , a color filter 92 and a line-scan camera 94 which is connected to an evaluation circuit 96 .
[0085] The cylindrical lens 86 and the aspheric lens 88 are made and arranged such that light of the laser diode 69 is shaped to form a transmitted light beam 98 which is divergent in two directions orthogonal to one another and has an aperture angle α parallel to the direction of movement B of the bending tool 32 which is smaller than a further aperture angle α in a direction orthogonal to the direction of movement B.
[0086] The aspheric lens 88 is furthermore designed such that received light is focused onto the line-scan camera 94 through the slit diaphragm 90 and the color filter 92 after reflection at the beam splitter 70 .
[0087] The slit diaphragm 90 has a slit 99 which is arranged in a plane through the holding arms 38 and 40 perpendicular to the direction of movement B.
[0088] The color filter 92 , which includes an interference filter, serves for the elimination of outside light or interfering light and substantially only transmits light of the laser diode 69 .
[0089] The line-scan camera 94 includes a plurality of elongate photo-detection elements 100 in the CMOS or CCD technology (cf. FIG. 7) which are arranged parallel to one another transversely to their longitudinal direction and which have a length along their longitudinal axis of approximately 250 μm and a length in a direction transversely thereto of approximately 12.5 μm (cf. FIG. 7).
[0090] The line-scan camera 94 is connected to the evaluation circuit 96 which receives and monitors electrical signals emitted by the photo-detection elements 100 on the reception of light. When an interruption of a light path is detected, an alarm signal is emitted to the drive device of the bending tool 32 .
[0091] A restriction device 102 held at the holder 66 at the holding arm 40 has parallel, flatly rectangular, retro-reflective elements 104 (cf. FIG. 6) which are arranged transversely to the linear track of the bending tool and thus of the direction of movement B. The short sides of the retro-reflective elements are aligned parallel to the direction of movement B. An encoding is formed by this arrangement. The retro-reflective elements 104 are formed from a conventional retro-reflective foil.
[0092] For the monitoring, in particular during the movement of the bending tool 32 , light of the laser diode 69 is beamed by the cylindrical lens 86 and by the aspheric lens 88 into the divergent transmitted light beam 98 which is less divergent in a direction parallel to the direction of movement B than in a direction perpendicular thereto (cf. FIGS. 4 and 5). The aperture angle □ can amount to, for example, 1° and the aperture angle □′ to, for example, approximately 0° at a spacing of the restriction device from the transmission/reception unit 84 of, for example, 2 m.
[0093] In accordance with the encoding, the retro-reflective elements 104 reflect a fan of part beams 106 into a fan of received light beams 108 which are now somewhat convergent due to the retro-reflection. The fanned part beams 106 or the received light beams 108 are only shown partly as separate beams in FIG. 5 for reasons of clarity.
[0094] Furthermore, the transmitted light beam 98 is restricted in a direction of divergence parallel to the direction of movement B by the retro-reflective elements 104 whose short sides are aligned parallel to said direction of divergence. Their extent in the direction of movement B is selected in accordance with a mean amplitude of the transmission/reception unit 84 to be expected by a factor of 10 smaller than the width of the transmitted light beam 98 at the direction of restriction 102 . The part beams 106 reflected into the received light beams 108 are therefore less divergent than the transmitted light beam 98 in a direction parallel to the direction of movement. The width of the transmitted light beam 98 in the direction of divergence parallel to the direction of movement B at the restriction device 102 is thus also larger than a width of the received light beams 108 produced by the reflection directly at the restriction device 102 .
[0095] The part beams 106 and, due to the retro-reflective properties of the retro-reflective elements 104 also the received light beams 108 , thus define a protected zone 110 which is shown as hatched and whose position is fixed by the transmission/reception unit 84 and by the restriction device 102 and which is arranged in fan-like shape substantially areally perpendicular to the direction of movement B of the bending tool 32 parallel to its lower side at a spacing corresponding to the trailing path N.
[0096] The received light beams 108 are guided through the aspheric lens 88 via the beam splitter 70 through the slit diaphragm 90 . The slit 99 of the slit diaphragm 90 is arranged parallel to a direction of divergence of the received light beams 108 at the location of the slit diaphragm which corresponds to the direction in which the transmitted light beam 98 was restricted to the received light beam 108 by the restriction device 102 in the direction of movement B. The slit 99 is thus also arranged perpendicular to the direction of movement B. The slit diaphragm 90 therefore brings about an increase in the depth of field perpendicular to the direction of movement B of the bending tool 32 , but not in a direction orthogonal thereto which corresponds to the direction in which the divergent transmitted light beam 98 was restricted parallel to the direction of movement B.
[0097] After passing through the color filter 92 , where outside light and interfering light is filtered, the imaging of the retro-reflective elements 104 shown only schematically in FIG. 7 appears on the line-scan camera 94 such that a spatial resolution is present in the viewfinder region perpendicular to the direction of movement B. In FIG. 7, the photo-detection elements 100 are shown too wide in comparison with the images of the retro-reflective elements 104 for reasons of clarity.
[0098] The photo-detection elements 104 are arranged with their elongate directions parallel to the slot 99 and thus to a direction of divergence of the received light bundles 108 at the location of the photo-detection elements 104 which corresponds to the direction in which the transmitted light beam 98 was restricted to the received light beam 108 by the restriction unit 102 in the direction of movement B. The effects of vibration-induced movements of the restriction device 102 , and thus the received light beam 108 parallel to the direction of movement B, can thereby be easily intercepted.
[0099] Analog to the first two embodiments, by the use of the restriction device 102 with retro-reflective elements 104 , a protected zone 110 which is arranged in a constant manner relative to the bending tool 32 , is narrow in the direction of movement B and allows a safe monitoring of the zone beneath the bending tool 32 , and thus low downtimes of the bending press, also results with vibrations of the transmission/reception unit 84 and of the restriction device 102 toward one another in the direction of movement B or on tilting movements of the transmission/reception unit 84 with respect to the restriction device 102 in a plane which contains the direction of movement B.
[0100] A bending press with a protective apparatus in accordance with a fourth preferred embodiment of the invention is shown partly in FIGS. 8 and 9. It is substantially shown like the bending press in the third embodiment such that the same reference numerals are used for the same components and the statements on these components also apply correspondingly in this embodiment.
[0101] In contrast to the bending press in the third embodiment, a diaphragm 112 is provided between the aspheric lens 88 and the beam splitter 70 and has a butterfly-like diaphragm aperture 114 (cf. FIG. 8). Two wing regions 116 of the diaphragm aperture 114 are arranged substantially parallel to the areal protected zone 110 and thus transversely to the direction of movement B or to the direction in which the divergent transmitted light beam 98 can be restricted by the restriction unit 102 (cf. FIG. 9).
[0102] A width D of a restriction of the diaphragm aperture 114 corresponds to the height of the retro-reflective elements 104 in the direction of the direction of movement B.
[0103] The diaphragm 112 is arranged at such a spacing from a lower edge 118 of the bending tool 32 that the protected zone 110 lies at the height of the restriction of the diaphragm aperture 114 and the received light beams 108 can pass through it (cf. FIG. 9).
[0104] In the event of a maladjustment between the restriction device 102 and the transmission/reception unit 84 in the direction of movement B, the light path is interrupted at the middle of the protected zone 110 since the received light beams 108 can no longer pass through the only narrow diaphragm aperture 114 in this region. Such a maladjustment in the direction of high safety relevance directly beneath the lower edge 118 of the bending tool 32 is therefore easy to recognize.
[0105] A maladjustment in the angular position of the diaphragm 112 or of the transmission/reception unit 84 with respect to the restriction unit 102 , and thus to the protected zone 110 , for example by assembly imprecision or by vibrations, does not, in contrast, necessarily result in an interruption of the light path. This is illustrated in FIG. 9 in which the diaphragm 112 is only shown schematically while omitting the aspheric lens 88 . The wing regions 114 are made such that the received light beams 108 can still pass through the diaphragm 112 in the event of maladjustments by angles of up to approximately 3° and no interruption of the light path takes place. Since the marginal region of the protected zone 110 has the function of recognizing an intervention approaching from the side, the different spacings of the protected zone 110 from the bending tool 32 in this region are of lesser importance.
[0106] Tiltings between the transmission/reception unit 84 and the restriction device along the lower edge 118 of the bending tool 32 caused by vibrations do not have a negative effect since the retro-reflective elements 104 substantially reflect the transmitted light beam 98 or the part beams 106 onto themselves. Furthermore, for example, retro-reflective foils have a certain scattered portion on reflection by which such maladjustments are likewise partly compensated.
[0107] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | A protective device for securing to a component movable along a track and for the monitoring of a protected zone moving with the component includes a light transmitter for the radiation of a divergent transmitted light beam into a spatial zone containing the protected zone, a light receiver for the reception of at least some of the light of the transmitted light beam of the light transmitter radiated into the spatial zone and for the emitting of corresponding received signals, and a restriction device which is arranged in the direction of a transmitted light path after a section of the transmitted light path which contains the protected zone and by means of which the transmitted light beam can be restricted to a less divergent received light beam defining the width of the protected zone in at least one direction. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a full-mesh optical wavelength division multiplexing transmission network transmission device for transmitting a plurality of optical signals wavelength-division multiplexed among a plurality of transmitting and receiving apparatuses.
This specification is based on Japanese Patent Application (No. 11(1999)-229174) to Japan Patent Office, and contents described in this Japanese Patent Application will be incorporated as a part of this specification.
2. Descriptions of the Related Art
An optical wavelength division multiplexinging (WDM) transmission system, which transmits a plurality of optical signals on one optical fiber by allocating the signals to different wavelengths, can increase significantly the capacity of its transmission path. In addition, the optical WDM transmission system can perform wavelength addressing which is capable of allocating the destination information relating to the optical signals to the respective wavelengths. Furthermore, a star-type WDM system, in which an N×N wavelength multi/demultiplexer having a periodic wavelength demultiplexing property in input/output combination is arranged in the center so as to connect N transmitting and receiving apparatuses therebetween, can realize a full-mesh WDM transmission network device capable of interconnecting the apparatus through independent N×N signal paths by using only N wavelengths optical signals.
FIG. 25 is a block diagram for explaining a schematic constitution of a conventional full-mesh WDM transmission network device. Referring to FIG. 25, reference numerals 1 to 4 denote transmitting and receiving apparatuses; 5 to 8 , transmitters for sending WDM signals (wavelength λ K :K=1, 2, . . . , N); 9 to 12 , receivers for receiving the WDM signals (wavelength λ K :K=1, 2, . . . , N); 13 to 16 , 1×N wavelength multiplexers for multiplexing optical signals having different N wavelengths onto one optical fiber, 17 to 20 , 1×N wavelength demultiplexing circuits for demultiplexing the WDM signals wavelength-multiplexed on one optical fiber, into signals having N wavelengths; 21 , an N×N wavelength multi/demultiplexer having a periodic wavelength demultiplexing property in input/output combination, which has a first I/O port group ( 1 , 2 , . . . , N on the left side) composed of N ports and the opposing second I/O port group ( 1 , 2 , . . . , N on the right side) composed of N ports; and 22 to 29 , optical fibers for optically connecting the transmitting and receiving apparatuses 1 to 4 , to the I/O ports of the N×N wavelength multi/demultiplexer 21 . In the optical fibers 22 to 29 , the wavelengths λ K (K=1, 2, . . . , N) of the WDM signals propagating on the optical fibers, the signals being wavelength-multiplexed, and the directions of the WDM signals to be transmitted, which are indicated by arrows, are shown.
In this prior art 1×N AWGs (arrayed-waveguide grating wavelength multi/demultiplexer) each having a first I/O port composed of one port and a second I/O port group composed of N ports facing the one first I/O port are used as the 1×N wavelength multiplexers 13 to 16 and the 1×N wavelength demultiplexing circuits 17 to 20 . An N×N AWG having a first I/O port group composed of N ports and a second I/O port group composed of N ports facing the first I/O port group and having a periodic wavelength demultiplexing property in input/output combination is used as the N×N wavelength multi/demultiplexer 21 .
FIG. 26 is a table showing a periodic wavelength demultiplexing property in input/output combination for N×N AWG (N=8), and a port connection rule between the transmitting and receiving apparatus and the AWG in the conventional full-mesh WDM transmission network device. The N×N AWG having the wavelength demultiplexing property of the periodic input/output relation can be realized by a method recorded in Japanese Patent Application No. 10(1998)-210679, and the like. The wavelength demultiplexing property between eight ports of the first input/output group of the N×N AWG and eight ports of the second input/output group thereof is periodic as shown by the wavelength λ K (K=1, 2, . . . , 8) in FIG. 26 .
The N×N AWG is a circuit symmetrical with respect to the first I/O port group and the second I/O port group. For example, the multiplexed WDM signal wavelength λ K (K=1, 2, . . . , 8) input from a predetermined port of the first I/O port group is wavelength-demultiplexed and output to each port of the second I/O port group. In contrast, the multiplexed WDM signal wavelength λ K (K=1, 2, . . . , 8) input from a predetermined port of the second I/O port group is wavelength-demultiplexed and output to each port of the first I/O port group.
The arrows shown above the each wavelength λ K in FIG. 26 express the relation of the input/output among the ports. The arrows toward the right mean that the first I/O port group side is used as an input port and the second I/O port group side is used as an output port, and the arrows toward the left mean that second I/O port group side is used as an input port and the first I/O port group is used as an output port. To be more specific, in the conventional full-mesh WDM transmission network device, the whole of the first I/O port group side is used as the input port, and the whole of the second I/O port group side is used as the output port. Although there are 64 (8×8) paths among 8×8 AWG ports, the 64 paths can be independently established at only 8 wavelengths by using of the periodic wavelength demultiplexing property as shown in FIG, 26 .
By connecting the I/O ports of the AWG to each transmitting and receiving apparatus, signals can be transmitted independently therebetween through all the paths which can be established among the eight transmitting and receiving apparatuses. Moreover, since a specified wavelength λ K is allocated to the respective path, if a wavelength corresponding to a receiver is selected on the transmitter side, a wavelength addressing function to transmit the signal automatically to an objective receiver can be realized.
FIG. 27 is a diagram for explaining the wavelength addressing. In FIG. 27, reference numerals 31 to 38 denote eight transmitting and receiving apparatuses ( 1 ) to ( 8 ), and 39 denotes a 8×8 AWG. The wavelength demultiplexing property of the 8×8 AWG and the port connection rule between each of the transmitting and receiving apparatuses and the 8×8 AWG are described in FIG. 26 . An optical signal having a wavelength λ 2 transmitted from the transmitting and receiving apparatus ( 1 ) 31 is guided to the port 1 of the first I/O port group of the 8×8 AWG 39 , and switched within the 8×8 AWG 39 . The optical signal is then sent to the transmitting and receiving apparatus ( 2 ) 32 from the port 2 of the second I/O port group thereof. Similarly, a return signal λ 2 sent back from the transmitting and receiving apparatus ( 2 ) 32 is transmitted to the transmitting and receiving apparatus ( 1 ) 31 via the 8×8 AWG 39 . For example, optical signals λ 3 and λ 5 transmitted from the transmitting and receiving apparatus ( 1 ) 31 are automatically delivered to the transmitter ( 3 ) 33 and the transmitting and receiving apparatus ( 5 ) 35 , respectively.
FIG. 28 is a graph showing atypical transmission spectrum property between certain input and output ports of the AWG fabricated as a silica-based planar lightwave circuit. Although a wavelength of an optical signal to be transmitted between the input and output ports is equal to λ K , other than this optical signal also an optical signal (λ 1 , λ 2 , . . . , λ K−1 , λ K+1 , . . . , λ N ) input from the same port can be scarcely transmitted therebetween. This is the noise called crosstalk light. An intensity ratio of the crosstalk light to the optical signal is approximately −30 dB with respect to a wavelength (λ K−1 , λ K+1 ) adjacent to the wavelength λ K , and approximately −40 dB with respect to other wavelengths (λ 1 , λ 2 , . . . , λ K−2 , λ K+2 , . . . , λ N ).
In the N×N AWG of the conventional full-mesh WDM transmission network device, the WDM signals of N wavelengths are input from all ports of the first I/O port group. For example, in the case of the 8×8 AWG having the wavelength demultiplexing property of the periodic input/output relation as shown in FIG. 26, the optical signal λ 5 (thick solid line) which is transmitted from the transmitting and receiving apparatus ( 1 ) 31 and input to the 8×8 AWG via the port 1 of the first I/O port group (the port group on the left side of the 8×8 AWG) is output from the port 5 of the second I/O port group (the port group on the right side of the 8×8 AWG), and received by the transmitting and receiving apparatus ( 5 ) 35 .
Furthermore, the optical signal λ 6 (thick broken line) which is transmitted from the transmitting and receiving apparatus ( 2 ) 32 and input to the 8×8 AWG via the port 2 of the first I/O port group is output from the port 5 of the second I/O port group, and received by the transmitting and receiving apparatus ( 5 ) 35 . At this time, crosstalk light (thin solid line) of the optical signal λ 5 , which is transmitted from the transmitting and receiving apparatus ( 2 ) 32 and input via the port 2 of the first I/O port group, is also output from the port 5 of the second input/output group. Similarly, crosstalk lights of the optical signal λ 5 transmitted from other transmitting and receiving apparatuses are also output from the port 5 of the second I/O port group. As a result, one optical signal λ 5 and seven crosstalk lights having the equal wavelength are output from the port 5 of the second I/O port group. The crosstalk lights having equal wavelengths are called coherent crosstalk lights. At this time, since the coherent crosstalk lights from the port 2 and the port 8 of the first I/O port group, that is, the ports cyclically adjacent to the port to which the optical signal λ 5 is input, are crosstalk light from the adjacent wavelength (adjacent crosstalk light), these coherent crosstalk lights show intensities stronger than those of other five coherent lights.
Like the N×N AWG in the conventional full-mesh WDM transmission network device, when N optical signals having the equal wavelength are input from the same I/O port group side, N−1 coherent crosstalk lights always occur. Moreover, since the coherent crosstalk light is the noise having a wavelength equal to that of the optical signal, the optical signal and the noise cannot be separated from each other by a wavelength demultiplexing circuit of the transmitting and receiving apparatus, and the noise may increase owing to the interference of the plurality of coherent crosstalk lights.
In the conventional full-mesh WDM transmission network device, a certain WDM wavelength light received by the transmitting and receiving apparatus is a sum of one optical signal and N−1 coherent crosstalk lights, and two waves among these waves are the adjacent crosstalk lights. If the optical signal has the longest wavelength λ N or the shortest wavelength λ 1 , one wavelength is the adjacent crosstalk light. Accordingly, a signal noise ratio S/N is expressed as follows:
S/N= P Signal /[2 PAdjCT +( N −3) P othCT ] (1)
where P AdjCT , P OthCT and P Signal are the adjacent crosstalk light intensity, the non-adjacent crosstalk light intensity and the signal light intensity. Assuming that P AdjCT /P Signal is equal to −30 dB and P OthCT /P Signal is equal to −40 dB, S/N is 27 dB when N=4, 26 dB when N=8, and 25 dB when N=16.
As taught by the formula (1), in the conventional full-mesh WDM transmission network device noises created by the coherent crosstalk lights are accumulated with an increase in the number N of the transmitting and receiving apparatuses connected, so that S/N of the WDM wavelength light decreases. This implies that communication quality of the system deteriorates along with scale expansion. In contrast, a system satisfying a predetermined communication quality standard is limited in its scale. This is a serious problem in designing the system.
SUMMARY OF THE INVENTION
The present invention was made in view of such problems, and the object of the present invention is to provide a large scale full-mesh optical wavelength division multiplexing transmission network device which reduces the accumulation number of coherent crosstalk lights that cause noise, and has a communication quality more excellent than the conventional full-mesh optical wavelength division multiplexing transmission network device, without any modification of constituent components constituting the conventional one. The constituent components include a transmitter, a receiver, a 1×N wavelength multi/demultiplexer, an N×N wavelength multi/demultiplexer, and an optical fiber.
The full-mesh optical wavelength division multiplexing transmission network device of the present invention comprises N transmitting and receiving apparatuses; and an N×N wavelength multi/demultiplexer having a first I/O port group composed of N ports connected to a different one of said N transmitting and receiving apparatuses and a second I/O port group composed of N ports connected to a different one of said N transmitting and receiving apparatuses, wherein an optical signal having a different wavelength for each port of the second I/O port group among optical signals having N kinds of wavelength is transmitted between any one of the ports of the first I/O port group and each port of the second I/O port group; an optical signal having a different wavelength for each port of the first I/O port group among optical signals having N kinds of wavelength is transmitted between any one of the ports of the second I/O port group and each port of the first I/O port group; as a result, N port combinations for transmitting optical signals having an equal wavelength exist for each wavelength, among N×N port combinations made by the N ports of the first I/O port group and the N ports of the second I/O ports; among the N port combinations for transmitting the optical signals having the equal wavelength, in M port combinations the optical signals are transmitted from the first I/O port group to the second I/O port group, and in N−M port combinations the optical signals are transmitted from the second I/O port group to the first I/O port group; and the port of the second I/O port group for receiving the optical signal from the port of the first I/O port group connected to the any one of the transmitting and receiving apparatuses and the port of the first I/O port group for receiving the optical signal from the port of the second I/O port group connected to the any one of the transmitting and receiving apparatuses are connected to the different transmitting and receiving apparatus.
In the optical wavelength division multiplexing transmission network device of the invention, N is preferably an even number and M is equal to N/2.
In the optical wavelength division multiplexing transmission network device of the invention, wavelengths of all optical signals transmitted from any one of the ports of one I/O port group to the other I/O port group are preferably different from wavelengths of all optical signals transmitted from a port adjacent to the said one port of the one I/O port group to the other I/O port group.
In the optical wavelength division multiplexing transmission network device of the invention, the transmitting and receiving apparatus preferably further includes: N−M transmitters; M receivers; a 1×N wavelength multi-demultiplexer which demultiplexes an optical signal output from predetermined one port of the first I/O port group into M optical signals having different wavelengths, inputs the demultiplexed optical signals to the different receivers among the M receivers, multiplexes optical signals output from said N−M transmitters into one optical signal, and transmits the multiplexed optical signal to predetermined one port of the first I/O port group; M transmitters, N−M receivers; and a 1×N wavelength multi/demultiplexer which demultiplexes an optical signal output from predetermined one port of the second I/O port group into N−M optical signals having different wavelengths, inputs the demultiplexed optical signals to the different receivers among the N−M receivers, multiplexes optical signals output by said M transmitters into one optical signal, and transmits the multiplexed optical signal to predetermined one port of the first I/O port group.
According to the present invention, a full-mesh optical wavelength division multiplexing transmission network device can be realized, which is capable of reducing the accumulation number of coherent crosstalk lights that cause noise, exhibiting excellent communication quality, and being mass produced, without any modification of constituent components (the transmitters, the receivers the 1×N AWG, the N×N AWG and the optical fiber) constituting the conventional one.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram for explaining a schematic constitution of a first embodiment of the present invention;
FIG. 2 is a table showing a wavelength demultiplexing property and a port connection rule for an AWG of the first embodiment of the present invention;
FIG. 3 is a diagram for explaining coherent crosstalk light of the first embodiment of the present invention;
FIG. 4 is a diagram for explaining a wavelength addressing of the first embodiment of the present invention;
FIG. 5 is a block diagram for explaining a schematic constitution of a second embodiment of the present invention;
FIG. 6 is a table showing a wavelength demultiplexing property and a port connection rule for an AWG of the second embodiment of the present invention;
FIG. 7 is a diagram for explaining coherent crosstalk light of the second embodiment of the present invention;
FIG. 8 is a diagram for explaining a wavelength addressing of the second embodiment of the present invention;
FIG. 9 is a block diagram for explaining a schematic constitution of a third embodiment of the present invention;
FIG. 10 is a table showing a wavelength demultiplexing property and a port connection rule for an AWG of the third embodiment of the present invention;
FIG. 11 is a diagram for explaining coherent crosstalk light of the third embodiment of the present invention;
FIG. 12 is a diagram for explaining a wavelength addressing of the third embodiment of the present invention;
FIG. 13 is a block diagram for explaining a schematic constitution of a fourth embodiment of the present invention;
FIG. 14 is a table showing a wavelength demultiplexing property and a port connection rule for an AWG of the fourth embodiment of the present invention;
FIG. 15 is a diagram for explaining coherent crosstalk light of the fourth embodiment of the present invention;
FIG. 16 is a diagram for explaining a wavelength addressing of the fourth embodiment of the present invention;
FIG. 17 is a block diagram for explaining a schematic constitution of a fifth embodiment of the present invention;
FIG. 18 is a table showing a wavelength demultiplexing property and a port connection rule for an AWG of the fifth embodiment of the present invention;
FIG. 19 is a diagram for explaining coherent crosstalk light of the fifth embodiment of the present invention;
FIG. 20 is a diagram for explaining a wavelength addressing of the fifth embodiment of the present invention;
FIG. 21 is a block diagram for explaining a schematic constitution of a sixth embodiment of the present invention;
FIG. 22 is a table showing a wavelength demultiplexing property and a port connection rule for an AWG of the sixth embodiment of the present invention;
FIG. 23 is a diagram for explaining coherent crosstalk light of the sixth embodiment of the present invention;
FIG. 24 is a diagram for explaining a wavelength addressing of the sixth embodiment of the present invention;
FIG. 25 is a block diagram showing a schematic constitution of a conventional device;
FIG. 26 is a table showing a wavelength demultiplexing property of a conventional 8×8 AWG and a port connection rule;
FIG. 27 is a diagram for explaining a wavelength addressing of a conventional device;
FIG. 28 is a graph showing an example of a transmission spectrum characteristic between input/output ports of a silica-based planar AWG; and
FIG. 29 is a diagram for explaining coherent crosstalk light of the conventional device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention will be described below.
It should be noted that the embodiments described below do not limit the spirt and scope of the invention defined by the claims.
To achieve the object of the present invention, all combinations of features described in the embodiments are not always necessary.
Embodiment 1
FIG. 1 is a block diagram for explaining a first embodiment of the present invention, which shows a schematic constitution of a full-mesh WDM transmission network device of N=4. Referring to FIG. 1, reference numerals 41 to 44 denote a transmitting and receiving apparatus; 45 to 52 , a transmitter for sending a WDM signal (wavelength λ K : K=1, 2, 3, 4); 53 to 60 , a receiver for receiving a WDM signal (wavelength λ K : K=1, 2, 3, 4); 61 to 68 , a 1×4 wavelength multi/demultiplexer which multiplexes optical signals of two different wavelengths into one optical fiber and demultiplexes a WDM signal which is wavelength-multiplexed to one optical fiber, into two wavelengths; 69 , a 4×4 wavelength multi/demultiplexer having a first I/O port group ( 1 to 4 on the left side) composed of four ports and a second I/O port group ( 1 to 4 on the right side) composed of four ports, the 4×4 wavelength multi/demultiplexer having a periodic wavelength demultiplexing property in input/output combination; and 70 to 77 , an optical fiber for optically connecting each of the transmitting and receiving apparatuses 41 to 44 and each of the I/O ports of the 4×4 wavelength multi/demultiplexes 69 . In FIG. 1, shown are the wavelengths (λ K : K=1, 2, 3, 4) of the WDM signal wavelength-multiplexed and transmitted on the corresponding optical fiber 70 to 77 , and the transmission directions (arrow) thereof.
In this embodiment, as the 1×4 wavelength multi/demultiplexes 61 to 68 , a 1×4 AWG (array waveguide diffraction grating) wavelength multi/demultiplexer was used, and as the 4×4wavelength multi/demultiplexer 69 , a 4×4 AWG having a periodic wavelength demultiplexing property in input/output combination was used. Constituent components (a transmitter, a receiver, a 1×4 AWG, a 4×4 AWG and an optical fiber) constituting the full-mesh WDM transmission network device of this embodiment are the same as those of the prior art. Note that while the 1×4 AWG was used exclusively for the wavelength multiplexer or the wavelength demultiplexing circuit in the prior art in this embodiment of the present invention the 1×4 AWG is used for the wavelength multi/demultiplexer that performs the wavelength multiplexing and demultiplexing simultaneously.
FIG. 2 is a table showing a periodic wavelength demultiplexing property in input/output combination of the 4×4 AWG and a port connection rule between the transmitting and receiving apparatuses and the 4×4 AWG in this embodiment of the present invention. The wavelength demultiplexing property of the 4×4 AWG has the same periodicity as that of the prior art. Although the connection relation between the transmitting and receiving apparatuses and the first I/O port group of the 4×4 AWG is also the same as that of the prior art the connection relation between the transmitting and receiving apparatus and the second I/O port group of the 4×4 AWG is different from that of the prior art. Furthermore, unlike the prior art according to combinations of the 4×4 AWG ports and the wavelengths of the optical signals, some optical signals are input from the first I/O port group side and output to the second I/O port group side, and other optical signals are input from the second I/O port group side and output to the first I/O port group side. Thus optical signals input/output bidirectionally.
In this embodiment, two optical signals among the four optical signals having the equal wavelength are input from the first I/O port group side to the 4×4 AWG, and other two optical signals are input from the second I/O port group side thereto. Since the lightwaves which are traveling in opposite directions are independent from each other, the optical wave input from the first I/O port group side and the optical wave input from the second I/O port group side, which have the equal wavelength, never interfere with each other within the 4×4 AWG. Accordingly, the WDM wavelength light output from the port of the 4×4 AWG includes only one optical signal and one coherent crosstalk light. For example, as shown in FIG. 3, the light having the wavelength λ 3 , which is output from the port 2 of the second I/O port group, includes only the optical signal λ 3 (thick solid line) input from the port 2 of the first I/O port group and the crosstalk light (thin solid line) of the optical signal λ 3 input from the port 1 of the first I/O port group, and does not include the crosstalk lights of the optical signals λ 3 input from the ports 1 and 4 of the second I/O port group. Specifically, the accumulation number of the coherent crosswalk lights is reduced to one from three, which is the accumulation number in the prior art.
In this embodiment, since the two optical signals having the equal wavelength, which are input from the first I/O port group side, are input from the ports adjacent to each other and the optical signals input from the second I/O port group side are input from the ports cyclically adjacent to each other, one coherent crosstalk light included in the output WDM wavelength light from the 4×4 AWG is a crosstalk light contributed from an adjacent port. Accordingly, in the full-mesh WDM transmission network device of this embodiment S/N of the WDM wavelength light received is expressed as follows:
S/N= P Signal /P AdjCT (2)
S/N is equal to 30 dB when P Signal /P AdjCT is assumed to be −30 dB, and the S/N is improved by 3 dB compared to 27 dB in the prior art.
FIG. 4 is a diagram for explaining wavelength addressing in this embodiment. In FIG. 4, reference numerals 81 to 84 denote four transmitting and receiving apparatuses, and reference numeral 85 denotes a 4×4 AWG. The wavelength demultiplexing property of the 4×4 AWG 85 and the connection relation between the transmitting and receiving apparatuses and the 4×4 AWG 85 are explained in FIG. 2 . For example, the optical signal having the wavelength λ 4 ,transmitted from the transmitting and receiving apparatus ( 1 ) 81 , is guided to the port 3 of the second I/O port group in the 4×4 AWG 85 , and switched within the 4×4 AWG 85 . This optical signal is then sent to the transmitting and receiving apparatus ( 2 ) 82 from the port 2 of the first I/O port group. Similarly, the return signal λ 2 returned from the transmitting and receiving apparatus ( 2 ) 82 is guided to the port 2 of the second I/O port group in the 4×4 AWG 85 , and then sent to the transmitting and receiving apparatus ( 1 ) 81 from the port 1 of the first I/O port group.
Furthermore, one of the two optical signals having the wavelength λ 1 returned from the transmitting and receiving apparatus ( 1 ) 81 is guided to the port 3 of the second I/O port group in the 4×4 AWG 85 , and automatically delivered to the transmitting and receiving apparatus ( 3 ) 83 from the port 3 of the first I/O port group. The other is guided to the port 1 of the first I/O port group in the 4×4 AWG 85 , and automatically delivered to the transmitting and receiving apparatus ( 4 ) 84 from the port 1 of the second I/O port group. These two optical signals are transmitted from the transmitters 45 and 46 of the transmitting and receiving apparatus ( 1 ) 41 in FIG. 1 .
As described above, the full-mesh WDM transmission network device in this embodiment uses the constituent components similar to those of the prior art, and keeps the similar wavelength addressing function, while reducing the accumulation number of the coherent crosstalk lights included in each WDM wavelength light to one from three, thus realizing higher quality communication. Specifically, the S/N of the received light is improved by 3 dB.
Note that the table shown in FIG. 2 is strictly an example, and other examples applicable to this embodiment exist. The way to prepare such tables will be explained below
(1) Connection of the First I/O Port
The port 1 of the first I/O port group is connected to the transmitting and receiving apparatus ( 1 ), and the port 2 is connected to the transmitting and receiving apparatus ( 2 ). The port 3 is connected to the transmitting and receiving apparatus ( 3 ), and the port 4 is connected to the transmitting and receiving apparatus ( 4 ).
(2) Determination of Directions of the Optical Signals
Direction of the optical signal in each column of the table (direction of the arrow) will be any one of the following cases 1 to 4:
Case 1. . . . The following optical signals will be directed to the right, and the remaining will be directed to the left.
the optical signal between the port 1 of the first I/O port group and the port 1 of the second I/O port group
the optical signal between the port 1 of the first I/O port group and the port 3 of the second I/O port group
the optical signal between the port 4 of the first I/O port group and the port 1 of the second I/O port group
the optical signal between the port 4 of the first I/O port group and the port 3 of the second I/O port group
the optical signal between the port 2 of the first I/O port group and the port 2 of the second I/O port group
the optical signal between the port 2 of the first I/O port group and the port 4 of the second I/O port group
the optical signal between the port 3 of the first I/O port group and the port 2 of the second I/O port group
the optical signal between the port 3 of the first I/O port group and the port 4 of the second I/O port group
Case 2. . . . The following optical signals will be directed to the right and the remaining will be directed to the left.
the optical signal between the port 2 of the first I/O port group and the port 1 of the second I/O port group
the optical signal between the port 2 of the first I/O port group and the port 3 of the second I/O port group
the optical signal between the port 3 of the first I/O port group and the port 1 of the second I/O port group
the optical signal between the port 3 of the first I/O port group and the port 3 of the second I/O port group
the optical signal between the port 1 of the first I/O port group and the port 2 of the second I/O port group
the optical signal between the port 1 of the first I/O port group and the port 4 of the second I/O port group
the optical signal between the port 4 of the first I/O port group and the port 2 of the second I/O port group
the optical signal between the port 4 of the first I/O port group and the port 4 of the second I/O port group
Case 3. . . . The following optical signals will be directed to the right, and the remaining will be directed to the left.
the optical signal between the port 1 of the first I/O port group and the port 1 of the second I/O port group
the optical signal between the port 1 of the first I/O port group and the port 3 of the second I/O port group
the optical signal between the port 2 of the first I/O port group and the port 1 of the second I/O port group
the optical signal between the port 2 of the first I/O port group and the port 3 of the second I/O port group
the optical signal between the port 3 of the first I/O port group and the port 2 of the second I/O port group
the optical signal between the port 3 of the first I/O port group and the port 4 of the second I/O port group
the optical signal between the port 4 of the first I/O port group and the port 2 of the second I/O port group
the optical signal between the port 4 of the first I/O port group and the port 4 of the second I/O port group
Case 4. . . . The following optical signals will be directed to the right, and the remaining will be directed to the left.
the optical signal between the port 3 of the first I/O port group and the port 1 of the second I/O port group
the optical signal between the port 3 of the first I/O port group and the port 3 of the second I/O port group
the optical signal between the port 4 of the first I/O port group and the port 1 of the second I/O port group
the optical signal between the port 4 of the first I/O port group and the port 3 of the second I/O port group
the optical signal between the port 1 of the first I/O port group and the port 2 of the second I/O port group
the optical signal between the port 1 of the first I/O port group and the port 4 of the second I/O port group
the optical signal between the port 2 of the first I/O port group and the port 2 of the second I/O port group
the optical signal between the port 2 of the first I/O port group and the port 4 of the second I/O I/O port group
(3) Connection of the Second I/O Port Group
In accordance with the direction of the optical signal, that is, the cases 1 to 4, each port of the second I/O port group and the transmitting and receiving apparatuses ( 1 ) to ( 4 ) are connected as follows:
For the cases 1 and 2. . . . The ports of the second I/O port group and the transmitting and receiving apparatuses ( 1 ) to ( 4 ) are connected in any one of the following manners:
The port 1 of the second I/O port group is connected to the transmitting and receiving apparatus ( 1 ), and the port 2 is connected to the transmitting and receiving apparatus ( 2 ). The port 3 is connected to the transmitting and receiving apparatus ( 4 ) and the port 4 is connected to the transmitting and receiving apparatus ( 3 ).
The port 1 of the second I/O port group is connected to the transmitting and receiving apparatus ( 4 ), and the port 2 is connected to the transmitting and receiving apparatus ( 2 ). The port 3 is connected to the transmitting and receiving apparatus ( 1 ) and the port 4 is connected to the transmitting and receiving apparatus ( 3 ).
The port 1 of the second I/O port group is connected to the transmitting and receiving apparatus ( 1 ), and the port 2 is connected to the transmitting and receiving apparatus ( 3 ). The port 3 is connected to the transmitting and receiving apparatus ( 4 ) and the port 4 is connected to the transmitting and receiving apparatus ( 2 ).
The port 1 of the second I/O port group is connected to the transmitting and receiving apparatus ( 4 ), and the port 2 is connected to the transmitting and receiving apparatus ( 3 ). The port 3 is connected to the transmitting and receiving apparatus ( 1 ) and the port 4 is connected to the transmitting and receiving apparatus ( 2 ).
The port 1 of the second I/O port group is connected to the transmitting and receiving apparatus ( 2 ), and the port 2 is connected to the transmitting and receiving apparatus ( 1 ). The port 3 is connected to the transmitting and receiving apparatus ( 3 ) and the port 4 is connected to the transmitting and receiving apparatus ( 4 ).
The port 1 of the second I/O port group is connected to the transmitting and receiving apparatus ( 3 ), and the port 2 is connected to the transmitting and receiving apparatus ( 1 ). The port 3 is connected to the transmitting and receiving apparatus ( 2 ) and the port 4 is connected to the transmitting and receiving apparatus ( 4 ).
The port 1 of the second I/O port group is connected to the transmitting and receiving apparatus ( 2 ), and the port 2 is connected to the transmitting and receiving apparatus ( 4 ). The port 3 is connected to the transmitting and receiving apparatus ( 3 ) and the port 4 is connected to the transmitting and receiving apparatus ( 1 ).
The port 1 of the second I/O port group is connected to the transmitting and receiving apparatus ( 3 ), and the port 2 is connected to the transmitting and receiving apparatus ( 4 ). The port 3 is connected to the transmitting and receiving apparatus ( 2 ) and the port 4 is connected to the transmitting and receiving apparatus ( 1 ).
For the cases 3 and 4. . . . Connection is made in any one of the following manners:
The port 1 of the second I/O port group is connected to the transmitting and receiving apparatus ( 1 ), and the port 2 is connected to the transmitting and receiving apparatus ( 3 ). The port 3 is connected to the transmitting and receiving apparatus ( 2 ) and the port 4 is connected to the transmitting and receiving apparatus ( 4 ).
The port 1 of the second I/O pot group is connected to the transmitting and receiving apparatus ( 2 ), and the port 2 is connected to the transmitting and receiving apparatus ( 3 ). The port 3 is connected to the transmitting and receiving apparatus ( 1 ) and the port 4 is connected to the transmitting and receiving apparatus ( 4 ).
The port 1 of the second I/O port group is connected to the transmitting and receiving apparatus ( 1 ), and the port 2 is connected to the transmitting and receiving apparatus ( 4 ). The port 3 is connected to the transmitting and receiving apparatus ( 2 ) and the port 4 is connected to the transmitting and receiving apparatus ( 3 ).
The port 1 of the second I/O port group is connected to the transmitting and receiving apparatus ( 2 ), and the port 2 is connected to the transmitting and receiving apparatus ( 4 ). The port 3 is connected to the transmitting and receiving apparatus ( 1 ) and the port 4 is connected to the transmitting and receiving apparatus ( 3 ).
The port 1 of the second I/O port group is connected to the transmitting and receiving apparatus ( 3 ), and the port 2 is connected to the transmitting and receiving apparatus ( 1 ). The port 3 is connected to the transmitting and receiving apparatus ( 4 ) and the port 4 is connected to the transmitting and receiving apparatus ( 2 ).
The port 1 of the second I/O port group is connected to the transmitting and receiving apparatus ( 4 ), and the port 2 is connected to the transmitting and receiving apparatus ( 1 ). The port 3 is connected to the transmitting and receiving apparatus ( 3 ) and the port 4 is connected to the transmitting and receiving apparatus ( 2 ).
The port 1 of the second I/O port group is connected to the transmitting and receiving apparatus ( 3 ), and the port 2 is connected to the transmitting and receiving apparatus ( 2 ). The port 3 is connected to the transmitting and receiving apparatus ( 4 ) and the port 4 is connected to the transmitting and receiving apparatus ( 1 ).
The port 1 of the second I/O port group is connected to the transmitting and receiving apparatus ( 4 ), and the port 2 is connected to the transmitting and receiving apparatus ( 2 ). The port 3 is connected to the transmitting and receiving apparatus ( 3 ) and the port 4 is connected to the transmitting and receiving apparatus ( 1 ).
The table is completed by the above-described manners (1) to (3). The table completed in such ways satisfies the following conditions {circle around (1)} to {circle around (5)}. Note that in this embodiment N is four.
{circle around (1)} The ports 1 to N of the first I/O port group are connected to different transmitting and receiving apparatuses among the transmitting and receiving apparatuses ( 1 ) to (N), respectively. Moreover, the ports 1 to N of the second I/O port group are connected to different transmitting and receiving apparatuses among the transmitting and receiving apparatuses ( 1 ) to (N), respectively.
{circle around (2)} The input/output combinations between the first and second I/O port groups have the periodic wavelength demultiplexing property. To be more specific, each of N optical signals, which has a different wavelength from the others, is transmitted at each of N paths between any one of the ports of the first I/O port group and N ports of the second I/O port group. Moreover, each of N optical signals, which has a different wavelength from the others, is transmitted at each of N paths between any one of the ports of the second I/O port group and N ports of the first I/O port group. As a result, among N×N port combinations made by the N ports of the first I/O port group and the N ports of the second I/O port group, there are N port combinations for each wavelength, through which optical signals having the same wavelength are transmitted.
{circle around (3)} Among the N port combinations made by any one of the ports of the first I/ 0 port group and each port of the second I/O port group, the optical signals are transmitted from the first I/O port group to the second I/O port group through the N/2 port combinations, and the optical signals are transmitted from the second I/O port group to the first I/O port group through the remaining port combinations.
{circle around (4)} Among the N port combinations through which optical signals having an equal wavelength are transmitted, the optical signals are transmitted from the first I/O port group to the second I/O port group through the N/2 port combinations, and the optical signals are transmitted from the second I/O port group to the first I/O port group through the remaining port combinations.
{circle around (5)} The ports of the second I/O port group to which the optical signals are transmitted from the ports of the first I/O port group connected to any one of the transmitting and receiving apparatuses and the ports of the first I/O port group to which the optical signals are transmitted from the ports of the second I/O port group connected to this transmitting and receiving apparatus are respectively connected to different transmitting and receiving apparatuses.
In the above described conditions {circle around (1)} to {circle around (5)}, the number of the port combinations through which the optical signals are transmitted from the first I/O port group to the second I/O port group are made to be equal to that of the port combinations through which the optical signals are transmitted from the second I/O port group to the first I/O port group, that is, N/2. However, both numbers need not to be equal necessarily. Note that if both numbers are made to be equal, the best communication quality can be achieved.
Embodiment 2
FIG. 5 is a block diagram for explaining a second embodiment of the present invention, which shows a schematic constitution of the full-mesh WDM transmission network device in which the number N is increased to eight from four in the first embodiment. In FIG. 5, reference numerals 91 denotes a transmitting and receiving apparatus; 92 and 93 , transmitters for transmitting a WDM signal (wavelength λ K : K=1 to 8); 94 and 95 , receivers for receiving the WDM signal (wavelength λ K : K=1 to 8); 96 and 97 , 1×8 wavelength multi/demultiplexes for multiplexing four optical signals having different wavelengths onto one optical fiber and demultiplexing a WDM signal wavelength-multiplexed onto one optical fiber, into four optical signals; 98 , an 8×8 wavelength multi/demultiplexer having a first I/O port group (ports 1 to 8 on the left side) composed of eight ports and a second I/O port group (ports 1 to 8 on the right side) composed of eight ports, the 8×8 wavelength multi/demultiplexer showing a periodic wavelength demultiplexing property in input/output combination, and 99 and 100 , optical fibers for optically connecting the transmitting and receiving apparatus 91 and the I/O ports of the 8×8 wavelength multi/demultiplexer 98 . Although the 8×8 wavelength multi/demultiplexer 98 is connected to the eight transmitting and receiving apparatuses, illustrations for the seven transmitting and receiving apparatuses other than the transmitting and receiving apparatus ( 1 ) 91 are omitted. In FIG. 5, the wavelength (wavelength λ K : K=1 to 8) of the WDM signals transmitted through the optical fibers 99 and 100 , the WDM signals being wavelength-multiplexed, and the transmission directions of the WDM signals, indicated by the arrow, are illustrated.
In this embodiment, a 1×8 AWG was used as the 1×8 wavelength multi/demultiplexes 96 and 97 , and an 8×8 AWG having a periodic wavelength demultiplexing property in input/output combination was used as the 8×8 wavelength multi/demultiplexer 98 . Constituent components including the transmitter, the receiver, the 1×8 AWG, the 8×8 AWG and the optical fiber, which constitute the full-mesh WDM transmission network device of this embodiment, are identical to those of the prior art. Although the 1×8 AWG was conventionally used exclusively for the wavelength multiplexer or the wavelength demultiplexing circuit, this embodiment of the present invention uses the 1×8 AWG for the wavelength multi/demultiplexer that performs the wavelength multiplexing and demultiplexing simultaneously, similarly to the first embodiment.
FIG. 6 is a table showing a periodic wavelength demultiplexing property in input/output combination of the 8×8 AWG and a port connection rule between the transmitting and receiving apparatuses and the 8×8 AWG in this embodiment of the present invention. Although the wavelength demultiplexing property of the 8×8 AWG is the same as that of the prior art, the connection relation between the transmitting and receiving apparatuses and the second I/O port group of the 8×8 AWG is different from that of the prior art similarly to the first embodiment. Moreover, the 8×8 AWG performs bi-directional input/output for the optical signals.
In this embodiment, the four optical signals among the eight optical signals having the equal wavelength are input from the first I/O port group side to the 8×8 AWG, and other four optical signals are input from the second I/O port group side thereto. Since lightwaves which are traveling in opposite directions are independent from each other, a predetermined WDM wavelength light output from the port of the AWG includes only one optical signal and three coherent crosstalk lights. For example, as shown in FIG. 7, the light having the wavelength λ 3 , which is output from the port 2 of the second I/O port group, includes only the optical signal λ 3 (thick solid line) input from the port 2 of the first I/O port group and the crosswalk lights (thin solid line) of the optical signals λ 3 input from the ports 1 , 5 and 6 of the first I/O port group, and does not include the crosswalk lights of the optical signals λ 3 input from the ports 1 , 4 , 5 and 8 of the second I/O port group. Specifically, the accumulation number of the coherent crosstalk lights is reduced to three from seven that is the accumulation number in the prior art.
In this embodiment, since the four optical signals having the equal wavelength, which are input from the first I/O port group side, are input from the ports 1 , 2 , 5 and 6 or the ports 3 , 4 , 7 and 8 and the four optical signals having the equal wavelength, which are input from the second I/O port group side, are input from the ports 1 , 4 , 5 and 8 or the ports 2 , 3 , 6 and 7 , respectively, three coherent crosstalk lights included in the output WDM wavelength fight are one adjacent crosstalk light and two non-adjacent crosstalk lights. Accordingly, in the full-mesh WDM transmission network device of this embodiment, the S/N of the WDM wavelength light received is expressed as follows.
S/N= P Signal /[P AdjCT +2 P OthCT ] (3)
The S/N is equal to 29 dB when P AdjCT /P Signal is assumed to be −30 dB and P OthCT /P Signal is assumed to be −40 dB, respectively, and the S/N is improved by 3 dB compared to 26 dB in the prior art.
FIG. 8 is a diagram for explaining wavelength addressing in this embodiment. In FIG. 8, reference numerals 101 to 108 denote eight transmitting and receiving apparatuses, and reference numeral 109 denotes an 8×8 AWG. The wavelength demultiplexing property of the 8×8 AWG and the connection relation between the transmitting and receiving apparatuses and the 8×8 AWG are explained in FIG. 6 . For example, the optical signal having the wavelength λ 6 , transmitted from the transmitting and receiving apparatus ( 1 ) 101 , is guided to the port 5 of the second I/O port group in the 8×8 AWG, and switched within the 8×8 AWG 109 . This optical signal is then sent to the transmitting and receiving apparatus ( 2 ) 102 from the port 2 of the first I/O port group. Similarly, the return signal λ 4 transmitted from the transmitting and receiving apparatus ( 2 ) 102 is guided to the port 4 of the second I/O port group in the 8×8 AWG 109 , and then sent to the transmitting and receiving apparatus ( 1 ) 101 from the port 1 of the first I/O port group. Moreover, the optical signals having the wavelengths λ 5 andλ 7 , transmitted from the transmitting and receiving apparatus ( 1 ) 101 , for example, are automatically delivered to the transmitting and receiving apparatus ( 5 ) 105 and the transmitting and receiving apparatus ( 3 ) 103 , respectively.
As described above, the full-mesh WDM transmission network device in this embodiment uses the constituent components similar to those of the prior art, and keeps the similar wavelength addressing function, while reducing the accumulation number of the coherent crosstalk lights included in each WDM wavelength light to three from seven, thus realizing higher quality communication. Specifically, the S/N of the received light is improved by 3 dB.
Embodiment 3
FIG. 9 is a block diagram for explaining a third embodiment of the present invention, which shows a schematic constitution of the full-mesh WDM transmission network device in which the number N is increased to 16 compared to the first and the second embodiments. In FIG. 9, reference numeral 111 denotes a transmitting and receiving apparatus; 112 and 113 , transmitters for transmitting a WDM signal (wavelength λ K : K=1 to 16); 114 and 115 , receivers for receiving the WDM signal (wavelength λ K : K=1 to 16); 116 and 117 , 1×16 wavelength multi/demultiplexes for multiplexing eight optical signals having different wavelengths onto one optical fiber and demultiplexing a WDM signal wavelength-multiplexed onto one optical fiber, into eight optical signals; 118 , a 16×16 wavelength multi/demultiplexer having a first I/O port group (ports 1 to 16 on the left side) composed of sixteen ports and a second I/O port group (ports 1 to 16 on the right side) composed of sixteen ports, the 16×16 wavelength multi/demultiplexer showing a periodic wavelength demultiplexing property in input/output combination; and 119 and 120 , optical fibers for optically connecting the transmitting and receiving apparatus 111 and the I/O ports of the 16×16 wavelength multi/demultiplexer 118 . Although the 16×16 wavelength multi/demultiplexer 118 is connected to the sixteen transmitting and receiving apparatuses, illustrations for the fifteen transmitting and receiving apparatuses other than the transmitting and receiving apparatus ( 1 ) 111 are omitted. In FIG. 9, illustrated are the wavelength λ K : K=1 to 16) of the WDM signals transmitted through the optical fibers 119 and 120 , the WDM signals being wavelength-multiplexed, and the transmission directions of the WDM signals, indicated by the arrow.
In this embodiment, a 1×16 AWG was used as the 1×16 wavelength multi/demultiplexes 116 and 117 , and a 16×16 AWG having a periodic wavelength demultiplexing property in input/output combination was used as the 16×16 wavelength multi/demultiplexer 118 . Constituent components including the transmitter the receiver, the 1×16 AWG, the 16×16 AWG and the optical fiber, which constitute the full-mesh WDM transmission network device of this embodiment, are identical to those of the prior art. Although the 1×16AWG was conventionally used exclusively for the wavelength multiplexer or the wavelength demultiplexing circuit, this embodiment of the present invention uses the 1×16 AWG for the wavelength multi/demultiplexer that performs the wavelength multiplexing and demultiplexing simultaneously, similarly to the first and second embodiments.
FIG. 10 is a table showing a periodic wavelength demultiplexing property in input/output combination of the 16×16 AWG and a port connection rule between the transmitting and receiving apparatuses and the 16×16 AWG in this embodiment of the present invention. Although the wavelength demultiplexing property of the 16×16 AWG is the same as that of the prior art, the port connection rule between the transmitting and receiving apparatuses and the second I/O port group of the 16×16 AWG is different from that of the prior art, similarly to the first and second embodiments. Moreover, the 16×16 AWG performs bi-directional input/output for the optical signals.
In this embodiment, the eight optical signals among the sixteen optical signals having the equal wavelength are input from the first I/O port group side to the 16×16 AWG, and other eight optical signals are input from the second I/O port group side thereto. Since lightwaves which are traveling in opposite directions are independent from each other, a predestined WDM wavelength light output from the port of the AWG includes only one optical signal and seven coherent crosstalk lights. For example, as shown in FIG. 11, the light having the wavelength λ 3 , which is output from the port 2 of the second I/O port group, includes only the optical signal λ 3 (thick solid line) input from the port 2 of the first I/O port group and the crosstalk lights (thin solid line) of the optical signals 3 input from the ports 1 , 5 , 6 , 9 , 10 , 13 , and 14 of the first I/O port group, and does not include the crosstalk lights of the optical signal 13 input from the ports 1 , 4 , 5 , 8 , 9 , 12 , 13 , and 16 of the second I/O port group. Specifically, the accumulation number of the coherent crosstalk lights is reduced to seven from fifteen that is the accumulation number in the prior art.
In this embodiment since the eight optical signals having the equal wavelength, which are input from the first I/O port group side, are input from the ports 1 , 2 , 5 , 6 , 9 , 10 , 13 , and 14 or the ports 3 , 4 , 7 , 8 , 11 , 12 , 15 , and 16 and the eight optical signals having the equal wavelength, which are input from the second I/O port group side, are input from the ports 1 , 4 , 5 , 8 , 9 , 12 , 13 , and 16 or the ports 2 , 3 , 6 , 7 , 10 , 11 , 14 , and 15 , seven coherent crosstalk lights included in the output WDM wavelength light are one adjacent crosstalk light and six non-adjacent crosstalk lights. Accordingly, in the full-mesh WDM transmission network device of this embodiment, the S/N of the WDM wavelength light received is expressed as follows:
S/N= P Signal /[P AdjCT +6 P OthCT ] (4)
The S/N is equal to 28 dB when P AdjCT /P Signal is assumed to be −30 dB and P OthCT /P Signal is assumed to be −40 dB, respectively, and the S/N is improved by 3 dB compared to 25 dB in the prior art.
FIG. 12 is a diagram for explaining wavelength addressing in this embodiment. In FIG. 12, reference numerals 121 to 136 denote sixteen transmitting and receiving apparatuses, and reference numeral 137 denotes a 16×16 AWG. The wavelength demultiplexing property of the 16×16 AWG and the connection relation between the transmitting and receiving apparatuses and the 16×16 AWG are explained in FIG. 10 . For example, the optical signal having the wavelength λ 10 , transmitted from the transmitting and receiving apparatus ( 1 ) 121 , is guided to the port 9 of the second I/O port group in the 16×16AWG 137 , and switched within the 16×16 AWG 137 . This optical signal is then sent to the transmitting and receiving apparatus ( 2 ) 122 from the port 2 of the first I/O port group. Similarly, the return signal λ 8 transmitted from the transmitting and receiving apparatus ( 2 ) 122 is guided to the port 8 of the second I/O port group in the 16×16 AWG 137 , and then sent to the transmitting and receiving apparatus ( 1 ) 121 from the port 1 of the first I/O port group. Moreover, the optical signals having the wavelengths λ 6 and λ 9 , transmitted from the transmitting and receiving apparats ( 1 ) 121 , for example, are automatically delivered to the transmitting and receiving apparatus ( 6 ) 126 and the transmitting and receiving apparatus ( 9 ) 129 , respectively.
As described above, the full-mesh WDM transmission network device in this embodiment uses the constituent components similar to those of the prior art, and keeps the similar wavelength addressing function, while reducing the accumulation number of the coherent crosstalk lights included in each WDM wavelength light to seven from fifteen, thus realizing higher quality communication. Specifically, the S/N of the received light is improved by 3 dB.
Embodiment 4
FIG. 13 is a block diagram for explaining a fourth embodiment of the present invention, which shows a schematic constitution of a full-mesh WDM transmission network device having a different connection constitution from that of the first embodiment, in which the number N is four. Referring to FIG. 13, reference numerals 141 to 144 denote a transmitting and receiving apparatus; 145 to 152 , a transmitter for sending a WDM signal (wavelength λ K : K=1, 2, 3, 4); 153 to 160 , a receiver for receiving a WDM signal (wavelength λ K : K=1, 2, 3, 4); 161 to 168 , a 1×4 wavelength multi/demultiplexer which multiplexes two optical signals of different wavelengths onto one optical fiber and demultiplexes a WDM signal wavelength-multiplexed on one optical fiber, into two optical signals of different wavelengths; 169 , a 4×4 wavelength multi/demultiplexer having a first I/O port group ( 1 to 4 on the left side) composed off our ports and a second I/O port group ( 1 to 4 on the right side) composed of four ports, the 4×4 wavelength multi/demultiplexer having a periodic wavelength demultiplexing property in input/output combination; and 170 to 177 , an optical fiber for optically connecting each of the transmitting and receiving apparatuses 141 to 144 and the I/O port of each of the 4×4 wavelength multi/demultiplexer 169 . In FIG. 13, shown are the wavelengths (λ K : K=1, 2, 3, 4) of the WDM signals transmitted on the corresponding optical fibers 170 to 177 , the WDM signals being wavelength-multiplexed, and the transmission directions (arrow) thereof.
In this embodiment, as the 1×4 wavelength multi/demultiplexes 161 to 168 , a 1×4 AWG was used, and as the 4×4 wavelength multi/demultiplexer 169 , a 4×4 AWG having a periodic wavelength demultiplexing property in input/output combination was used. Constituent components including the transmitter, the receiver, the 1×4 AWG, the 4×4 AWG and the optical fiber, which constitute the full-mesh WDM transmission network device of this embodiment, are the same as those of the prior art. Note that although the 1×4 AWG was conventionally used exclusively for the wavelength multiplexer or the wavelength demultiplexing circuit, in this embodiment of the present invention the 1×4 AWG is used for the wavelength multi/demultiplexer which performs the wavelength multiplexing and demultiplexing simultaneously, similarly to the first to third embodiments.
FIG. 14 is a table showing a periodic wavelength demultiplexing property in input/output combination of the 4×4 AWG and a port connection rule between the transmitting and receiving apparatuses and the 4×4 AWG in this embodiment. The wavelength demultiplexing property of the 4×4 AWG has the same periodicity as that of the prior art. However the connection relation between the transmitting and receiving apparatuses and the second I/O port group of the 4×4 AWG is different from that of the prior art similarly to the first to third embodiments. A bi-directional input/output of the optical signal is performed.
In this embodiment, two optical signals among the four optical signals having an equal wavelength are input from the first I/O port group side to the 4×4 AWG, and other two optical signals are input from the second I/O port group side thereto. Since lightwaves which are traveling in opposite directions are independent from each other, a predetermined WDM wavelength light output from the port of the 4×4 AWG includes only one optical signal and one coherent crosstalk light. For example, as shown in FIG. 15, the light having the wavelength λ 3 , which is output from the port 2 of the second I/O port group, includes only the optical signal λ 3 (thick solid line) input from the port 2 of the first I/O port group and the crosstalk light (thin solid line) of the optical signal λ 3 input from the port 4 of the first I/O port group, and does not include the crosstalk lights of the optical signals λ 3 input from the ports 1 and 3 of the second I/O port group. Specifically, the accumulation number of the coherent crosstalk lights is reduced to one from three, which is the accumulation number in the prior art.
In this embodiment, since the two optical signals having the equal wavelength, which are input from the same port group side, are input from the ports which are not adjacent to each other, for example, the ports 1 and 3 or the ports 2 and 4 , one coherent crosstalk light included in the output WDM wavelength light from the 4×4 AWG is a nonadjacent crosstalk light. Accordingly, in the full-mesh WDM transmission network device of this embodiment, the S/N of the WDM wavelength light received is expressed as follows.
S/N= P Signal /P OthCT (5)
The S/N is equal to 40 dB when P othCT /P signal is assumed to be −40 dB, and the S/N is improved by 13 dB compared to 27 dB of the prior art.
FIG. 16 is a diagram for explaining wavelength addressing in this embodiment. In FIG. 16, reference numerals 181 to 184 denote four transmitting and receiving apparatuses, and reference numeral 185 denotes 4×4 AWG. The wavelength demultiplexing property of the 4×4 AWG and the connection relation between the transmitting and receiving apparatuses and the 4×4 AWG are explained in FIG. 14 . For example, one optical signal having the wavelength λ 1 transmitted from the transmitting and receiving apparatus ( 1 ) 181 is guided to the port 4 of the second I/O port group in the 4×4AWG 185 , and switched within the 4×4 AWG 185 . This optical signal is then sent to the transmitting and receiving apparatus ( 2 ) 182 from the port 2 of the first I/O port group. Similarly, the return signal λ 2 returned from the transmitting and receiving apparatus ( 2 ) 182 is guided to the port 3 of the second I/O port group in the 4×4 AWG 185 , and then sent to the transmitting and receiving apparatus ( 1 ) 181 from the port 1 of the first I/O port group. Furthermore, the other optical signal having the wavelength λ 1 , and one optical signal having the wavelength λ 2 , which are transmitted from the transmitting and receiving apparatus ( 1 ) 181 , are automatically delivered to the transmitting and receiving apparatuses ( 4 ) 184 and ( 3 ) 183 , respectively.
As described above, the full-mesh WDM transmission network device in this embodiment uses the constituent components similar to those of the prior art, and maintains the same wavelength addressing function, while reducing the accumulation number of the coherent crosstalk lights included in each WDM wavelength light to one from three, thus realizing higher quality communication. Specifically, the S/N of the received light is improved by 13 dB.
Note that the table shown in FIG. 14 is strictly an example, and another examples applicable to this embodiment exist. The way to prepare such tables will be explained below.
(1) Connection of the First I/O Port
The port 1 of the first I/O port group is connected to the transmitting and receiving apparatus ( 1 ), and the port 2 is connected to the transmitting and receiving apparatus ( 2 ). The port 3 is connected to the transmitting and receiving apparatus ( 3 ), and the port 4 is connected to the transmitting and receiving apparatus ( 4 ).
(2) Determination of Directions of the Optical Signals
Direction of the optical signal in each column of the table (direction of the arrows) will be any one of the following cases 1 to 4.
Case 1. . . . The following optical signals will be directed to the right, and the remaining will be directed to the left.
the optical signal between the port 1 of the first I/O port group and the port 1 of the second I/O port group
the optical signal between the port 1 of the first I/O port group and the port 2 of the second I/O port group
the optical signal between the port 2 of the first I/O port group and the port 2 of the second I/O port group
the optical signal between the port 2 of the first I/O port group and the port 3 of the second I/O port group
the optical signal between the port 3 of the first I/O port group and the port 3 of the second I/O port group
the optical signal between the port 3 of the first I/O port group and the port 4 of the second I/O port group
the optical signal between the port 4 of the first I/O port group and the port 4 of the second I/O port group
the optical signal between the port 4 of the first I/O port group and the port 1 of the second I/O port group
Case 2. . . . The following optical signals will be directed to the right, and the remaining will be directed to the left.
the optical signal between the port 1 of the first I/O port group and the port 4 of the second I/O port group
the optical signal between the port 1 of the first I/O port group and the port 1 of the second I/O port group
the optical signal between the port 2 of the first I/O port group and the port 1 of the second I/O port group
the optical signal between the port 2 of the first I/O port group and the port 2 of the second I/O port group
the optical signal between the port 3 of the first I/O port group and the port 2 of the second I/O port group
the optical signal between the port 3 of the first I/O port group and the port 3 of the second I/O port group
the optical signal between the port 4 of the first I/O port group and the port 3 of the second I/O port group
the optical signal between the port 4 of the first I/O port group and the port 4 of the second I/O port group
Case 3. . . . The following optical signals will be directed to the fight and the remaining will be directed to the left.
the optical signal between the port 1 of the first I/O port group and the port 3 of the second I/O port group
the optical signal between the port 1 of the first I/O port group and the port 4 of the second I/O port group
the optical signal between the port 2 of the first I/O port group and the port 4 of the second I/O port group
the optical signal between the port 2 of the first I/O port group and the port 1 of the second I/O port group
the optical signal between the port 3 of the first I/O port group and the port 1 of the second I/O port group
the optical signal between the port 3 of the first I/O port group and the port 2 of the second I/O port group
the optical signal between the port 4 of the first I/O port group and the port 2 of the second I/O port group
the optical signal between the port 4 of the first I/O port group and the port 3 of the second I/O port group
Case 4. . . . The following optical signals will be directed to the right, and the remaining will be directed to the left.
the optical signal between the port 1 of the first I/O port group and the port 2 of the second I/O port group
the optical signal between the port 1 of the first I/O port group and the port 3 of the second I/O port group
the optical signal between the port 2 of the first I/O port group and the port 3 of the second I/O port group
the optical signal between the port 2 of the first I/O port group and the port 4 of the second I/O port group
the optical signal between the port 3 of the first I/O port group and the port 4 of the second I/O port group
the optical signal between the port 3 of the first I/O port group and the port 1 of the second I/O port group
the optical signal between the port 4 of the first I/O port group and the port 1 of the second I/O port group
the optical signal between the port 4 of the first I/O port group and the port 2 of the second I/O port group
(3) Connection of the second I/O port group
The ports of the second I/O port group and the transmitting and receiving apparatuses ( 1 ) to ( 4 ) are connected in any one of the following manners.
The port 1 of the second I/O port group is connected to transmitting and receiving apparatus ( 4 ), and the port 2 is connected to the transmitting and receiving apparatus ( 3 ). The port 3 is connected to the transmitting and receiving apparatus ( 2 ) and the port 4 is connected to the transmitting and receiving apparatus ( 1 ).
The port 1 of the second I/O port group is connected to the transmitting and receiving apparatus ( 3 ), and the port 2 is connected to the transmitting and receiving apparatus ( 2 ). The port 3 is connected to the transmitting and receiving apparatus ( 1 ) and the port 4 is connected to the transmitting and receiving apparatus ( 4 ).
The port 1 of the second I/O port group is connected to the transmitting and receiving apparatus ( 2 ), and the port 2 is connected to the transmitting and receiving apparatus ( 1 ). The port 3 is connected to the transmitting and receiving apparatus ( 4 ) and the port 4 is connected to the transmitting and receiving apparatus ( 3 ).
The port 1 of the second I/O port group is connected to the transmitting and receiving apparatus ( 1 ), and the port 2 is connected to the transmitting and receiving apparatus ( 4 ). The port 3 is connected to the transmitting and receiving apparatus ( 3 ) and the port 4 is connected to the transmitting and receiving apparatus ( 2 ).
The table is completed by the above-described ways (1) to (3). The table completed in such ways satisfies the following condition {circle around (6)} in addition to the conditions {circle around (1)} to {circle around (5)} described in the first embodiment. Note that in this embodiment N is four.
{circle around (6)} The wavelengths of all the optical signals transmitted from any one of the ports of one I/O port group to the other I/O port group, are different from a wavelength of any optical signal transmitted from a port adjacent to the said one port toward the other I/O port group.
Embodiment 5
FIG. 17 is a block diagram for explaining a fifth embodiment of the present invention, which shows a schematic constitution of a full-mesh WDM transmission network device in which the number N is increased to eight compared to the fourth embodiment. Referring to FIG. 17, reference numerals 191 denotes a transmitting and receiving apparatus; 192 and 193 , a transmitter for sending a WDM signal (wavelength λ K : K=1, 2, 3, . . . , 8); 194 and 195 ,a receiver for receiving a WDM signal (wavelength λ K : K=1, 2, 3, . . . , 8); 196 and 197 , a 1×8 wavelength multi/demultiplexer which multiplexes four optical signals of different wavelengths onto one optical fiber and demultiplexes a WDM signal, wavelength-multiplexed onto one optical fiber, into four optical signals; 198 , an 8×8 wavelength multi/demultiplexer having a first I/O port group ( 1 to 8 on the left side) composed of eight ports and a second I/O port group ( 1 to 8 on the right side) composed of eight ports, the 8×8 wavelength multi/demultiplexer having a periodic wavelength demultiplexing property in input/output combination; and 199 and 200 , an optical fiber for optically connecting each of the transmitting and receiving apparatus 191 and the I/O port of the 8×8 wavelength multi/demultiplexer 198 . Although the 8×8 wavelength multi/demultiplexer 198 is connected to the eight transmitting and receiving apparatuses, illustrations for the seven transmitting and receiving apparatuses other than the transmitting and receiving apparatus ( 1 ) 191 are omitted. In FIG. 17, shown are the wavelengths (λ K : K=1, 2, 3, . . . , 8) of the WDM signals transmitted on the corresponding optical fibers 199 and 200 , the WDM signals being wavelength-multiplexed, and the transmission directions (arrow) thereof.
In this embodiment, as the 1×8 wavelength multi/demultiplexes 196 and 197 , a 1×8 AWG was used, and as the 8×8 wavelength multi/demultiplexer 198 , an 8×8 AWG having a periodic wavelength demultiplexing property in input/output combination was used. Constituent components including the transmitter, the receiver, the 1×8 AWG, the 8×8 AWG and the optical fiber, which constitute the full-mesh WDM transmission network device of this embodiment, are the same as those of the prior art. Note that although the 1×8 AWG was conventionally used exclusively for the wavelength multiplexer or the wavelength demultiplexing circuit, in this embodiment the 1×8 AWG is used as the wavelength multi/demultiplexer which performs the wavelength multiplexing and demultiplexing simultaneously, similarly to the first to fourth embodiments.
FIG. 18 is a table showing a periodic wavelength demultiplexing property in input/output combination of the 8×8 AWG and a port connection rule between the transmitting and receiving apparatuses and the 8×8 AWG in this embodiment. The wavelength demultiplexing property of the 8×8 AWG has the same periodicity as that of the prior art. However the connection relation between the transmitting and receiving apparatuses and the second I/O port group of the 4×4 AWG is different from that of the prior art, similarly to the first to third embodiments. A bi-directional input/output of the optical signal is performed.
In this embodiment, the four optical signals among the eight optical signals having the equal wavelength are input from the first I/O port group side to the 8×8 AWG, and other four optical signals are input from the second I/O port group side thereto. Since lightwaves which are traveling in opposite directions are independent from each other, a predetermined WDM wavelength light output from the port of the 8×8 AWG includes only one optical signal and thee coherent crosstalk lights. For example, as shown in FIG. 19, the light having the wavelength λ 3 , which is output from the port 2 of the second I/O port group, includes only the optical signal λ 3 (thick solid line) input from the port 2 of the first I/O port group and the crosstalk lights (thin solid line) of the optical signals λ 3 input from the ports 4 , 6 , and 8 of the first I/O port group, and does not include the crosstalk lights of the optical signals λ 3 input from the ports 1 , 3 , 5 , and 7 of the second I/O port group. Specifically, the accumulation number of the coherent crosstalk lights is reduced to three from seven that is the accumulation number in the prior art.
In this embodiment since the four optical signals having the equal wavelength which are input from the same port group side, are input from either the ports 1 , 3 , 5 , and 7 or the ports 2 , 4 , 6 , and 8 , which are not adjacent to each other, three coherent crosstalk lights included in the output WDM wavelength light from the 8×8 AWG are non-adjacent crosstalk lights. Accordingly, in the full-mesh WDM transmission network device of this embodiment the S/N of the WDM wavelength light received is expressed as follows.
S/N= P Signal /3 P OthCT (6)
The S/N is equal to 35 dB when P othCT /P signal is assumed to be −40 dB, and the S/N is improved by 9 dB compared to 26 dB in the prior art.
FIG. 20 is a diagram for explaining wavelength addressing in this embodiment. In FIG. 20, reference numerals 201 to 208 denote eight transmitting and receiving apparatuses, and reference numeral 209 denotes an 8×8 AWG. The wavelength demultiplexing property of the 8×8 AWG and the connection relation between the transmitting and receiving apparatuses and the ports of the 8×8 AWG are explained in FIG. 18 . For example, one optical signal having the wavelength λ 1 transmitted from the transmitting and receiving apparatus ( 1 ) 201 is guided to port 8 of the second I/O port group of the 8×8 AWG 209 , and switched within the 8×8 AWG 209 . This optical signal is then sent to the transmitting and receiving apparatus ( 2 ) 202 from the port 2 of the first I/O port group. Similarly, the return signal λ 7 returned from the transmitting and receiving apparatus ( 2 ) 202 is guided to the port 7 of the second I/O port group in the 8×8 AWG 209 , and then sent to the transmitting and receiving apparatus ( 1 ) 201 from the port 1 of the first I/O port group. Furthermore, the optical signals having the wavelengths λ 4 and λ 6 , which are transmitted from the transmitting and receiving apparatus ( 1 ) 201 , for example, are automatically delivered to the transmitting and receiving apparatuses ( 5 ) 205 and ( 3 ) 203 , respectively.
As described above, the full-mesh WDM transmission network device in this embodiment uses the constituent components similar to those of the prior art, and keeps the similar wavelength addressing function, while reducing the accumulation number of the coherent crosstalk lights included in each WDM wavelength light to three from seven, thus realizing higher quality communication. Specifically, the S/N of the received light is improved by 9 dB.
Embodiment 6
FIG. 21 is a block diagram for explaining a sixth embodiment of the present invention, which shows a schematic constitution of a full-mesh WDM transmission network device in which the number N is increased to sixteen compared to the fourth and fifth embodiments. Referring to FIG. 21, reference numerals 211 denotes a transmitting and receiving apparatus; 212 and 213 , a transmitter for sending a WDM signal (wavelength λ K : K=1, 2, 3, . . . , 16); 214 and 215 , a receiver for receiving a WDM signal (wavelength λ K : K=1, 2, 3, . . . , 16); 216 and 217 , a 1×16 wavelength multi/demultiplexer which multiplexes eight optical signals of different wavelengths onto one optical fiber and demultiplexes a WDM signal wavelength-multiplexed on one optical fiber, into eight optical signals of different wavelengths; 218 , a 16×16 wavelength multi/demultiplexer having a first I/O port group ( 1 to 16 on the left side) composed of sixteen ports and a second I/O port group ( 1 to 16 on the right side) composed of sixteen ports, the 16×16 wavelength multi/demultiplexer having a periodic wavelength demultiplexing property in input output combination; and 219 and 220 , an optical fiber for optically connecting each of the transmitting and receiving apparatus 211 and the I/O port of the 16×16 wavelength multi/demultiplexer 218 . Although the 16×16 wavelength multi/demultiplexer 218 is connected to the sixteen transmitting and receiving apparatuses, illustrations for the fifteen transmitting and receiving apparatuses other than the transmitting and receiving apparatus ( 1 ) 211 are omitted. In FIG. 21, shown are the wavelengths (λ K : K 1, 2, 3, . . . , 16) of the WDM signals transmitted on the corresponding optical fibers 219 and 220 , the WDM signals being wavelength-multiplexed, and the transmission directions (arrow) thereof.
In this embodiment, as the 1×16 wavelength multi/demultiplexes 216 and 217 , a 1×16 AWG was used, and as the 16×16 wavelength multi/demultiplexer 218 , a 16×16 AWG having a periodic wavelength demultiplexing property in input/output combination was used. Constituent components including the transmitter, the receiver, the 1×16 AWG, the 16×16 AWG and the optical fiber, which constitute the fir-mesh WDM transmission network device of this embodiment, are the same as those of the port art. Note that although the 1×16 AWG was conventionally used exclusively for the wavelength multiplexer or the wavelength demultiplexing circuit, in this embodiment the 1×16 AWG is used as the wavelength multi/demultiplexer which performs the wavelength multiplexing and demultiplexing simultaneously, similarly to the first to fifth embodiments.
FIG. 22 is a table showing a periodic wavelength demultiplexing property in input/output combination of the 16×16 AWG and a port connection rule between the transmitting and receiving apparatuses and the 16×16 AWG in this embodiment. The wavelength demultiplexing property of the 16×16 AWG has the same periodicity as that of the prior art. However the connection relation between the transmitting and receiving apparatuses and the second I/O port group of the 16×16 AWG is different from that of the prior art, similarly to the first to fifth embodiments. A bi-directional input/output of the optical signal is performed.
In this embodiment eight optical signals among the sixteen optical signals having the equal wavelength are input from the first I/O port group side to the 16×16 AWG, and other eight optical signals are input from the second I/O port group side thereto. Since lightwaves which are traveling in opposite directions are independent from each other, a predetermined WDM wavelength light output from the port of the 16×16 AWG includes only one optical signal and seven coherent crosstalk lights. For example, as shown in FIG. 23, the light having the wavelength λ 3 , which is output from the port 2 of the second I/O port group, includes only the optical signal λ 3 (thick solid line) input from the port 2 of the first I/O port group and the crosstalk lights (thin solid line) of the optical signals λ 3 input from the ports 4 , 6 , 8 , 10 , 12 , 14 , and 16 of the first I/O port group, and does not include the crosstalk lights of the optical signals λ 3 input from the ports 1 , 3 , 5 , 7 , 9 , 11 , 13 , and 15 of the second I/O port group. Specifically, the accumulation number of the coherent crosstalk lights is reduced to seven from fifteen hat is the accumulation number in the prior art.
In this embodiment, since the eight optical signals having the equal wavelength, which are input from the same port group side, are input from either the ports 1 , 3 , 5 , 7 , 9 , 11 , 13 , and 15 or the ports 2 , 4 , 6 , 8 , 10 , 12 , 14 , and 16 which are not adjacent to each other, seven coherent crosstalk lights included in the output WDM wavelength light from the 16×16 AWG are non-adjacent crosstalk lights. Accordingly, in the full-mesh WDM transmission network device of this embodiment, the S/N of the WDM wavelength light received is expressed as follows:
S/N= P Signal /7 P OthCT (7)
The S/N is equal to 32 dB when P otheCT /P signal is assumed to be −40 dB, and the S/N is improved by 7 dB compared to 25 dB in the prior art.
FIG. 24 is a diagram for explaining wavelength addressing in this embodiment. In FIG. 24, reference numerals 221 to 236 denote sixteen transmitting and receiving apparatuses, and reference numeral 237 denotes a 16×16 AWG. The wavelength demultiplexing property of the 16×16 AWG and the connection relation between the transmitting and receiving apparatuses and the ports of the 16×16 AWG are explained in FIG. 22 . For example, one optical signal having the wavelength λ 1 transmitted from the transmitting and receiving apparatus ( 1 ) 221 is guided to the port 16 of second I/O port group of the 16×16 AWG 237 , and switched within the 16×16 AWG 237 . This optical signal is then sent to the transmitting and receiving apparatus ( 2 ) 222 from the port 2 of the first I/O port group. Similarly, the return signal λ 15 returned from the transmitting and receiving apparatus ( 2 ) 222 is guided to the port 15 of the second I/O port group in the 16×16 AWG 237 , and then sent to the transmitting and receiving apparatus ( 1 ) 221 from the port 1 of the first I/O port group. Furthermore, the optical signals having the wavelengths λ 8 and λ 11 , which are transmitted from the transmitting and receiving apparatus ( 1 ) 221 , for example, are automatically delivered to the transmitting and receiving apparatuses ( 9 ) 229 and ( 6 ) 226 , respectively.
As described above, the full-mesh WDM transmission network device in this embodiment uses the constituent components similar to those of the prior art and maintains the same wavelength addressing function, while reducing the accumulation number of the coherent crosstalk lights included in each WDM wavelength light to seven from fifteen, thus realizing higher quality communication. Specifically, the S/N of the received light is improved by 7 dB.
Although the full-mesh optical wavelength division multiplexing transmission network device of the present invention in which N is 4, 8 and 16 in six embodiments, was described, as a matter of course, it is possible to constitute the full-mesh optical wavelength division multiplexing transmission network device of the present invention even when N takes any value. Moreover, the connection relation between the transmitting and receiving apparatuses and the ports of the N×N AWG and the combinations of the transmitting directions of the optical signals between I/O ports in the N×N AWG are not limited to those illustrated in FIGS. 2, 6 , 10 , 14 , 18 and 22 . It is apparent that other connection relations and other combinations, by which the operations similar to those of the embodiments can be realized, are within the spirit and scope of the present invention. | The object of the present invention is to provide a full-mesh optical wavelength division multiplexing transmission network device which is capable of exhibiting excellent communication quality and being mass produced, by reducing the accumulation number of coherent crosstalk lights, without any modification of constituent components constituting the conventional one. In the full-mesh optical wavelength division multiplexing transmission network device, provided is an N×N wavelength multi/demultiplexer having a periodic wavelength demultiplexing property in input/output combination, which performs input/output from/to first and second I/O port groups for optical signals and allows lightwaves traveling in opposite directions not to interfere with each other within the circut, thus reducing the accumulation number of coherent crosstalk lights in WDM wavelength lights and improving S/N of a received light. Particularly, by preventing the accumulation of adjacent crosstalk lights, communications with higher quality can be achieved. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to fire barrier assemblies for apertures through which one or more electrical cables may pass and more specifically, to a novel construction of the frame and sealing elements for achieving the fire barrier.
2. Prior Art
The U.S. Pat. No., to Williams, 1,851,940, discloses a closure for conduits and the like having electrical cables passing therethrough wherein a septum or plug comprised of one or more pieces of resilient material having cutout portions for receiving the cables, is inserted into the conduit in close fitting relation about the cables. A pair of end plates on opposite sides of the septum or plug are then bolted together and upon being drawn together will force the resilient material into close intimate engagement with the conduit wall and the external surface of the cables.
The U.S. Pat. No., to Brattberg, 2,732,226, is directed to a pressure-tight packing assembly for conductors passing through a wall. The pressure-tight packing assembly consists of a short, rectangular tube which is filled in part with elastic blocks of varying sizes. Adjacent blocks may be provided with comlimentary grooves which will define a cylindrical passage for a specific size electrical condutor and some blocks are provided without grooves to merely act as fillers. After the blocks and cables are all assembled in the desired relationship, a final pressure sealing may be obtained between the conductors, the elastic blocks and the tube by compressing the blocks in a direction perpendicular to the cables by means of a common plate. Suitable arrangements are then provided to fill the gap left between the opposite side of the plate and the tube.
The U.S. Pat. No., to Anderberg, 3,976,825, is directed to a lead through for electrical cables which will be fire proof, gas proof and liquid proof at a predetermined temperature. The cables extend through an opening in a ceiling, floor or wall and a pair of complimentary guide strips, each of which is provided with a semi-cylindrical groove, surround each cable. Interfitting filling members are also provided to completely fill the opening. There is no compression applied to the filling members, guide strips or cables so that each of these elements may readily be withdrawn from the opening in order to change the configuration and add or substract cables passing therethrough. The guide strips and filling members are composed of a material having a high coefficient of cubic expansion whereby in the event of fire, the guide means and filling members will expand to form a tight seal within the frame and against the cables. One end of the assembly may be coated with a material to seal the spaces between the guide strips and the cables in a gas tight and liquid proof manner.
The U.S. Pat. No., to Bradley et al, 4,061,344, is directed to a fitting for penetration through fire rated barriers to provide for the passage of pipes, cables, or conduits. According to one embodiment of this patent, a plurality of layers or plates of intumescent material are provided in alternating relationship with one or more layers or plates of an elastomeric sealing material. A pair of rigid compression plates are provided on opposite sides of the assembly and are adjustably secured together by means of bolts extending through the assembly. One or more apertures may be provided through the plurality of layers or plates for the passage of a cable or the like. The rigid compression plates may be coated with an intumescent material and upon drawing the rigid compression plates together, the elastomeric plates will be expanded to closely grip the walls of the opening and the cables passing therethrough. The elastomeric material provides a gas and liquid seal at normal temperatures and upon being exposed to elevated temperatures, the intumescent material will expand to compensate for the destruction or shrinking of the elastomeric material and the insulation surrounding an electrical cable to maintain a tight seal between the opening and the conductor of the electrical cable. In another embodiment according to this patent, a single heterogeneous member comprising both the sealing material and the intumescent material is disposed between the two compression plates.
SUMMARY OF THE INVENTION
The present invention is directed to a new and improved fire barrier assembly for use with electrical cables or the like passing through an opening in a fire wall. A plurality of plate-like assemblies of varying thicknesses, each of which is comprised of a plate of elastomeric-intumescent material and a pair of compression plates disposed at opposite ends thereof which are interconnected by adjustable connecting means to vary the spacing between the compression plate are disposed in a rectilinear frame in side-by-side relation perpendicular to the fire wall. Each plate is slidably connected to the frame by a tongue and groove connection. At least one pair of plate-like members are provided with complimentary semi-cylindrical grooves so that upon location of said pair of plate-like assemblies in side-by-side relation within the frame, at least one cylindrical passage will be provided for the reception of a cable or the like therethrough. A plurality of cylindrical passages may be provided in said pair of plate-like members which are all of the same radius while other pairs of plate-like members may be provided with one or more cylindrical passages having different radii. Other plate-like members are provided with semi-cylindrical grooves on opposite faces thereof and still other plate-like members which act as filler members are not provided with any grooves.
Upon completely filling the rectinlinear frame with plate-like assemblies with one or more cables or the like disposed in respective passages, the connecting means between the end plates are adjusted to draw each pair of end plate towards each other so as to expand the elastomeric-intumescent plate into sealing engagement with the frame, adjacent plates and cables or the like passing therethrough. It is also contemplated that the rectinlinear frame could be completely filled with a single plate-like assembly or a plurality of plate-like assemblies which are not provided with grooves to accomodate cables or the like. All of the end plates disposed on one side of the frame have a dimension which will prevent the entry of the plates into the frame whereas the end plates at the opposite end of each plate-like assembly are dimensioned such that they can be drawn into the frame. The exterior surfaces of the end plates and the frame are coated with an intumescent material to provide additional heat insulation.
The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of a preferred embodiment of the invention as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an end elevation view of a fire barrier assembly according to the present invention with some of the end plates removed.
FIG. 2 is an exploded, partially sectioned end elevation view of the frame for the fire barrier assembly in partially assembled condition.
FIG. 3 is a side elevation view of the fire barrier assembly according to the present invention.
FIG. 4 is a sectional view taken along the line IV--IV of FIG. 1.
FIGS. 5A and 5B are end elevation views showing two different sizes of filler plates of elastomeric-intumescent material.
FIG. 5C is an end elevation view of an elastomeric-intumescent plate having semi-cylindrical grooves in opposite surfaces thereof.
FIGS. 5D-I are end elevation views of various sized pairs of elastomeric-intumescent material plates providing different diameter cylindrical passages.
DETAILED DESCRIPTION OF THE INVENTION
The fire barrier assembly 10 according to the present invention is adapted to be located in an opening 12 in a fire wall 14. The term fire wall includes ceilings, floors or any other structural element intended to act as a fire stop.
The fire barrier assembly 10 is comprised of a rectilinear frame 16 which may be constructed of any suitable size. In order to facilitate the construction of the frame in various sizes, the frame 16 is comprised of two end pieces 18 and 20 and two elongated side pieces 22 and 24. The end pieces 18 and 20 are provided with through passages 26 and 28 for the passage of bolts 30 and 32 which are threaded into engagement with threaded bores 34 and 36 to secure the end pieces to the elongated side pieces. The end pieces 18 and 20 are preferably of a single size whereas the side pieces 22 and 24 come in a variety of lengths to provide different size rectilinear frames. The plate-like assemblies which are adapted to be inserted into the frame are preferably of the same height but vary in thickness as will be described hereinafter. Thus, by utilizing side pieces 22 and 24 of different lengths, the number of plate-like assemblies which can be accomodated within the frame can be varied. A plurality of apertures 38 are provided in the peripherial flange of the frame 16 for the passage of bolts 40 to secure the frame 16 to the fire wall 14.
A plurality of plate-like assemblies 42 are adapted to be located in side-by-side relation within the aperture defined by the frame 16. While each of the plate-like assemblies 42 may vary in width as well as in the number and size of cable accomodating grooves, the construction of a representative plate assembly is best understood by reference to FIG. 4. Each plate-like assembly 42 is comprised of a plate or block 46 of an elastomeric-intumescent material, the composition of which will be described in greater detail hereinafter, which is provided with one or more ribs or projections 48 extending the length of the top and bottom surfaces of the plate 46. The width of each rib 48 is slightly less than the distance between the ribs 50 on the side members 22 and 24 to provide a tongue and groove connection for slidably supporting each of the plate-like assemblies 42 in the frame 16.
As best seen in FIGS. 1 and 5, the plates of elastomeric-intumescent material come in a wide variety of widths and may or may not be provided with semi-cylindrical grooves of varying sizes. The plates 46 such as shown in FIG. 4 and FIGS. 5D, F, G, H and I are provided with a plurality of longitudinally extending parallel semi-cylindrical grooves 52 in only one side surface of the plate. When two of these plates are disposed adjacent each other in the frame 16, the semi-cylindrical grooves will define a plurality of cylindrical passages extending entirely through the frame. Such cylindrical passages are adapted to receive electrical cables 54 as shown in FIG. 4 which have a diameter substantially equal to the diameter of the cylindrical passage. The plates 46 may be fitted about the cables prior to insertion into the frame or the cables may be fed through the cylindrical passages after the plates are located in the frame 16. The latter procedure would be much more difficult due to frictional forces and assembly prior to insertion into the frame would be the preferred method. The number of grooves in each plate and the thickness of the plate will vary depending upon the diameter of the grooves formed in the plate. The thicker plates have more than one rib 48 on the top and bottom surfaces so that all of the spaces between the ribs 50 on the frame will be filled. The plates 46' as shown in FIG. 5E, have a large number of smaller diameter grooves 52' and therefore the grooves may be located in opposite side faces of the plate in staggered relationship. The plate 46" as shown in FIG. 5C, also shows a plurality of small diameter grooves 52" located in opposite side faces of the plate with the grooves disposed directly opposite each other. This, of course, can only take place for the very smallest groove diameters so that sufficient material will be disposed between the opposed grooves. The plates 46'" as shown in FIGS. 5A and B are not provided with any grooves and act as filler plates. Thus, depending upon the number and size of the cables passing through the frame 16, various combinations of plates can be assembled as shown in FIG. 1. While only six electrical conduits 54 are shown in the cylindrical passages of FIG. 1, it is obvious that the other cylindrical passages defined by the semi-cylindrical grooves 52 would also have electrical conduits, electrical cables or the like passing therethrough. In those instances where two adjacent plates define a plurality of cylindrical passages and there are not enough cables or conduits to fill all of the passages, a cylindrical filler plug of the same material as the plates 46 could be inserted in the passage.
Once the assembly of elastomeric-intumescent plates, cables, conduits and the like are assembled in the frame to completely fill the same, it is necessary to apply pressure to the opposite surfaces of the assembly in order to compress the elastomeric-intumescent material into close intimate engagement with the frame, each other and the cables, conduits or the like passing therethrough. In order to accomplish this, each plate-like assembly 42 is provided with a pair of end compression plates 56 and 58 disposed on opposite ends thereof. Each plate of elastomeric-intumescent material, whether it be a grooved plate or a filler plate, is provided with two through bores 53 and 55. As best shown in FIG. 4, a pair of bolts 60 and 62 are non-rotatably secured to the top and bottom ends of the compression plate 58 and extend through the passages 53 and 55 and through corresponding apertures in the ends of the compression plate 56 and nuts 64 and 66 are threaded on the protruding ends of the bolts 60 and 62. Each plate 56 has a vertical dimension greater than the vertical dimension of the opening in the frame 16 as best shown in FIGS. 1 and 4 so that each compression plate will abut against the outer surface of the side members 22 and 24 of the frame 16. On the other hand, the vertical dimensions of the plate 58 are less than the distance between opposed ribs 50 on the top and bottom members 22 and 24 of the frame 16 so that a compression plate 58 can be drawn within the frame 16. The end compression plates 56 and 58 are preferably assembled in combination with the respective elastomeric-intumescent plate 46 prior to insertion into the frame 16. However, the nuts 64 and 66 are backed off to an extent so that the plate 46 is not under any compression.
After the rectilinear opening in the frame 16 is completely filled with plate-like assemblies 42, the nuts 64 and 66 on each assembly 42 will be tightened down an equal amount to draw the compression plates 58 toward the compression plates 56 and compress the elastomeric-intumescent material of the plates 46 into tight sealing engagement with the adjacent plates, the frame and the conduits or the like passing therebetween. Substantially equal compression can be applied to each plate-like assembly 42 by turning the nuts 64 and 66 until the ends of the bolts 60 and 62 all protrude an equal amount.
During construction of a building or the like in which the fire barrier assembly is to be located, the various cables would be run through the opened frame until such time as the construction work neared completion. At that time, the cables, conduits or the like could be assembled with the plate-like assemblies 42 within the opening of the frame 16. Pressure would not be applied to the plates until such time as the job was completely finished so that last minute changes could easily be accomplished by simply withdrawing the necessary plate assemblies 42, removing cables or running additional cables and reassemblying the proper plate assemblies 42.
As previously stated, the various plates 46 are constructed of an elastomeric-intumescent material. This material is preferably a combination of neoprene rubber and a filler of natural whiting (CaCO 3 ). When the neoprene is oxidized with heat or burned, it generates hydrogen chloride which, with water, forms hydrochloric acid. The natural whiting filler reacts with the hydrochloric acid to neutralize it, forming calcium chloride and carbon dioxide. Calcium chloride is highly deliquescent and the carbon dioxide gas that is formed expands with heat, thereby expanding the rubber.
Under ordinary conditions, the elastomeric-intumescent material composition according to the present invention will provide an air-tight barrier when compressed to prevent the passage of smoke or other vapors. Should a fire occur causing the destruction of the insulating material around an electrical conductor passing through the fire barrier, the expansion of the neoprene rubber will apply radial pressure on the electrical cable expelling the melting wire insulation and clamping the conductors into a tight bundle of copper, preventing the passage of any gas or flame from the fire to the cold side of the unit. In order to further enhance the efficiency of the fire barrier assembly, the external surfaces of the frame and compression plates can be coated with a layer of intumescent material 70. As shown in FIG. 4, the material 70 was applied to the external surfaces of the frame 16 and the compression plate 50 subsequent to their assembly. However, it is fully contemplated by the present invention that a similar coating of intumescent material could be located on the exposed surfaces of the frame 16 and compression plate 58 on the other side of the wall 14 in the same manner as shown. Rather than apply the intumescent material after the plate assemblies 42 are assembled in the frame and the frame is attached to the wall, the surfaces of the frame 16 and the surfaces of the compression plates 56 and 58 which would subsequently be exposed after assembly, could be precoated prior to assembly so that in situ coating step could be eliminated. It is also contemplated that the material 70 could be eliminated entirely.
The construction shown and described could also be used as a simple vapor barrier, watertight barrier, or dirt and dust-proof barrier without any modifications. In those instances where the possibility of intense heat is not a factor, any suitable elastomeric material without an intumescent filler could be utilized.
While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention. | The fire barrier assembly is comprised of a frame through which one or more electrical cables may be passed and a plurality of sealing elements clamped in the frame in contact with each electrical cable and the frame to provide an airtight barrier. Each element has a plate-like configuration and is comprised of an elastomeric body having intumescent material mixed therewith and opposing end members connected by bolts so that upon movement of the end members toward each other the elastomeric body will expand into intimate engagement with adjacent elements, the frame and each cable passing through the frame. Adjacent elements on opposite sides of an electrical cable are provided with complimentary grooves to define a cylindrical passage for each cable and additional filler elements may be provided without grooves. An external coating of intumescent material is applied to the outer surfaces only of the frame and end members to provide a heat insulating layer. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention:
The present invention relates to a door gear motor operator.
More particularly, the present invention relates to an independent band spring door gear motor operator.
2. Description of the Prior Art:
Gear motor operators can be adapted to most independent push up band spring doors. By the use of gear motor operators, the strenuous task of manually lifting and pulling down the door is eliminated.
On larger doors, such as bay doors, which use torsion spring axles, a coil spring is incorporated inside the axle pipe. A shaft is welded to the inside of the pipe and protrudes through the end plate and is powered by a chain and sprocket arrangement. This results in the turning of the axle pipe which lifts and lowers the door, as required.
In solution, the U.S. Pat. No. 1,943,371 to Cross relates to end locks for fire doors of the rolling shutter type.
When automatic door openers are provided on doors, such as garage doors it has found to be undesirable to provide a key locking system for the door wherein the door is mechanically locked on operation of the key. This feature has become more undesirable when the automatic door opener is a radio controlled automatic door opener. The reason for the undesirable provision of a key locking means is that once the door is key locked the automatic door opener can be accidentally or unwantingly placed in operation to open the door. If this occurs, then the electric motor used to open the door become locked and thus the motor draws a stalling current. This current is sufficient to burn out the motor and as a consequence initiate a fire.
The U.S. Pat. No. 4,452,292 to Leivenzon et al. relates to an automatic opening means for a door, and a key locking facility which mechanically locks the door in a closed position.
In solution, the U.S. Pat. No. 4,721,146 to Wardlaw relates to driving mechanisms permitting the safe operation of the door in either the manual drive or motor drive mode.
Rolling doors may be constructed as exemplified by the U.S. Pat. No. 2,820,516 and include operating mechanisms as exemplified by the U.S. Pat. Nos. 3,637,004, 3,853,167 and 2,934,139.
To operate roller doors by means of chain and sprocket mechanisms are not very satisfactory in that they require periodic service, are noisy to operate, and require regular lubrication.
To control the operation of the roller door or shutter by electrical means, two such electrically operated mechanisms are described in the Australian Pat. Application Nos. AUA 30718/77 in the name of B.W.N. Industries PTY. LTD. and 44163/79 in the name of Byrne and Davidson Doors (NSW) PTY. Limited.
In solution, the U.S. Pat. No. 4,392,392 to Perisic et al. relates to the operating mechanism by which the door or shutter curtain can be wound onto or unwound from its supporting drum wheels so as to open and close same.
The electric motor and its associated gear train rotates, as a body, simultaneously with the door curtain supporting drum wheels and by having the electric motor housed within the core of the door curtain.
In the art of garage door operator mechanisms it has been necessary for an installer of the operator to accurately adjust the upper and lower limit stops of the door so that power to the driving motor can be removed when the door reaches those positions. Usually this adjustment involves correctly locating limit stop switches on the door frame in the door opened and door closed positions so that when the door reaches those positions the driving motor can be switched off. Alternatively, screw threaded adjustments have been provided which are arranged on a movable part of an operator mechanism so as to switch off the fixed position limit switch of the respective opened and closed positions. A typical example of such operator mechanism is disclosed, for example, in the Australian Pat. No. 528,744.
Other forms of operators which are used for "tilt-up" or "lift-up" doors are disclosed, for example, in U.S. Pat. Nos. 3,439,727 and 4,107,877. U.S. Pat. No. 3,439,727 discloses a chain drive system. The U.S. Pat. No. 4,107,877 uses a similar carriage member, but instead of having a chain drive it has a screw thread which rotatably and screw threadably engages with the carriage.
In both U.S. Pat. No. 3,439,727 and the U.S. Pat. No. 4,107,877 for the "lift-up" or "tilt-up" doors, complicated adjusting means are provided for the setting of the opened and closed positions of the door so that power to the motor can be removed when the door reaches those positions.
In solution, the U.S. Pat. No. 4,706,727 to Leivenson et al. relates to a door operator for use in domestic garage doors of the "roll-up" type or the "tilt-up" or "lift-up" type.
In solution, the U.S. Pat. No. 3,739,832 to Sivin relates to an overhead grille capable of emergency ascending movement from its closed position so as to provide an emergency or exit opening beneath its lower edge.
It has been the practice heretofore in raising and lowering heavy closures to employ counterbalancing devices for facilitating movement thereof. Such devices in the art have torsional springs that are wound up as the closure descends, allowing setting up an increased potential force when the closure reaches its ultimate descent. This force assists in lifting the closure upon manually raising the same, the spring unwinding with decreasing force as the closure is rolled upon its drum. Counterbalancing devices employing torsional type springs, however, are unsatisfactory, particularly in view of the heavy steel wire that is required and also in view of the end connections therefor. Attempts have been made to overcome these disadvantages by utilizing the expansive and contractive force of springs but these have also been unsuccessful.
In solution, the U.S. Pat. No. 2,543,711 to Schultz relates to vertically movable closures for door and window openings.
The following U.S. patents disclose structures known in the relevant art: U.S. Pat. No. 3,595--May 25, 1844, U.S. Pat. No. 330,956--Nov. 24, 1885, U.S. Pat. No. 1,022,939--Apr. 9, 1912, U.S. Pat. No. 2,513,042--Jun. 27, 1950, U.S. Pat. No. 2,545,400--Mar. 13, 1951, U.S. Pat. No. 2,906,323--Sept. 29, 1959, U.S. Pat. No. 3,065,785--Nov. 27, 1962, and U.S. Pat. No. 4,010,790--Mar. 8, 1977.
In solution, the U.S. Pat. No. 4,301,851 to Gitkin relates to a combined roller shutter and awning for a door assembly such as a sliding glass door arrangement providing access between the interior of a building.
Numerous innovations for door motor operators have been provided in the prior art that are adapted to be used. Even though these innovations may be suitable for the specific individual purposes to which they address, they would not be suitable for the purposes of the present invention as heretofore described.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an independent band spring door gear motor operator that avoids the disadvantages of the prior art.
More particularly, it is an object of the present invention to provide an independent band spring door gear motor operator of the present invention that eliminates the need for torsion springs, heavy axles, and shafts. This reduces the cost factor by a substantial amount. Furthermore, the size and weight of the door determines the amount of flat springs needed. If necessary, more than one gear motor can be used.
In keeping with these objects, and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a power assist device for raising and lowering an independent band spring door, and having prime mover means, means for controlling the prime mover means, a band spring cage, and means for mechanically connecting the control means to the band spring cage.
In accordance with another feature of the present invention, prime mover means include a gear motor.
Another feature of the present invention is that the gear motor is a direct currrent electrical gear motor.
Yet another feature of the present invention is that the controlling means include a gear motor operator.
Still another feature of the present invention is that the mechanical connecting means include a roller chain set.
Yet still another feature of the present invention is that the roller chain set has a roller chain and a sprocket.
Still yet another feature of the present invention is that it further comprises an axle pipe having a first end and a second end and on which the small direct current electrical motor, the motor operator, and the band spring cage are colinearly mounted.
Another feature of the present invention is that it further comprises a first end plate and a second end plate in which the axle pipe is fixed.
Yet another feature of the present invention is that it further comprises a first band spring arrangement, a second band spring arrangement, and a third band spring arrangement mounted on the axle pipe.
Still another feature of the present invention is that the first band spring arrangement is disposed intermediate the first end plate and the band spring cage while the second band spring arrangement is disposed intermediate the second end plate and the direct current electrical gear motor.
Yet still another feature of the present invention is that the first band spring arrangement the second band spring arrangement and a third band spring arrangement, each have a plate with a substantially disposed throughbore through which the axle pipe passes.
Still yet another feature of the present invention is that the axle pipe contains three spring arrangements each further having a flat coil band spring with an end that is bolted on to the axle pipe.
Another feature of the present invention is that the roller chain has a plurality of fingers extending therefrom and in the direction of and terminating on the band spring cage.
Yet another feature of the present invention is that the band spring cage has a plurality of horizontal straps which are the connection straps disposed between the two halves of the band spring cage, and also the connection point of the travel end of the band spring.
Still another feature of the present invention is that the band spring cage has a plate on which the plurality of fingers of the roller chain terminate.
Yet still another feature of the present invention is that the gear motor operator has a shaft on which the pinion gear sprocket is rotatably mounted.
Still yet another feature of the present invention is that the plate contains a central throughbore through which the axle pipe passes.
Another feature of the invention is that the plurality of fingers extending from the ring gear roller chain is variable depending upon the diameter of the band spring cage, size, and type of roller chain.
Yet another feature of the present invention is that the plurality of horizontal straps of the band spring cage is five.
Still another feature of the present invention is that it further comprises a power switch, a transmitter, in addition to the manual back up.
Another feature of the present invention is that it can be adapted to any independent band spring door without modification to existing band spring cages, due to the use of a planetary roller chain instead of a conventional planetary gear set, with teeth that will not stand up to the up and down and side to side shifting problem. The planetary roller chain is guided by the gear motor operator sprocket thus preventing shifting and or disengagement of planetary roller chain.
Another feature of the present invention is that it contains limit switches that automatically control the travel distance of door opening and closing.
The novel features which are considered 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 the specific embodiments when read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a head on view of the present invention being utilized to push up and down a conventional independent curtain mounted to a store;
FIG. 2 is a cross-sectional view taken at line 2--2 in FIG. 3;
FIG. 3 is a side view, with areas cut away, of the present invention shown in FIG. 1;
FIG. 4 is a front view of a plate shown in FIG. 3;
FIG. 5 is a front view of the sprocket drive shown in FIG. 3;
FIG. 6 is a side view of the electrical apparatus utilized by the present invention; and
FIG. 7 is a perspective view of the present invention.
LIST OF REFERENCE NUMERALS UTILIZED IN THE DRAWING
10--independent band spring door gear motor operator of the present invention
11--gear head of the independent band spring door gear motor operator 10
12--store front mounting the independent band spring door motor operator 10
14--independent band spring door located on the store front 12
15--limit switch slave gear sprocket
16-- direct current motor included in the independent band spring door motor operator 10
17--limit switch device enclosure
18--band spring cage included in the independent band spring door gear motor operator 10
19--limit switch roller chain
20--axle pipe for colinearly receiving the gear motor 16, the gear motor operator 11, and the band spring cage
21--limit switch master gear sprocket
22--first end of the axle pipe 20
23--gear motor mounting bolt
24--second end of the axle pipe 20
26--end plate for receiving the first end 22 of the axle pipe 20
28--end plate for receiving the second set 24 of the axle pipe 20
30--band spring cage disposed between the end plate 26 and the independent band spring door gear motor operator 10
32--band spring cage disposed between the end plate 28 and the independent band spring door gear motor operator 10
33--flat coil band spring of the band spring cage 18
34--end plate of the band spring arrangement 32
35--end plate of the band spring cage 18
36--central throughbore in the end plate 34
37--central throughbore in the end plate 34
38--flat coil band spring of the band spring cage 32
40--fixed end of the flat coil band spring 38
41--fixed end of the flat coil band spring 33
42--tongue of the fixed end 40
43--tongue of the fixed end 33
44--bolt on in the axle pipe 20 for receiving the fixed end
45--bolt on in the axle pipe 20 for receiving the fixed end
46--end plate of the band spring cage 30
48--central throughbore in the end plate 46
50--flat coil band spring of the band spring cage 30
52--plurality of fingers extending from the ring gear roller chain 64
53--fixed end of the flat coil band spring 50
54--tongue of the flat coil band spring 50
56--bolt in the in the axle pipe 20 for receiving the fixed end
57--"S"--hook connecting door to the band spring cage
58--intermediate portion of the independent band spring door gear motor operator 10
60--horizontal strap of the band spring cage
62--plate providing the closing side for the band spring cage 18
64--ring gear roller chain of the independent band spring cage 18
66--shaft of the gear motor operator 11
68--pinion gear sprocket mounted to the shaft 66
70--throughbore in the plate 62
72--power cord for the independent band spring door gear motor operator 10
74--operating power switch for the independent band spring door gear motor operator 10
76-- direct current battery
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, the independent band spring door gear motor operator is shown generally at 10, mounted to a store front 12, and operating a push up and a push down independent band spring door 14.
The independent band spring door gear motor operator 10 includes a small direct current electric motor 16, a gear head 11, and a band spring cage 18. The gear motor 16, the gear motor operator 11, and the band spring cage 18 are all mounted colinearly on an axle pipe 20.
The axle pipe 20 has a first end 22 and a second end 24. The first end 22 of the axle pipe 20 mounts into an end plate 26. While the second end 24 of the axle pipe 20 mounts into another end plate 28. The end plate 26 and the end plate 28 are fixed and function as journals for the axle pipe 20.
Intermediate the end plate 26 and the independent band spring door gear motor operator 10 is disposed a band spring arrangement 30.
Intermediate the end plate 28 and the independent band spring door gear motor operator 10 is disposed another band spring arrangement 32.
As shown in FIG. 2, the band spring arrangement 32 consists of an end plate 34 while the band spring 32 is bolted to the axle.
The band spring arrangement 32 further consists of a flat coil band spring 38 which has a fixed end 40 and a tongue 42. The fixed end 40 is connected to the axle pipe 20 by bolting the tongue 42 of the flat coil band spring 38 to the axle pipe 20. As can be seen, the door 14 wraps around itself.
Intermediate the end plate 26 and the independent band spring door gear motor operator 10 is disposed another band spring arrangement 30.
As again shown in FIG. 2, the band arrangement 30 consists of an end plate 46 having a central throughbore 48, through which the axle pipe 20 passes.
The band spring arrangement 30 further consists of a flat coil band spring 50 that has a fixed end 53 that is bolted to the axle. As can be seen, the door 14 wraps around itself.
The band spring cage 18, an intermediate portion 58, and the gear motor operator 11 are shown in greater detail in FIGS. 3 and 4.
The intermediate portion 58 is a ring gear sprocket 64 with a plurality of fingers 52 extending therefrom. The band spring cage 18 contains a plurality of fingers 60. The plurality of fingers 52 is optional since a solid ring 52 may work as well. The plurality of fingers 60 terminate at the plate 62 which provides the closing side for the band spring cage 18. As shown, the axle pipe 20 is stationary and passes through the band spring cage 18.
The gear motor operator 11 consists of a shaft 66 and a pinion gear 68 mounted to the shaft 66. As can be seen in FIGS. 3 and 5, the pinion gear sprocket 68 meshes with the roller chain ring gear 64. Thus, the band spring cage, the intermediate portion 58, the gear motor operator 11, and the gear motor 16, together now form an integral unit.
FIG. 4 shows the plate 62 with the plurality of fingers 60 extending therefrom. The axle pipe 20 is shown passing through the throughbore 70 in the plate 62.
FIG. 5 shows the roller chain 64 meshed with the sprocket gear 68 which is mounted to the shaft 66.
Now referring to FIG. 6 which shows that only a minimal amount of electrical work is necessary to operate the independent band spring door gear motor operator 10.
The gear motor operator 11 attaches to the motor 16, and both mount onto the axle pipe 20. The motor 16 is connected, via a power cord 72, to an operating switch 74. The power cord 72 then continues on to the direct current battery 76 that could be optionally located on the axle or elsewhere.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the type described above.
While the invention has been illustrated and described as embodied in a independent band spring door gear motor operator, it is not intended to be limited to the details shown, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention.
A stationary gear motor is mounted to the axle pipe and turns the band spring cage. The stationary pipe is mounted between two end plates. The stationary pipe contains one or more cages with a band spring having one end fastened to the pipe and the other end attached to the horizontal strap of the cage.
Thus, when cage rotates in the opposing direction to that of the curtain, where travel winds the band springs. After the springs are wound while in the down position, the curtain is fastened to the spring cages by means of S hook. One end of the S hook inserts into corrugation of the curtain, the other end is inserted onto an available horizontal strap of the spring cage.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | A power assist device for raising and lowering an independent band spring door is disclosed. The present invention includes a prime mover, an operator controlling the prime mover, a band spring cage, and a roller chain gear set mechanically connecting the operator to the band spring cage so that there is no back lash in the gear set. | 4 |
RELATED APPLICATION
[0001] This application is a divisional application of application Ser. No. 09/961,442 filed Sep. 24, 2001, entitled “Integrated System for Controlling Diesel Engine Emissions” which is a continuation-in-part application of application Ser. No. 09/339,080 filed Jun. 23, 1999, entitled, “Multiple Stage Aftertreatment System”, now U.S. Pat. No. 6,293,096.
TECHNICAL FIELD
[0002] This invention relates generally to emission control for internal combustion engines, and more particularly to a control system for diesel engines that provides integrated control of engine and post-combustion emission control devices, the latter including both DPF and LNT devices.
BACKGROUND OF THE INVENTION
[0003] New emission limits call for major reductions in oxides of nitrogen (NO x ) and particulate matter (PM) emissions from diesel engines. Engine manufacturers have developed systems for exhaust gas recirculation (EGR), and diesel particulate filters (DPF) to achieve low NO x /PM emissions. The use of DPFs has been found to reduce PM below the stringent requirements of the new emission standards proposed for the 2005 through 2010 time frame. However, NO x emissions are still six to eight times higher than the proposed standards for model year 2007.
[0004] To achieve the target NO x emission levels, new post-combustion devices are being experimented with. These devices include selective catalytic reduction (SCR) using urea or ammonia as reductant, and lean NO x traps (LNT) (otherwise known as NO x adsorbers) using hydrocarbon as reductant. Although SCR systems have been used in stationary applications for several years they are now being developed for the mobile fleet with good success. However, greater NO x reduction than SCRs can deliver is still hoped for and the LNT system promises to achieve the desired NO x conversion efficiency.
SUMMARY OF THE INVENTION
[0005] The invention is directed to methods and systems for controlling diesel engine emissions. In all embodiments, the diesel engine's exhaust system has at least a diesel particulate filter (DPF) and a lean NO x trap (LNT). The DPF may be one of two types: a first type that uses a catalyzed soot filter or a second type that uses a continuously regenerated trap. In either case, the LNT is monitored to determine the need for regeneration or desulfurization. In the former case, the catalyzed soot filter is also monitored to determine the need for regeneration. A fuel injector is used to inject fuel upstream of the LNT under certain conditions, and a bypass may be used to bypass exhaust upstream of the LNT to provide richer or hotter exhaust to the LNT. The sensor outputs and controls for providing the appropriate heat or fuel mix for regeneration and desulfurization may be controlled with enhancements to existing engine control circuitry.
[0006] Features of the invention include the capability of integration of engine controls with control of post combustion emission control devices. Intake throttling, existing EGR systems, and post-combustion injection can be used, alternatively or in combination, for the purpose of regenerating the LNT. Existing EGR can be used to reduce NO x without adversely affecting the ability to maintain low PM emissions. A portion of the exhaust can be diverted to assist in creating a stoichiometric air-to-fuel ratio at the inlet of the LNT to facilitate regeneration. Overall, the system performs all of the above while not affecting drivability.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 illustrates a first embodiment of a multiple stage aftertreatment system.
[0008] [0008]FIG. 2 illustrates a second embodiment of a multiple stage aftertreatment system.
[0009] [0009]FIG. 3 illustrates a NO x and PM reduction system having a CSF-LNT unit in the exhaust path.
[0010] [0010]FIG. 4 illustrates a NO x and PM reduction system having a CRT-LNT unit in the exhaust path.
DETAILED DESCRIPTION
[0011] Tri-Stage Aftertreatment Device
[0012] U.S. patent application Ser. No. 09/339,080, entitled “Multiple Stage Aftertreatment System” to Khair, et al., now U.S. Pat. No. 6,293,096, and assigned to Southwest Research Institute, describes an aftertreatment system for reducing the amount of nitrogen oxide and particulate matter in engine exhaust gases without the need for electric heating elements to increase the temperature of the exhaust gas to periodically regenerate the particulate filter. The aftertreatment system does not require the injection of additional fuel in each cylinder of the engine to provide additional necessary hydrocarbon to reduce the NO x to N 2 (nitrogen). It has an internal bypass for the NO 2 trap to control the rate of NO 2 directed to the carbon trap.
[0013] A first preferred embodiment of the aftertreatment system is generally indicated by reference numeral 8 in FIG. 1, and effectively combines the functions of a CRT (catalytically regenerated trap), a LNT (lean NO x trap), and a carbon trap in a single system for the reduction of both NO x (nitrogen oxides) and PM (particulate matter) emissions. The aftertreatment system 8 is particularly adapted to operate in lean air-fuel ratio engines, such as diesel engines, and uses the excess oxygen present in the exhaust stream of such lean burn engines to reduce the amount of NO x and carbonaceous particulate matter discharged into the atmosphere. The main elements of aftertreatment system 8 are a first stage 10 , a second stage 20 , a third stage 30 , and a hydrocarbon fuel injector 40 interposed between the first stage 10 and the second stage 20 .
[0014] The first stage 10 has an inlet 12 which is adapted to receive exhaust gases discharged from an internal combustion engine, such as a diesel engine (not shown). Typically, the exhaust gas from a diesel engine contains various oxides of nitrogen (NO x ) and particularly NO (nitric oxide) and NO 2 (nitrogen dioxide), as well as HC (hydrocarbons), CO (carbon monoxide), CO 2 (carbon dioxide), PM (particulate matter), and other products of the combustion process. The first stage 10 of the aftertreatment system includes an oxidation catalyst 14 , preferably a noble metal such as platinum or palladium. The catalyst 14 oxidizes the NO in the exhaust gas stream, in the presence of the catalyst, to NO 2 . This reaction is represented by Formula 1:
1) NO+½O 2 →NO 2
[0015] Thus, NO 2 (nitrogen dioxide) is formed and is carried into the second stage 20 of the aftertreatment system 8 .
[0016] The second stage 20 of the aftertreatment system 8 includes a first portion 22 and a second portion 24 . The first portion 22 contains a lean NO x trap (LNT). The lean NO x trap stores NO 2 under lean fuel-air mixture (i.e., oxygen-rich) engine operation, then reduces the stored NO 2 to N 2 and O 2 under rich fuel-air conditions. In most diesel applications, rich fuel-air conditions do not frequently occur during normal over-the-road or other relatively steady state operation. The portion of the NO 2 stored in the LNT 22 of the second stage 20 combines with the supplemental HC provided by the periodic injection of supplemental HC (hydrocarbon fuel) upstream of the second stage 20 to form N 2 , H 2 O and CO 2 . The reduction of NO 2 in the second stage is represented by Formula 2:
2) NO 2 +HC+O 2 →N 2 +H 2 O+CO 2
[0017] With continued reference to FIG. 1, the hydrocarbon fuel injector 40 is in fluid communication with a source 42 of pressurized hydrocarbon fuel, for example diesel fuel such as that used in the normal operation of the engine. The reduction conversion efficiency of NO 2 to N 2 and O 2 in the second stage is typically somewhat less than 100% and therefore, some NO 2 is expected to escape the LNT 22 and pass on to the third stage 30 . Another portion of the NO 2 formed in the first stage 10 bypasses the LNT 22 of the second stage by being directed through the second portion bypass 24 of the second stage 20 . The size of the bypass 24 can be readily determined by experimentation for specific applications to ensure good NO x and PM emission reduction.
[0018] The third stage 30 of the aftertreatment system 8 in the first embodiment of the present invention includes a carbon trap oxidizer 32 such as a ceramic cordierite wallflow trap. In the carbon trap oxidizer 32 , the NO 2 reacts with carbon in the trap and forms CO 2 and N 2 . Thus, the unconverted NO 2 from the first portion 22 of the second stage 20 , as well as bypassed NO 2 passing through the second portion 24 of the second stage 22 , is reduced to nitrogen and CO 2 and is represented below by Formula 3:
3) 2NO 2 +2C→N 2 +2CO 2
[0019] Thus, in the first stage 10 of the multiple stage aftertreatment system 8 , NO resulting from the diesel combustion process combines with excess oxygen in the exhaust gas stream to form NO 2 , aided by the catalyst 14 in the first stage 10 . In the second stage 20 , a lean NO x trap stores the NO 2 formed by the oxidation catalyst 14 of the first stage 10 . The stored NO 2 then combines with supplemental HC, injected by the injector 40 to form N 2 , H 2 O, and CO 2 . Unconverted as well as bypassed NO 2 then proceed to the carbon trap oxidizer 32 of the third stage 30 , where NO 2 is reduced to N 2 and carbon is oxidized to CO 2 , NO 2 is stored in the LNT portion 22 of a second stage 20 as long as the exhaust is lean (oxygen-rich). As the LNT portion 22 reaches its NO 2 storage capacity limits, the fuel injector 40 , positioned just upstream of the LNT portion 22 , delivers supplemental hydrocarbon in the form of diesel fuel, thereby reducing NO 2 to N 2 .
[0020] Switching from the NO 2 storage mode to the reducing mode is preferably controlled by the use of a NO x sensor 50 positioned in the exhaust downstream of the second stage 20 , and preferably between the second stage 20 and the third stage 30 . The NO x sensor 50 senses the NO x content of the exhaust stream and is thereby capable of indirectly detecting engine load. The NO x sensor 50 delivers an electrical signal 52 to a programmable controller 54 which conditions the electrical signal 52 and controls the operation of the hydrocarbon fuel injector 40 . Thus, fuel can be controllably injected into the aftertreatment system 8 under desired engine operating conditions to enhance the performance of the LNT portion 22 of the second stage. An alternative to sensing NO x is measuring exhaust gas temperature for use as an indicator of engine speed and load. NO x formation in diesel engines is a function of engine temperature, generally increasing as the combustion temperature increases, and thus it can be inferred that NO x formation is taking place at a high rate under high temperature engine operating conditions. At such times, supplemental diesel fuel can be injected to reduce the NO x emissions. It is desirable that the fuel used for engine operation be a low sulfur fuel to prevent damage to catalysts in the system.
[0021] A second embodiment of the aftertreatment system is indicated by reference numeral 108 in FIG. 2. In the second embodiment, the lean NO x trap and carbon trap are reversed with respect to their positions in the first embodiment, but still effectively produce the same desirable reduction in both NO x and particulate matter in the exhaust emission stream. As in the first embodiment, the first stage 110 includes an oxidation catalyst 114 positioned just downstream of an inlet 112 . The catalyst 114 oxidizes the NO in the exhaust stream in the presence of the catalyst, to NO 2 . Thus, the reaction that takes place in the first stage of the second embodiment is the same as that shown in Formula 1 above.
[0022] In the second embodiment, the second stage 130 includes a carbon trap oxidizer 132 , such as a ceramic cordierite wallflow trap. In the carbon trap 132 , NO 2 in the gas stream discharged from the first stage reacts with the carbon component of the carbonaceous particulate matter in the exhaust gas stream, reducing at least a portion of the NO 2 to N 2 and simultaneously oxidizing the carbon to form carbon dioxide (CO 2 ). The amount of NO 2 reduced is dependent upon the amount of carbon present, and therefore, the reduction of NO 2 to N 2 may not be 100%. That is, the exhaust gas stream discharged from the second stage 132 usually will contain both reduced NO 2 (N 2 ) and oxidized carbon (CO 2 ) as well as some residual nitrogen dioxide (NO 2 ), as represented below by Formula 4:
4) 2NO 2 +2C+NO 2 →N 2 +2CO 2 +NO 2
[0023] With continued reference to FIG. 2, the third stage 120 includes a lean NO x trap (LNT) 122 . The gas stream emitted from the second stage 130 , containing nitrogen, carbon dioxide and a remaining portion of nitrogen dioxide passes through the third stage 120 . The third stage lean NO x trap is arranged to store the remaining portion of the nitrogen dioxide discharged from the second stage, and with the addition of a supplemental hydrocarbon fuel, reduce the stored nitrogen dioxide to nitrogen, water in a gaseous state, and carbon dioxide, and discharge a gaseous stream from the multiple stage aftertreatment system 108 that consists essentially of nitrogen, water and carbon dioxide. This reaction is represented above by Formula 2.
[0024] Aftertreatment system 108 has a hydrocarbon fuel injector 140 that is positioned between the second stage 130 and the third stage 120 at a position adapted to controllably inject selected amounts of hydrocarbon fuel, from a pressurized source 142 , into the gaseous stream discharged from the second stage 130 , prior to the gaseous stream being received by the third stage 120 . As described above, the lean NO x trap 122 stores the remaining portion of the NO 2 then combines the stored NO 2 with supplemental HC, injected by the injector 140 to form N 2 , H 2 O and CO 2 . NO 2 is stored in the lean NO trap portion 122 of the third stage 120 when the exhaust is lean (oxygen-rich). As the lean NO x trap portion 122 reaches its NO 2 storage capacity limits, the fuel injector 140 , positioned just upstream of the lean NO x trap 122 delivers supplemental hydrocarbon (HC) in the form of diesel fuel, thereby inducing NO 2 reduction to N 2 .
[0025] Switching the NO 2 from the storage mode to the reducing mode may be controlled, as described above, by the use of a NO x sensor 150 positioned in the exhaust downstream of the third stage 120 . The NO x sensor 150 senses the NO x content of the exhaust stream and is thereby capable of indirectly determining engine load. The NO x sensor 150 delivers an electrical signal 152 to a programmable controller 154 which conditions the electrical signal 152 and controls the operation of the hydrocarbon fuel injector 140 . Thus, fuel can be controllably injected into the aftertreatment system 108 under desired engine operating conditions to enhance the performance of the lean NO x trap portion 122 of the third stage 120 .
[0026] The multiple stage aftertreatment devices described above combine the functions of a catalytically regenerated trap (CRT) with a lean NO x trap (LNT) in a single system for the reduction of both NO x and PM emissions. This effectively maximizes the common features of both systems, such as a noble metal catalyst and its NO 2 formation capability.
[0027] Integrated Systems for Diesel Engine Control
[0028] The following description is directed to the integration of an emission control system consisting of a diesel engine equipped with an EGR and intake throttle, and capable of post-injection, with post-combustion exhaust emission control devices. The emission control devices in the exhaust are a DPF, LNT, supplemental fuel (reductant) injector, and a bypass valve. The tri-stage concepts discussed above are integrated into the overall engine emission control system.
[0029] Two categories of control systems are discussed, each using a different DPF system. A first system uses a Catalyzed Soot Filter (CSF), whereas a second system uses a Continuously-Regenerated Trap (CRT™). The following description describes two systems: a CSF-LNT system and a CRT-LNT system. Both systems have at least seven features that interact to facilitate control of the regeneration and/or desulfurization of the emissions components:
[0030] 1) Intake air throttling
[0031] 2) A venturi used to enhance EGR flow
[0032] 3) Cooled EGR System
[0033] 4) Post combustion fuel injection (in-cylinder and/or in exhaust)
[0034] 5) A bypass valve in the exhaust stream to direct flow during desulfurization
[0035] 6) Placement of the supplemental fuel injector in the exhaust
[0036] 7) Embedded software that contains integration and control logic
[0037] CSF-LNT Configuration and Control
[0038] [0038]FIG. 3 illustrates the CSF-LNT system 300 , which has the engine controls noted above (i.e., EGR line 301 , EGR valve 302 , EGR cooler 303 , intake throttle 304 , intake venturi 305 , electronic engine controls 322 ). The exhaust system has a CSF 310 , an LNT 311 , a bypass valve 313 , and a fuel injector 317 , as well as CSF pressure and temperature sensors 330 and 333 , and LNT NO x sensors 331 and 332 . Sensor 330 monitors CSF dP (pressure drop), and sensors 331 and 332 monitor NO x levels before and after the LNT 311 .
[0039] As explained below, the monitoring sensors 330 - 333 are used to determine the need for regeneration of both systems. Their output signals may be delivered to engine controller 322 , which performs appropriate algorithms for implementing the regeneration and desulfurization described below, including control of various engine and exhaust devices so as to enhance conditions for regeneration and desulfurization.
[0040] CSF 310 may be any device that acts as a particulate filter, wherein part or all of the surface of the filter is “catalyzed” (i.e., coated with catalytically active materials). NO in the exhaust is oxidized to NO 2 on the catalyzed surfaces of the filter, and the NO 2 then oxidizes the carbon trapped on the filter. For the rate of regeneration to exceed the rate of trapping in the CSF 311 (i.e., the CSF can clean out any accumulated soot particles), the temperature must generally exceed 380° C. If long periods of operation are performed below this temperature (for example sustained idle or light load operation), it may be necessary to artificially elevate the temperature of the CSF 310 for a period of time to clean it.
[0041] A bypass valve 313 is incorporated upstream of the CSF 310 to allow a small portion of the exhaust to be routed around the CSF 310 , via a bypass line 315 , and reintroduced into the exhaust upstream of the LNT 311 . A supplemental fuel injector (SFI) 317 is located in the exhaust between the CSF 310 and LNT 311 to allow for injection of additional fuel to supplement the air-to-fuel ratio of the exhaust entering the LNT 311 . All of these systems are controlled from the electronic control module (ECM) 322 .
[0042] Under normal operation, all of the engine exhaust passes first through the CSF 310 and then through the LNT 311 . The CSF 310 traps insoluble particulates and oxidizes volatile organic particulates. In addition, if the temperature is high enough (over 380° C.) some of the NO 2 generated by the CSF 310 removes carbon particles already trapped in the CSF 310 . Excess NO 2 from CSF 310 is stored on LNT 311 . The exhaust flows enters the LNT 311 , where any remaining NO is oxidized to NO 2 . The NO 2 then adsorbs on the surface of the LNT.
[0043] When the CSF 310 differential pressure indicates that regeneration is needed, and the temperature of the CSF 310 is not at the required level, the exhaust temperature is increased using control strategies programmed into the ECM 322 . This may be done using intake throttle 304 , increased EGR rate, or in-cylinder post-combustion fuel injection while the exhaust valves are open (referred to as post-injection). Intake throttling or increased EGR rate increases the exhaust gas temperature from the engine 320 . Post-injection increases the CSF temperature by using the exothermic heat generated by the oxidation of the post-injected fuel. These methods may be used separately or in combination, and may be optimized to produce the highest temperature for the smallest amount of performance and fuel penalty.
[0044] When NO x monitors at the inlet and outlet of the LNT 311 indicate that NO x reduction across the LNT 311 has fallen below acceptable levels, regeneration and/or desulfurization will be needed. LNT regeneration requires temperatures above 250° C. and a stoichiometric or slightly rich exhaust gas air-to-fuel ratio. If temperature is not sufficient for regeneration, it may be increased using any or a combination of the methods described above for increasing the CSF temperature.
[0045] To generate the rich exhaust gas air-to-fuel ratio, a variety of methods may be used. Intake throttling and increased EGR will generate higher CO levels in the exhaust. The bypass valve 313 may be used to pass a portion of this CO laden exhaust around the CSF 310 (which would otherwise oxidize and remove the CO), thus moving the exhaust closer to a rich condition upstream of the LNT 311 . Post-injection could also be used to add more fuel into the exhaust, again in conjunction with the bypass valve 313 . Some of the post-injected fuel may also make it through the CSF (or be partially oxidized to generate CO by the CSF) depending on exhaust gas temperature and flow rate. Finally, fuel injector 317 may be used to inject additional fuel into the exhaust upstream of the LNT 311 to ensure the rich exhaust conditions needed for regeneration. Any combination of these may be used, and the regeneration strategy may be optimized to achieve the fastest and most complete regeneration for the least amount of fuel economy and performance penalty.
[0046] If, after a period of regeneration, the NO x sensors indicate that NO x reduction across the LNT 311 has still not returned to acceptable levels, then a need for desulfurization is indicated. Desulfurization requires temperatures between 400° C. and 600° C., with higher temperatures requiring a shorter period of time to complete desulfurization. This increased temperature may be accomplished by any or a combination of the means described above for the CSF 310 . In addition, the bypass valve 313 may be used to pass some of the hot exhaust around the CSF 310 and into the LNT 311 in order to prevent some of the heat from being lost to the CSF. Finally, the fuel injector 317 may be used to generate heat in the LNT 311 by using the exothermic heat caused by oxidation of the injected fuel over the LNT itself. Any combination of these may be used, and the desulfurization strategy may be optimized to achieve the fastest and most complete desulfurization for the least amount of fuel economy and performance penalty. Desulfurization may be halted periodically to check if NO x reduction has returned to acceptable levels, and can be resumed if the check indicates more desulfurization is needed. If desulfurization is unsuccessful after several attempts, a problem with the LNT 311 could be indicated.
[0047] Balancing the above-described regeneration and desulfurization requirements calls for an integrated control strategy. Areas where several requirements overlap can be exploited to accomplish these tasks simultaneously (e.g., temperature increase episode for CSF regeneration can also be used for LNT regeneration and/or desulfurization) to reduce the overall fuel economy and performance penalties associated with such operation. In addition, episodes where exhaust temperatures and flow rates are ideal for regeneration can be exploited by using any of these techniques (e.g., post-injection during deceleration events, to allow a brief period of regeneration without affecting driveability).
[0048] CRT-LNT Configuration and Control
[0049] [0049]FIG. 4 illustrates another embodiment of an integrated system, a CRT™-LNT system 400 , which has then engine 420 and engine controls noted above (i.e., EGR line 401 , EGR valve 402 , EGR cooler 403 , intake throttle intake venturi 405 , electronic engine controls 422 ). As explained above CRT 410 is an alternative to the CSF of system 300 , and both devices have a LNT. The configuration of the system 400 is such that the bypass control valve 413 is placed upstream of the oxidation catalyst (OC) 410 a and is configured so as to bypass the OC 410 a . The next emissions component in the exhaust flow is the DPF 410 b , followed by the LNT 411 . Together the OC 410 a and DPF 410 b make up the CRT™ 410 .
[0050] CRT 410 may be any device that converts NO to NO 2 in a first step, followed by a wallflow DPF where carbonaceous particulate is accumulated. LNT 411 may be any device that has an oxidation catalyst to oxidize nitric oxide (NO) to nitrogen dioxide (NO 2 ), followed by an NO 2 trap (usually a base-metal oxide) wherein NO 2 is adsorbed on the surface. Temperature and pressure sensors 430 and 433 are placed at the DPF 410 b to determine the need for DPF regeneration, and NO x sensors 431 and 432 are used to determine the need for regeneration and desulfurization of the LNT 411 . Regeneration and desulfurization conditions are determined in a manner similar to the methods described above in connection with system 300 .
[0051] The LNT 411 is periodically regenerated under conditions of sufficient temperature and stoichiometric (or slightly rich) exhaust air-to-fuel ratio. In addition to regeneration, the LNT 411 is “desulfurized” periodically. This is necessary because sulfur (in the form of sulfur trioxide) adsorbs in the surface of the LNT 411 , blocking the sites used to trap NO 2 and thus reducing the efficiency of the LNT. Desulfurization requires high temperature (400° C. to 600° C.) for a sustained period of time (often several minutes—much more time than required for regeneration), and stoichiometric or slightly rich air-to-fuel ratio conditions.
[0052] Referring to FIG. 4, system 400 operates in the following manner. The OC 410 a converts NO to NO 2 in the exhaust stream. The exhaust then flows through the DPF 410 b , where PM in the exhaust is trapped and the carbon is reacted with NO 2 to form elemental nitrogen and carbon dioxide (CO 2 ). Excess NO 2 emitted from the DPF 410 b is stored on the LNT 411 , until the LNT is regenerated.
[0053] To integrate the CRT™-LNT system 400 , software logic is added to the engine controller 422 to monitor the system status and to control the regeneration/desulfurization of the emissions systems as needed. For the LNT 411 , NO x sensors 431 and 432 are monitored and their locations strategically determined, to develop a strategy for indicating when regeneration of the LNT 411 is required. An additional strategy monitors regeneration frequency and deciphers whether a regeneration or desulfurization is required. Once the condition for regeneration/desulfurization is met, an engine control strategy is used to create a rich condition, with adequate carbon monoxide (CO) to initiate regeneration in the NO x trap. To achieve this goal, intake throttling (to increase the vacuum across the venturi 405 , resulting in increased EGR) may be used to create a richer in-cylinder air-to-fuel ratio (increasing CO in the exhaust), the bypass valve 413 may be partially activated to prevent the consumption of the excess CO across the OC 410 a , and in-exhaust (or in-cylinder post combustion) supplemental fuel injection (SFI) 417 will be used to further raise CO and to increase the exhaust temperature to regenerate the LNT 411 . Additional logic may be programmed into the controller 422 to verify that the duration of regeneration/desulfurization event was adequate to achieve complete regeneration. CO emitted during DPF regeneration will also help regenerate the LNT 411 .
[0054] The control logic also monitors and controls the regeneration of the DPF 410 b . For the DPF 410 b , filter pressure drop (dP) and inlet exhaust temperature are monitored with pressure and temperature sensors 430 and 433 . A strategy is developed to determine when regeneration is necessary. Ideally, the regeneration strategy achieves continuous regeneration through engine management, and avoids cyclic regeneration. The strategy for continuous DPF regeneration involves identifying the balance point temperature (BPT) (the temperature at which the rate of soot accumulation is equal to the rate of regeneration), predicting in real-time whether the DPF is at or below the BPT, and continuously adjusting in-cylinder, post combustion fuel injection characteristics in an attempt to maintain BPT.
[0055] Other Embodiments
[0056] Other aspects, features and advantages of the present invention can be obtained from a study of this disclosure together with the appended claims. | A method for controlling diesel engine emissions is disclosed. The diesel engine's exhaust system has a NO x oxidation catalyst, a diesel particulate filter (DPF), and a lean NO x trap (LNT). The DPF is monitored to determine the need for regeneration. The LNT is monitored to determine the need for regeneration or desulfurization. A fuel injector is used to inject fuel upstream of the LNT under certain conditions, and a bypass may be used to bypass exhaust around the oxidation catalyst to provide richer or hotter exhaust to the LNT. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an actuator device, and more particularly to an actuator device for actuating an ejector of a scraper.
2. Description of the Prior Art
The ejector of a scraper is used for pushing the earth and sand when discharging them loaded in the bowl thereof on the ground. In general, a large power is required at the start of the operation, whilst a small power can meet the requirement near the end of the operation. Therefore, it is desired that the actuator for operating the ejector can develop a large power at the beginning of its stroke and reduce the power near the end of its stroke, but increase its moving speed.
The prior art actuator device for operating the ejector is disadvantages as disclosed, for example, in U.S. Pat. No. 3,035,361, in that it cannot develop a large power at the start of operation and has a low efficiency because of employing an ordinary actuator.
SUMMARY OF THE INVENTION
The present invention has been contemplated in view of the above-mentioned circumstances. A primary object of the present invention is to provide an actuator device for operating the ejector of a scraper which can develop a large power at the beginning of its stroke and which can reduce the power near the end of its stroke but increase the speed of movement thereof so as to achieve a high operational efficiency.
Another object of the present invention is to provide an actuator device for operating the ejector of a scraper comprising a double actuator which consists of two actuators each having a different stroke, the two actuators being fixed secured or connected in series, and valve means for controlling the supply of pressurized fluid into each of said two actuators.
A further object of the present invention is to provide a compact actuator device wherein said valve means is mounted on the actuator having a short stroke as an integral part thereof.
A still further object of the present invention is to provide an actuator device wherein said two actuators are separably constructed and can be used as an independent actuator.
In order to achieve the above objects of the present invention, there is provided an actuator device comprising: a first actuator both ends of which are closed by caps and in which a first piston is slidably accommodated and which has pressurized fluid supply and discharging ports formed at both ends thereof, said first piston having a piston rod projecting through the cap at the leading end thereof; a second actuator having an open end closed by the cap on the bottom side of said first actuator, said second actuator having a second piston slidably accommodated therein, said second piston having a piston rod extending through said cap on the bottom side and arranged opposite to the bottom face of the first actuator, said second actuator having pressurized fluid supply and discharging ports formed in both ends thereof; a slide valve including a vlave body formed as an integral part of the second actuator, said valve body having a spool slidably accommodated therein and biased by a spring in one direction; a load piston slidably mounted within a pressure chamber formed within said valve body on the opposite side of said spring, said load piston abutting against the rear end of said spool, said slide valve including a first inlet port which communicates with a port formed on the side of a bottom chamber of said first actuator, a second inlet port which communicates with a port formed on the side of a bottom chamber of said second actuator and which is permitted to communicate with said first inlet port when said spool is moved against the resilient force of the spring, a drain port which is normally communicated with said second inlet port and is cut off from communication the latter when the spool is moved against the biasing force of the spring and which always communicates with a port formed on the side of a rod chamber of said second actuator and a port which communicates said first inlet port with said pressure chamber, said slide valve including further an auxiliary port which leads to a chamber to be formed opposite to the rear end of the spool when the spool has been moved against the spring so as to permits communication between said chamber formed opposite to the rear end of the spool and said first inlet port; and an operating valve adapted to selectively supply the pressurized fluid deliverred by a pump into either a port formed on the side of a rod chamber of said first actuator or the first inlet port of said slide valve, wherein the stroke of said first actuator is longer than that of said second actuator.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will be apparent from the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a side elevational view of a scraper provided with an actuator device of the present invention,
FIG. 2 is a fragmentary enlarged side elevational view of an ejector of the scraper shown in FIG. 1, and
FIG. 3 is a fragmentary enlarged sectional view of the actuator device of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference is now made to FIG. 1 which is a side view of a scraper in which an actuator device 100 of the present invention is connected between an ejector 101 and a framework 102 of the scraper. Reference numeral 103 denotes a bowl of the scraper in which the earth and sand scraped by a blade 104 during the scraping operation is loaded through an end pit 105. When the earth and sand loaded in the bowl 103 is discharged, the ejector 101 is driven by the actuator 100 so as to discharge it through the lower pit 105 on the ground.
FIG. 2 is an enlarged view showing the ejector 101 and the actuator device 100 connected between the rear portion of the ejector 101 and the rear framework 102 of the scraper by means of pivot pins 107 and 108 so that the ejector 101 can be moved along a guide 106 within the bowl 103.
The present invention will now be described in detail below with reference to FIG. 3 which is an enlarged sectional view of the actuator device 100.
In FIG. 3, reference numeral 1 denotes a first actuator, both ends of which are closed by a first cap 2 and a second cap 3 and which has a piston 4 having a rod 4a projecting through the cap 2. The caps 2 and 3 have ports 5 and 6 formed therein so as to communicate with a rod chamber 1a and a bottom chamber 1b of the first actuator 1, respectively.
Reference numeral 7 denotes a second actuator having open one end, the open end being fixedly secured to the cap 3 on the bottom side of the first actuator 1 so as to be closed thereby. The second actuator 7 includes a piston 8 which is fitted therein and has a rod 9 extending through the cap 3 and facing the end face of the piston 4 of the first actuator 1. The second actuator 7 includes a rod chamber 7a and a bottom chamber 7b having ports 10 and 11 formed therein, respectively.
In the arrangement of the above-mentioned actuators 1 and 7, the stroke S 1 of the first actuator 1 is longer than the stroke S 2 of the second actuator 7.
Reference numeral 12 denotes a slide valve which comprises a valve body 13 formed as an integral part of the second actuator 7 and a spool 14 slidably inserted within the valve body 13. The valve body 13 has formed therein a first inlet port 15 which communicate with the port 6 of the bottom chamber 1b of the first actuator 1, a second inlet port 16 which communicates with the bottom chamber 7b of the second actuator 7 and a drain port 17 which communicates with the port 10 of the rod chamber 7a of the second actuator 7.
The spool 14 is biased by a spring 18, and under such condition its small diameter portion 14a allows the communication between the second inlet port 16 and the drain port 17. On the side of the spool 14 oposite to the spring 18, the end face of a load piston 20 having a smaller diameter than that of the spool 14 and located within a pressure chamber 19 abuts against the right hand end of the spool 14. The pressure chamber 19 communicates through a port 19a with the first inlet port 15. When the above-mentioned spool 14 is moved to the left in the drawing against the resilient force of the spring 18 by the action of the load piston 20, the reduced diameter portion 14a permits the communication between the first inlet port 15 and the second inlet port 16, and at the same time the communication between the second inlet port 16 and the drain port 17 is cut off.
The valve body 13 has an auxiliary port 21 formed therein which communicates with a chamber to be formed on the other end of the spool 14 when the spool has been moved to the left against the biasing force of the spring 18, the auxiliary port 21 communicating with the first inlet port 15.
Reference numeral 22 indicates an operating valve having a forward position 22a, a reversing or backward position 22b and a neutral position 22c. The change-over operation of the valve 22 enables the fluid deliverred by a pump 23 to be selectively supplied into either the first inlet port 15 of the slide valve 12 or the port 5 of the rod side chamber of the first actuator 1.
In the above-mentioned arrangement, when the operating valve 22 assumes its forward position 22a so as to supply the fluid from the pump 23 into the first inlet port 15, the fluid is introduced into the bottom chamber 1b of the first actuator 1, thereby moving the piston rod 4a of the first actuator 1 to the left. At that time, if a load of more than a predetermined value is exerted on the rod 4a, the pressure within the flow passage and the pressure chamber 19 will increase beyond the predetermined value so that the spool 14 of the slide valve 12 can be moved to the left against the resiliency of the spring 18. As a result, the first inlet port 15 is permitted to communicate with the second inlet port 16 so that the fluid under pressure deliverred by the pump 23 is introduced into the bottom chamber 7b of the second actuator 7 thereby to extend the rod 9 of the piston 8 of the second actuator 7.
Therefore, the operating force F of the piston rod 4a of the first actuator 1 is given by the following formula.
F={a.sub.1 +(a.sub.2 -b)}P
Wherein a 1 is cross sectional area of piston 8 of the second actuator 7; a 2 is cross-sectional area of the piston 4 of the first actuator; b is cross-sectional area of the piston rod 9 of the second actuator 7; and P is a fluid pressure.
The operating force F at the start of operation is large, and the large operating force F is maintained during the stroke S 2 of the piston 8 of the second actuator 7.
After the piston 8 of the second actuator 7 has reached the end of its stroke, the movement is made only by the piston 4 of the first actuator 1 and the operating force F is reduced so that the whole fluid is supplied into the bottom chamber 1b of the first actuator 1 thereby increasing the speed of movement of the piston 4.
Further, when both the first actuator 1 and the second actuator 7 are rendered operative, the fluid pressure will be reduced because the two actuators act to push the load. Consequently, the pushing force of the load piston 20 is reduced so as to cause the tendency of moving-back of the spool 14 by the action of the spring 18. However, since the end face of the spool 14 is opposite to the auxiliary port 21 at the stroke end thereof, the spool 14 is urged by the fluid pressure within the auxiliary port 21 against the biasing force of the spring 18. Therefore, even if there is a pressure drop as mentioned above, the spool 14 is not moved back immediately thereby preventing generation of chattering of the spool 14.
Though in the foregoing description there is disclosed an example comprising two actuators, it is of course possible to form the device with actuators of three or more. Further, the device of the present invention can be easily manufactured because each actuator is made separately. Moreover, general application of the device is available since each of the actuators can be used independently as an actuator for general use.
While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and has been described herein in detail a specific embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the principle of the invention and is not intended to limit the invention to the embodiment illustrated. | An actuator device for actuating ejector of a scraper comprising a first actuator having a long stroke, a second actuator having a short stroke, said first and second actuators being connected and fixedly secured in series so that the piston rod of said second actuator can be brought into contact with the piston of said first actuator, and valve means which normally permits the communication between the delivery side of a hydraulic pump and a pressure chamber of said first actuator and which also permits the communication between the delivery side of said pump and the pressure chamber of said second actuator when the pressure within the pressure chamber of said first actuator has increased beyond a predetermined value. | 4 |
This is a continuation, of application Ser. No. 828,312, filed Aug. 29, 1977, now U.S. Pat. No. 4,324,037.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to building elements or members, but more particularly the present invention relates to a composite structural unit, its method of construction, and a method of constructing or assembling the individual units of the present invention so as to form structural arrays such as for example walls, columns, slabs, ceilings and the like.
2. General Background
It is known to form structural building arrays comprised of a plurality of individual units held together in load bearing abutment to one another by means of overall tension members which extend through or otherwise connect all the individual units in a dimension of the assembled structural array. The tension members are constituted generally of iron, steel or like tensile members with externally threaded ends (or like suitable connections) which extend to the ends of the assemblies of the units such as by the use of plates, washers and nuts, or like end bearing connections. The so constructed unit can be tightly drawn together and handled as a complete structural load bearing unit. Such units are useful in the in situ construction of walls, pre-fabrication of walls, floor slabs, arches, beam and column forms, and the like.
Among the advantages offered by such structural units is that there exists no necessity of using grout, mortar, or like conventional connections between the units or rows of units. Thus the structure can be formed with a smooth, dry load bearing joint at any place and transported from that place of assembly to the location of its use as a complete load bearing self contained unit.
Whereas structural units of this type have generally attempted to solve the problem of providing a structurally sound unit which can be assembled and transported, or in fact assembled at the job site without the use of grout, and attentive labor, a significant deficiency nonetheless exists in the use of such structure units.
One problem which arises with structural units which are so connected in the prior art, is that point stresses often develop at the joints or faces of the units where these members are in abutment, these stress points often being effected after construction when the applied load is manifested. The points of strain set up within the units often cause chipping, cracking, or in fact fracture or failure. Such flaws can at least create an unsightly appearance and worse can result in a threatened stability and utility of the structure itself.
A further problem seen with many prior art structural units is that they require a substantial amount of initial bracing and secondary support to the arrays or individual building units themselves during construction and prior to the application of the tension members to the structure. Such a need for secondary support is time consuming, labor wasting, and expensive. Oftentimes, without the use of heavy construction equipment and construction crews, this type of secondary structural support is out of the question.
Some other prior art units are restricted to a single structural array by their very nature, and cannot be combined into several different forms as may be desired by the individual who is constructing a specific planned building.
It is accordingly an object of the present invention to provide a new and novel structural building unit wherein a structural core to the building unit is provided, having load-distributing surfaces thereon to which point stresses can be applied without significant damage.
Another object of the present invention is to provide a structural building unit which is particularly useful in structural concrete applications, such as reinforced concrete, poststressed concrete, concrete shells, and architectural applications.
A further object of the present invention is to provide a means to more evenly distribute the load stress to the joints of abutting individual structural members without the problem of fracture or cracking.
A further and more specific object of the present invention is to provide structural building units of such character which do not require the use of mortar to hold the units together and which have particular utility in the construction on site or offsite of structural arrays formed from a plurality of individual structural units such as concrete walls, floor slabs, arches, beams, columns, and the like.
A further object of the present invention is to provide a composite structural unit which is provided with means for attaching it to other like units in order to form an array, with the connection means therebetween being the only structural connection necessary in order to form a final and complete structural bond with the individual unit to the array to which it is being attached during construction itself--secondary structures and bracing being unnecessary.
Another object of the present invention is to provide a method of construction of a composite structural unit, which constructed unit requires no additional milling, filing or like refinement after its casting.
These objects and others are achieved in accordance with the present invention embodying an apparatus, or structural building unit, comprised of a inner structural material and there being provided thereon outer load-distributing surfaces to which connection means can be attached without the problem of point stresses creating cracks, chips, or the like.
3. Prior Art
The prior art discloses a number of patents which have been issued on various building systems which attempt to provide a final array of individual building units in order to form walls, ceilings, slabs and the like. A listing of some prior art systems which have been patented is listed in the following table.
______________________________________Prior Art PatentsU.S. Pat. No. Inventor(s) Issue Date______________________________________Re. 27,785 H. Kobayashi Oct. 16, 19732,102,447 D. D. Whitacre Dec. 14, 19372,684,589 A. Perreton July 27, 19542,929,236 H. W. Steward et al Mar. 22, 19603,145,502 D. Rubenstein Aug. 25, 19643,173,226 A. Solnick Mar. 16, 19653,260,025 C. Van Der Lely July 12, 19663,378,969 G. K. Larger Apr. 23, 1968______________________________________
Many of the devices or systems of the prior art which have been patented provide various drawbacks in their attempt to solve the aforementioned problems, to which problems the present invention is directed and which drawbacks and problems are solved by the present invention over the prior art.
U.S. Pat. No. 2,102,447 by Donald D. Whitacre provides a structural building system wherein there is the necessity to grind the contact surfaces between individual structural units prior to assembly. The present invention does not require the grinding or milling of the surfaces of the individual structural units prior to their use, but rather provides a method of construction by which the contact surfaces of the individual units are by their nature perfectly flat and aligned as is required before their use in forming an array.
The present invention provides a significant advantage over the prior art in that there is no necessity of the use of secondary structures or supplemental structures in order to support the array prior to the application of the tensioning members thereto. In the method of constructing the arrays of the present invention, the tension is applied with the addition of each structural unit and such tension member holds that individual structural unit in place without the use of secondary structures, secondary bars, or secondary supports in order to hold the unit until the entire structural unit can be tensioned. The Kobayashi patent, U.S. Pat. No. Re. 27,785 provides the use of such a supplemental structure until the concrete hardens. Such a device requires a secondary structure until the curing time of concrete gives it the desired strength.
U.S. Pat. No. 3,173,226 issued to Abraham Solnick requires the use of extra supportive framework.
In contrast to U.S. Pat. No. 3,145,502 issued to D. Rubenstein, in the present case of plates or surfaces made of plastic, the surface, if formed after the initial molding, is on the abutting surfaces not on the facing surfaces as in the Rubenstein patent.
The present invention does not require a complex system of rods which can only be stressed after an entire row of units is laid, such as is taught in the Perreton patent, U.S. Pat. No. 2,684,589.
U.S. Pat. No. 3,260,025, issued to C. Van Der Lely discloses the use of facings which are formed of a plastic material to make a seal. In the '025 patent, the object is to seal, not to distribute the load evenly over the contact surface as is the case with the present invention. The object of the present invention is to distribute the load and hence the facing material has different characteristics.
The rods with the present invention are not made continuous throughout the entire span as in the devices of the prior art, and do not transmit unequal loads with expansion and contraction effects of rods throughout a dimension of the entire structure.
Also a specific object is to provide a method of assembling the units whereby one unit is placed in position and means of applying compressive force to keep it in place is applied to that unit suitably by the application of tension to rods one end of which is anchored on a face of a unit already in place, that face being other than the one abutting the unit just positioned and the other end of the rod being attached to a face of the unit just positioned which is not identical to the abutting face of the unit just positioned.
DISCUSSION OF THE PRESENT INVENTION
Thus the present invention provides a structural unit construction which has inner structural load carrying capability, with an outer load-distributing surface which distributes the compressive load generated at the abutting surfaces of the individual structural units over a wider area, and transmits the loads through the interface formed between the facing of the structural unit and the face of the core material which forms the body of the structural unit, which is by the method of formation of the composite devoid of imperfections in mating interface which lead to point stresses.
By the use of hard or metal contact facings, the force is transferred from the core inner surface of the material which forms the structural unit to the metal surface of the contact plate which it must of necessity exactly match since the surface of the body of the structural unit was formed in contact with the facing. The force is then transferred from one outer metal surface to the outer surface of the metal or otherwise constituted facing of the abutting structural unit and then through the facing to the outer facing of the core body of the next structural unit. If there is unevenness of contact at the metal to metal interface the internal strength of the facing (metal) absorbs these stresses and distributes the force more evenly over the face of the core body. This ability of the facing becomes more and more important with the increase in compressive loads encountered with high tension in the tension rods and with greater height if the structural units are placed one atop the other as in the construction of columns or walls.
The present invention can be manufactured using structural units with clay as well as cement and like structurally sound materials, with the facings being manufactured of a suitable load-distributing material such as plastic, metal, and the like. The present invention provides such an individual structural unit which can be bound in face-to-face relationships in order to form constructive arrays. The units are self supported upon attachment using a suitable tension means such as an elongated metal rod, or a plurality thereof, preferably constituted of iron, steel, or like tensile material which is passed through a plurality of openings or perforations through the units themselves. The end portions of the rods can be externally threaded and adapted for threadable engagement with a plate, nut, or the like; however, any suitable means of connecting units together by affixing the end portions of the rod can be used.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature and objects of the present invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals and wherein:
FIG. 1 depicts a top plan view of a mold used in the method of construction of the preferred embodiment of the composite unit apparatus of the present invention--the composite unit shown therein in phantom lines;
FIG. 2 depicts a composite structural building array formed from a plurality of units of a first embodiment of the present invention, the array being characterized of one modular unit which constitutes the building described by reference to FIG. 3;
FIG. 3 is an elevational view of various sizes of composite units of the first embodiment of the present invention;
FIG. 4 is a perspective view of a slab section formed from an assembly of the second embodiment of the composite unit structure of the present invention held together by suitable tensioning means;
FIG. 5 depicts a cross sectional view taken along lines 5--5 of FIG. 4;
FIG. 6 is a cross sectional view of a typical slab formation using the third embodiment of the composite unit structure of the present invention;
FIG. 7 is a perspective view illustrating a fourth embodiment of the composite unit structure of the present invention being attached to form a structural column;
FIG. 8 is a sectional view taken along lines 8--8 of FIG. 7;
FIG. 9 is a sectional view taken along lines 9--9 of FIG. 8;
FIG. 10 is a side elevational view and partial section of a single isolated unit of the fourth embodiment of the composite unit structure of the present invention as employed in the structural array depicted by reference to FIGS. 7 and 8;
FIG. 11 depicts in plan a slab formed by members of a fifth alternative embodiment of the unit of the present invention;
FIG. 12 is a perspective view of a single unit of the alternative embodiment of the apparatus of the present invention as forms of the structure depicted by reference to FIG. 11; and
FIG. 13 is a top sectional view of the unit of FIGS. 11 and 12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a preferred embodiment of the mold 10 of the present invention which can be used to manufacture units 12 in accordance with the teaching of the present invention. As can best be seen by an inspection of FIG. 1, there is provided a shaped mold 10 having inner walls defining a shape corresponding to the desired shape of the individual unit 12 to be formed.
In FIG. 1, there is shown in phantom lines composite unit 12 which is comprised generally of an inner structural material 14 and outer load-distributing surfaces in the form of plates 16.
As can be seen in FIG. 1, in order to construct composite unit 12, outer load-distributing plates 16 are first placed in a desired position along the inner walls 11 of mold 10 such that when a suitable flowable material such as concrete, plastic, clay or the like is added to form inner core 14, it will exactly conform to the space provided between the load-distributing plates 16. If the mold 10 is properly constructed, inner walls 11 will act as a "jig" which will exactly position load-distributing plates 16 so that their outer surfaces 17 will not require additional filing or milling before use. The surfaces will easily fit together in face-to-face relationship, being compatible when several units 12 are combined to form an array. The connection or adhesion of plates 16 to unit 12 can be augmented using projections (not shown) attached to plate 16 which would act as anchors when inner core 14 "sets". Any suitable chemical bonding agent could likewise be used to augment the adhesion of the load-distributing plates to the structural core. Inded, it is also possible, though time consuming to apply the load-distributing plates after the structural core material has "set" if the chemical bonding agent has the ability to withstand the compressive loads and, like the structural core material, at some point during or following its application, flows to conform to the surfaces which it bonds, thus again not forming point stresses.
A further inspection of FIG. 1 will reveal the presence of a plurality of bores 18 which are provided through the center portion of unit 12. These bores 18 form openings through which tension means (which can be in the form of elongated metal rods) can pass so as to eventually fasten a plurality of units 12 together. There is further provided as is shown in FIG. 1, a recess 20 on the opposite ends of each bore 18 which provides an enlarged area to facilitate the location of a suitable fastener such as a bolt, or the like.
FIGS. 2 and 3 illustrate the use of completed composite units 12 to form a structural array such as a wall or the like. In FIG. 2, there can be seen three units 12 as is shown during their construction in FIG. 1. The completed units 12, it will be noted from FIG. 2, do not require any additional milling, planing, or surface treatment, in order that they may mate together in a perfect fit upon assembly. In FIG. 2, units 12 can be seen each having load bearing plates 16 on their load bearing surfaces. The inner core 14 is shown having been cast and hardened into the proper position as was illustrated in FIG. 1 with mold 10. Now, the inner core 14 is suitably hardened and has desirable compressive strength characteristics which of course are designed after considering the desired load carrying characteristics of the structure being built.
In FIG. 2, there is seen a plurality of tension members which are in the form of connecting rods 22. In FIG. 2, each connecting rod 22 can be an elongated rod of a material such as steel, iron, or like suitable tensile material. Rods 22 can be threaded being provided with threads 23 at their respective end portions as is known in the art. There can further be provided bolts 24 which threadably engage and attach to connecting rods 22 at threads 23. If desirable, washers 25 can be provided which are placed between bolt 24 and load bearing plates 16. It will be seen, that when connecting rod 22 is in its proper position, connecting together any two of units 12, bolts 24 will assume a flush position within recess 20 thereby not interfering with the addition of other units as the construction continues. The connection can be completed with a desired tension or stress to rod 22 by use of a connectional torque wrench to guarantee uniformity and consistency throughout the structure.
When constructing the device in this manner, it can be seen that by beginning with a single unit (designated as unit "A" in FIG. 2) it is easy to add additional units (such as "B" and "C" in FIG. 2) without any additional structural support other than rods 22. Thus, if one began by placement of unit A resting against a base slab 30 as is shown in FIG. 2, unit B could be added and attached thereto permanently and structurally by connecting rods 22 as is shown. In FIG. 2, every other bore 18 in unit 12 is provided with a rod 22 to connect units A and B together. Note, however, that in the alternate openings 18 the connecting rods 22 are connected only to unit B and project outwardly therefrom a distance which will allow the addition of a further unit when it is added after A and B are secured together. Such an arrangement is important, because each unit is completely affixed to the structural array upon bolting, but additional units 12 can always be added if desired. It is also important that the aligned tensile rods are not connected one to the other because unequal stresses are created within the array decreasing its strength.
In a like manner, there can be seen at the connection between units A and C, the use of every other or alternating connecting rods 22 in order to form the structural connection between A and C, with the alternate or other rods 22 being connected to C only and projecting a distance out therefrom in order to add another composite unit. The projection distance of the rods which will be used to add additional units 12 is designated by the letter D in FIG. 2.
Alternatively, the rods 22 need not be placed within unit C so that they project a distance D for the attachment of additional units 12, not shown. Instead, the additional unit 12, not shown, may be placed in abutment with unit C and then the rods 16 which attach it to unit C may be inserted through holes 18 and by suitable means anchored or attached at one end to the facing 16 of unit C which contacts facing 16 of unit A and attached at the other end to the vertical facing 16 of the unit 12, not shown, which is not in contact with a facing 16 of unit C.
FIG. 3 illustrates a structural array which can be for example a wall, and is designated generally by the numeral 40 in FIG. 3. There it can be seen that array 40 is constructed of a plurality of individual units 12, each being attached by means of a plurality of connecting rods 22 which can be threadably mounted (or like suitable connection) to the units as was described more fully above. Note in FIG. 2 that each alternating rod 22 is "staggered" so that there will always be a projecting amount of rod 22 beyond the surface of the previously connected unit so that additional units 12 can be added as needed. In FIG. 3, it can be seen that units 12 can be of varying dimensions within the teaching of this invention. Note smaller units 12a as they appear above door 32 and window 34 in FIG. 3. Likewise, units 12b are of a shorter dimension than units 12 which are substantially the height of array 40 which forms a wall in FIG. 3.
With the method of construction as described more fully above, it should be appreciated that there is no necessity for extra bracing or like supplemental support in order to apply the tensioning members 22 and connect additional units 12 to the array. To the contrary, each unit 12 when added to the structure and fastened into place using connections 22 is totally and completely structurally sound with the array 40 as a whole anf forms its structural part thereof without necessity of grout, concrete, supplemental supports, or the like, thus offering a significant economic advantage over the prior art with a significantly decreased possibility of the creation of point stresses found in the prior art in a more economic manner than in the prior art.
However, grout or mortar may be injected into the void area of the bores 18 between the rods and the wall of the bore to give an additional measure of strength if desired as is known in the art. However, such is not necessary and renders the structure more permanent.
Thus, it can be seen that utilizing the apparatus and method of construction of the present invention there can be constructed an array 40 of units 12 to form a wall simply by use of connecting rods 22 within the teaching of the present invention.
FIGS. 4 and 5 illustrate a second embodiment of the apparatus of the present invention. In FIG. 5, there can be seen a slab 50 constructed between columns 52. Slab 50 can be constructed of a plurality of units 53 using connecting rods 54. Units 54 in the second embodiment have generally diagonal load-distributing plates 56 which aid in the structural integrity of slab 50 which is subjected to high shearing forces as is apparent to one skilled in the art.
The use of diagonal plates 56 illustrates but a second embodiment of the teaching of the present invention, though the method of constructing units 53 would be by use of a mold 10 as was described more fully above and with reference to FIG. 1. The mold 10 used to cast units 53 would provide inner walls 11 which would create a "jig" effect to orient bearing plates 56 into a desired spaced relationship so that no additional milling, cutting, or forming of plates 56 would be required when the casting was completed. Openings would be provided through structural units 53 in the same manner as they were provided in the first embodiment discussed above so that connecting rods 54 could be "staggered" enabling the assembly of slab 50 without the necessity of extra structural supports, external bracing, grout, concrete, or the like. There is seen in FIG. 5 a plurality of openings 58 through which tensile connectors could pass in a direction traverse to the rods 54 shown in FIG. 5. Such traverse openings 58 would provide connection to slab 50 in a direction normal to the connection rods 54 shown in FIG. 5 so that the slab 50 could br braced in both directions as would be desirable. Note that in FIG. 5 there is shown recesses 59, 59' which allow a space into which bolts 60 or like connections can be placed so as not to interfere with the interface between successive structural units 53.
FIG. 6 illustrates a third embodiment of the composite structural unit of the present invention. The embodiment shown in FIG. 6 provides a slab structure designated generally as 62 attached to column 64 which utilizes a plurality of structural units 66 which are constructed within the teaching of the present invention using a suitable mold 10 giving the desired structural unit geometry. Units 66 provide diagonal load-distributing plates 68, each plate provided with a pair of recesses 69, 70 which can be used for the placement of a bolt 72 or like connective member at the end of a tension rod 74 as shown in the drawings. In FIG. 6, it can be seen that there is likewise provided a second cooperative bearing plate 75 which abuts and fits comfortably against plate 68 so as to form a mate therewith. Likewise, bearing plate 75 is provided with recesses 76 for the accompanyment of bolt heads 72 or like connectors. In the embodiment shown in FIG. 6, there can be provided two connective rods 74 in separate horizontal layers as is illustrated in the drawing. In the embodiment shown in FIG. 6, connective rods 74 could be of any high tensile material such as steel or the like, and the inner core 77 of units 66 could be formed of concrete for example. There is likewise provided openings 80 traverse to that direction of rods 74 in FIG. 6. Openings 80 and corresponding recesses 82 could be used to accompany rods 74 and bolts 72 respectively within the teaching of the present invention.
In order to suitably anchor the first unit as added to column 64, there could be provided an initial anchor rod 73 as is shown in the drawing, with the length of rod 73 being "developed" by its embedment into the concrete column 64 a desired distance as is known in the art. In FIG. 6 there is an alternating arrangement of rods 74 in the plane of the drawing. However, it should be understood that the alternating arrangement, which allows subsequent units to be added to the array, may be in a direction normal to the rods 74 shown in FIG. 6, the same effect being achieved.
FIGS. 7-10 illustrate a fourth embodiment of the composite structural unit of the present invention. There can be seen in FIGS. 7-10 a block 82 having load-distributing plates 83, 84, respectively, on its lower and upper portions as viewed in FIG. 10. Unit 82 would likewise be formed having an inner core 85 of a suitable material having the necessary compressive strength, and plates 83, 84 providing a surface which would have load-distributing characteristics necessary in order to transmit the compressive forces generated by connecting rods 90 to unit 82. In FIG. 7, there can be seen a column 92 constructed of a plurality of units 82. Column 92 would be merely a single array having individual units 82 "stacked" thereon as shown in the drawings. There would be provided a plurality of openings 86 through which connecting rods 90 could be placed as is shown best in FIGS. 7 and 8. Likewise, as with the previous embodiments of the present invention, there could be provided recesses 87 which would provide a space for bolts 93 which could be threadably connectable to the end portions of rods 90.
FIG. 8 helps illustrate the method of construction of the present invention to construct column 92 of FIG. 7. In FIG. 8 there is seen a base slab 94 which has embedded therein a plurality of connectors 90 so as to form a spot for "beginning" column 92. After the first structural unit is placed over the initial rods 90, successive units can be added by "staggering" the rods 90 so as to always provide an exposed portions "A" and "B" of rod 90 on units 82 as desired. It is within the teaching of the present invention that the pattern may be altered so that the individual rods 90 and the connecting rods of the other embodiment may be of sufficient length to pass through any number of structural units less than the number of structural units required for the entire eventual span creating a slightly different but basically similar interlocking pattern although FIG. 8 shows that number to be three. Note in FIG. 8 there are provided rods 90 which project a distance A above the uppermost unit 82. These rods 90 which project a distance A, would initially bolt or attach and hold the next unit added to the stack, whereas there is also provided rods 90 which project a second distance B above the last added unit shown in FIG. 8. When a second unit were to be added to the stack as shown in FIG. 8, the rods which project a distance B would be utilized to secure that particular unit into its position. Thus, there can be seen a method of construction shown with the column of FIGS. 7 and 8 which provides a connection of each successive unit to the column, with each connection forming a complete integral structural connection with the previous unit, there being no need for supplemental bracing, or other structural supports.
As in the first embodiment of the present invention and in all embodiments of the present invention the tensile rods 90 of FIGS. 7 and 8 need not project distances B and A, but may be inserted as required to attached successive structural units 82 to the columnar array 92 after placement of a structural unit in position on the columnar array.
FIG. 9 illustrates a top view of the column shown in FIG. 8, whereby it can be seen a plurality of openings 86 through which rods 90 can pass, and there can also be seen recesses 87.
FIGS. 11 through 13 illustrate a fifth embodiment of the apparatus of the present invention. In FIG. 12, hexagonal unit 100 is made to appear as a plurality of stacked solid layers 102, 104 and 106. It should be understood, however, that the exemplary number of three (3) layers provided to unit 100 as shown in FIG. 11 is not absolute. Each layer represents generally a line of force through which connections can be made through various abutting units so as to form an array as shown in FIG. 12, thus varying numbers of layers 102, 104, 106 could be provided.
In FIG. 12, there can be seen connection holes 110 through which suitable connecting rods (not shown) can be attached. Bearing plates 114 are provided at the outer edges of each layer 102, 104, 106 as is the case with previous units within the teaching of the present invention as was described more fully heretofore. The units 100 can be connected to form an array as shown in FIG. 11, with the rods 112 being alternatively arranged so that each unit 100 can be securely connected to the preceding unit 100 or to the array in the manner as depicted for the single structural unit 90A in FIG. 11. In FIG. 11, unit 90A is connected at its edges to units 90B, 90C, 90D, 90E, 90F and 90G. Tensile connectors 91, 92, 93, 94, 95 and 96 secure the array as is shown in FIG. 11. Thus an interlocking repeating pattern is formed. In FIG. 12, there is shown attached to the individual hexagonal structural unit 100 a load-distributing plate 103 with holes 101 passing through it and the structural core of the unit 100 with recesses 105 which allow the usage of the structural unit at the same time as both an element in a vertical array of a column, similar to the fourth embodiment of the invention described in conjunction with FIGS. 7 through 9, and an element in the horizontal two-dimensional array of a slab. Thus, the horizontal two-dimensional array of the slab and the one dimensional array of a column are integrally connected.
The structural units 100 can be formed much in the same way as the previous teachings of this application, in which a mold 10 is utilized having geometrically desirably arranged inner walls 11 to which walls there can be affixed bearing plates 114 prior to the addition of a desired flowable "setting" material. When the setting material hardens (for example in 28 days or so with concrete), the mold can be removed and the unit is ready for its operational use in a structural array or the like.
Because many varying and different embodiments may be made within the scope of the inventive concept herein taught, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirements of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense. | A building structural unit and its method of construction is disclosed. Additionally provided is a method for the building of structural arrays with a plurality of the structural units. The structural unit of the present invention provides an inner structural core portion having provided attached to the outer surface thereof load-distributing surfaces. Suitable attachment means can be provided in order to facilitate connection of a plurality of the individual units together forming a structural array such as a wall, slab, ceiling, column, or the like. The structural units can be fastened together by means of tension members such as for example threaded rods, with each individual unit being provided with bores therethrough through which the tension members or rods can pass. Bolted or like connections at the tension member ends bear upon the provided load distributing surface to complete the desired mating of the individual units. A method for connecting the units together in order to form the desired structural array allows each unit to be completely self supported structurally upon its connection to the previous unit or to the formed array itself. A first embodiment provides a substantially rectangular shaped structural unit, useful in wall construction (FIGS. 2 and 3); a second embodiment provides a diagonally interfacing unit, useful in the construction of slabs, ceilings and the like (FIGS. 4 and 5); a third embodiment also provides an alternative diagonally interfacing unit useful in slab and ceiling construction, a fourth embodiment provides a unit member suitable for column construction; in a fifth embodiment, a generally hexagonal unit structure is disclosed. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
REFERENCE TO A “MICROFICHE APPENDIX.” (See 37 CFR 1.96(c)).
[0003] Not Applicable.
BACKGROUND OF THE INVENTION
[0004] The present invention relates to that class of air conditioners in which the air is cooled by the latent heat of evaporation of water. This invention enhances the operation of this type of cooler by maintaining a deeper, insulated, sloped reservoir to provide cleaner and cooler circulating water eliminating the need for bleed off thus reducing water consumption while improving efficiency. In addition, the temperature of the air stream is pre-cooled by an air to water heat exchanger which also incorporates a solenoid operated bypass valve that regulates the amount of water introduced to the cooling media, thus increasing cooling efficiency, conserving water and allowing control of the final air outlet temperature.
BRIEF SUMMARY OF THE INVENTION
[0005] The invention is carried out by the inlet air stream passing over a water to air heat exchanger, prior to being circulated over the evaporative media which both cools the inlet air and the return water, which is returned to a reservoir that is insulated to maintain a large volume of water at near wet bulb temperature. The water from the reservoir is circulated through the heat exchanger and then across the cooling media by a pump with its suction located at mid-depth of the reservoir, isolating it from floating debris and heaver particles that settle to the bottom of the reservoir and are guided by the sloped bottom to an integral sump. A three way valve located between the heat exchanger and the evaporative media regulates the air outlet temperature by limiting the amount of water introduced to the cooling media.
[0006] This invention removes suspended particulate matter with a new and novel bottom pan that is tapered to a sump that can be purged manually or automatically.
[0007] A larger volume of water is pumped through a main header that discharges upward to avoid plugging of the distribution system. The larger volume of water aids the cooling of the air stream by adding convection cooling to the latent heat of evaporation.
[0008] This invention can be installed on new or existing evaporative air conditioners or as a self-contained device that can be retrofitted to new or existing evaporative air conditioners. It is accordingly the objective of this invention to provide increased performance of new or existing evaporative air conditioners, whether as an integral part or a separate detached water reservoir and distribution system. It is a further objective of this invention to provide debris removal for evaporative air conditioners, enhancing the life of the cooling media, motors, pumps, belts and pulleys. It is a further object of this invention to eliminate the need for evaporative air conditioners to bleed a portion of the water reservoir to minimize corrosion and scale buildup and to conserve water. It is a further object of this invention to have enhanced air/water contact, to maximize the extraction of heat from the inlet air stream.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0009] The objects and attendants advantages of this invention will be readily apparent to any one familiar with the field of the invention from the following detailed description taken in conjunction with the accompanying drawings in which:
[0010] FIG. 1 is a side sectional view through an evaporative air conditioner fitted with the water to air heat exchanger and the new reservoir system.
[0011] FIG. 2 is a side sectional view through an existing evaporative air conditioner retrofitted with the new reservoir system.
[0012] FIG. 3 is a sectional view of the new water distribution header.
DETAILED DESCRIPTION OF THE INVENTION
[0013] In the exemplary embodiment of the invention a substantially cubic or cylindrical cabinet I is fitted with an insulated reservoir 2 , which is provided with a sloping bottom 3 , and a debris sump 4 . The bottom of the reservoir is also provided with a shelf 5 , for mounting a water distribution pump 6 .
[0014] A water to air heat exchanger 7 is located upstream of the cooling media 8 . Water from the reservoir 2 is pumped by the water distribution pump 6 into the top of the water to air heat exchanger 2 and travels downward to the bottom of the water to air heat exchanger 2 . Air passing through the water to air heat exchanger 7 is pre-cooled prior to contact with the cooling media 8 . The water exits the bottom of the water to air heat exchanger and enters a solenoid dump valve 9 that either directs the water to the reservoir 2 or to the water distribution header 10 , thus regulating the amount of water introduced to the cooling media 8 . The water distribution header 10 , is fitted with a plurality upward facing water distribution holes and is mounted to the cabinet 1 , above the cooling media 8 . The space between the sloping bottom 3 and the cabinet 1 , is filled with foam insulation 11 . A drain line 12 is provided to purge the debris collector sump 4 , and is further fitted with either a manually valve, or optionally a solenoid operated valve 13 , for the removal of accumulated solids and particulate matter.
[0015] When the invention is assembled as a stand alone reservoir/distribution system to be retrofitted to existing evaporative air conditioners 14 , the reservoir 2 , the sloping bottom 3 , the shelf 5 , the pump 6 the sump 4 , drain line 12 , the drain valve 13 and a makeup water float valve 15 are assembled within their own cabinet 16 , which is fitted with a removable lid 17 . A feed line 18 and a return line 19 are provided to circulate the cold water to and from the existing air conditioner 14 . The addition of weirs 20 , assist in keeping particulate material away from the pump inlet.
[0016] In either case, the water distribution header 10 is fitted with water distribution holes or nozzles 21 that face upward and spray onto a reflector 22 . The excess water flow aids in cooling the inlet air as well as keeping the cooling media 8 flushed and clean. Under operation, water is pumped from midstream of the cool water reservoir 2 , by the water pump 6 , through the water to air heat exchanger 7 and then the solenoid operated three way valve 9 that diverts the correct amount of water to the distribution header 17 as required to maintain the set temperature, or in the case of the retrofit system directly to the water distribution header 17 .
[0017] The water is sprayed from a plurality of water nozzles 21 onto a reflector 22 , assuring both constant distribution of the water and preventing water nozzles 21 from becoming clogged. As the water returns from the cooling media 8 to the reservoir 2 , it has been cooled to near wet bulb temperature. The natural vibrations inherent with fans and blowers, causes the separated solid particulate matter to flow by gravity and the constant agitation from the falling water, to the new and novel debris collecting sump, while the lighter debris floats on the surface. The pedestal 5 assures the circulation pump 6 is continually circulating cool clean water through the water to air heat exchange 7 and over the cooling media 8 as required to maintain the thermostatic set temperature, and the insulation assures the water remains near wet bulb before being circulated over the media 8 again. This excess water flow in conjunction with the reduced reservoir temperature increases the efficiency of cooling the inlet air stream due to additional heat transfer through forced conduction, as the air is forced into contact with the cold water flow. | A air pre-cooler, water reservoir and distribution apparatus for evaporative air conditioners, incorporating an insulated, increased volume, self-cleaning water reservoir and a unique water distribution system, in which the cooling efficiency is increased through enhanced air water contact, and provides cleaner and cooler outlet air through particulate removal. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Australian provisional application 2010901458, filed on 7 Apr. 2010, which is hereby incorporated by reference herein.
TECHNICAL FIELD
[0002] The present invention relates to body boards for recreational purposes, and elements for providing reinforcement of them.
BACKGROUND ART
[0003] Body boards are a popular recreational and sporting product typically used for riding waves. They are usually constructed out of a dense foam outer shell surrounding a foam type core. It is common practice to also manufacture a reinforcing element called a “stringer” into the interior of the body board, to prevent excessive flexing and potential buckling of the board in the surf. Such reinforcing elements can be cylindrical rods made of fiberglasses other suitable material and are inserted during manufacture into a cavity drilled or molded into the core.
[0004] Once manufactured, the rigidity properties of the board are fixed, but it may be perceived as advantageous to the skilled body boarder to be able to adjust the rigidity of the body board to suit different surf conditions.
[0005] There is therefore a need to provide a way of allowing the amount of reinforcement or rigidity of the body board to be adjusted after manufacture.
SUMMARY OF INVENTION
[0006] According to a broad aspect of the invention there is provided a body board comprising a cavity for holding a reinforcing element, adapted to allow removal and replacement of the reinforcing element by a user.
[0007] In one embodiment, the body board cavity comprises a sleeve to facilitate insertion and removal of the reinforcing element.
[0008] In one embodiment, a retainer on the body board is adapted to engage with a securing part on the reinforcing element. The retainer and securing part may engage via corresponding screw threads. The retainer may be attached to the sleeve near an outer end thereof. The securing part of the reinforcing element may be attached to an outer end thereof.
[0009] In one embodiment, the body board is combined with at least one of the reinforcing elements.
[0010] In a second broad aspect of the invention there is provided a reinforcing element adapted to be removably inserted into a cavity of a body board by a user.
[0011] In one embodiment, the reinforcing element comprises a securing part adapted to engage with a retainer on the body board. The securing part may engage with the retainer on the body board via corresponding screw threads. The securing part may be attached to an outer end of the reinforcing element. The reinforcing element may further comprise a seal to engage with the body board to prevent ingress of water into the cavity.
[0012] In a third broad aspect of the invention there is provided a set of reinforcing elements of the second broad aspect, having a range of rigidities and adapted to be interchangeably used with the body board.
BRIEF DESCRIPTION OF DRAWINGS
[0013] FIG. 1 shows a body board and reinforcing element in accordance with one embodiment of the invention;
[0014] FIG. 2 shows the body board and reinforcing element of the embodiment of FIG. 1 with the reinforcing element part way inserted into the cavity.
[0015] FIGS. 3A and 3B shows details of a retainer on the body board and the securing part on the reinforcing element in the embodiment of FIG. 1 .
[0016] FIG. 4 shows an alternative to the configuration of FIGS. 3A and 3B .
[0017] FIG. 5 shows a range of alternative cavity positions for embodiments of the invention.
[0018] FIG. 6 shows an assembled reinforcing element according to the currently most preferred embodiment.
[0019] FIG. 7 shows details of a handle and seal of the reinforcing element of FIG. 6
[0020] FIG. 8 shows details of the securing part of the reinforcing element of FIG. 6 .
[0021] FIG. 9 shows details of the retainer in the body board adapted to receive the securing part of the reinforcing element of FIG. 6 .
DESCRIPTION OF EMBODIMENTS
[0022] Embodiments of the current invention will now be described with reference to the Figures.
[0023] Referring first to FIG. 1 , body board 1 composed of an outer shell and inner foam core comprises a cavity 2 . Cavity 2 extends through the shell at an end 3 thereof to provide insertion access. End 3 also comprises a retainer. A reinforcing element 4 comprises a cylindrical rod made of fiberglass, carbon fiber or similar material as is known in the art. Attached to an outer end of reinforcing element 4 is a securing part adapted to engage with the retainer.
[0024] Referring now to FIG. 2 , reinforcing element 4 is shown inserted part way into the cavity.
[0025] Referring now to FIG. 3A , details of the reinforcing element and cavity are shown. Reinforcing element 4 comprises a cylindrical fiberglass rod 6 adapted to slide inside sleeve 7 which lines the cavity, and a metal outer sleeve 10 at an outer end thereof. Sleeve 7 is composed of flexible plastic tubing glued to the foam core and is able to flex with the board at the same time as providing a durable and smooth surface to facilitate insertion and removal of reinforcing element 4 . Near an outer end of the sleeve 7 is attached a retainer comprising stainless steel inner female screw thread 8 held in place by metal crimp clamp 9 . Screwed into the fiberglass rod 6 with a male screw thread 11 is a stainless steel securing part 12 having a larger male screw thread 13 adapted to engage with the female screw thread 8 of the retainer. Securing part 12 further comprises a seal 14 adapted to engage with the retainer so as to prevent ingress of water into the cavity, and a recessed slot 15 to allow tightening of the security part onto the retainer with an Allen key or other appropriate tool.
[0026] Referring now to FIG. 3B , the reinforcing element is shown in the secured position.
[0027] Referring now to FIG. 4 , an alternative configuration is shown to that of FIGS. 3A and 3B . In this embodiment, the male screw thread 13 a is at the opposite end of the reinforcing element, and engages with a corresponding female screw thread 8 a at the innermost end of the sleeve 7 a.
[0028] Referring now to FIG. 5 , there are shown examples of alternative orientations and positions of the cavity in different embodiments of the invention. Multiple cavities are also within the scope.
[0029] Referring now to FIG. 6 , assembled reinforcing element 60 according to the currently most preferred embodiment of the invention comprises hollow reinforcing rod 61 with inner diameter 13 mm and outer diameter 16 mm, handle and seal assembly 70 with two O-ring seals 71 and 72 , and securing part 80 . Referring to FIG. 7 , handle and seal assembly 70 comprises nylon coated stainless steel cable 73 with ends 73 a and 73 b that are crimped during manufacture after insertion through handle holes 74 a and 74 b in cap 74 . The head of stainless steel bolt 75 rests inside recess 74 c and passes the through the centre hole of the aluminum cap 74 , and bolt 75 screws into thread 77 of aluminum rod engaging part 76 . Rod engaging part 76 has circular cross section and comprises two O-ring seal channels 78 to receive O-rings 71 and 72 , sized appropriately to engage with the inside of a 19 mm sleeve in the body board cavity, and a lower cylindrical section 79 sized to fit snugly inside the rod 61 at the outer end thereof, as viewed when installed in the body board. Referring to FIG. 8 , aluminum securing part 80 has a rod engaging part 81 also sized to fit snugly inside the rod 61 at the inner end of rod 61 , and hook-shaped spiral lock elements 82 a and 82 b. The spiral lock elements 82 a and 82 b engage with a retainer at an inner end of a sleeve lining the cavity in the board. Referring to FIG. 9 , sleeve 90 is an ordinary 19 mm diameter polyethylene irrigation pipe lining the cavity. Sleeve 90 may be held in the cavity by heat fusion of the outer end thereof with a base of the body board. The retainer comprises polyethylene end plug 91 (also as normally supplied for irrigation pipes) into which has been installed an aluminum or stainless steel rivet 92 passing also through sleeve 90 fix the end cap and to provide an engaging bar for the spiral lock elements 82 a and 82 b. When the securing part of rod 61 is pushed up the sleeve and after engaging with bar provided by rivet 92 , a quarter turn will cause spiral lock elements 82 a and 82 b to hook over the bar and be retained. Washer 94 spring-loaded with spring 93 urges the hooks to remain in the retained position. Removal involves the user pushing inwards on the handle and making a reverse quarter turn, whereby the reinforcing element can be pulled out.
[0030] There is thus provided a body board and removable reinforcing elements that together can provide an enhanced sporting experience. It will be appreciated that the invention comprises in its various aspects a board adapted to receive removable reinforcing elements, a combined board and reinforcing element, and the reinforcing element itself, alone or as part of a set having a range of flexibilities, adapted to be used interchangeably in a body board.
[0031] Persons skilled in the art will also appreciate that many variations may be made to the invention without departing from the scope of the invention.
[0032] For example, the retainer shown can be varied or may not be needed, and the reinforcing element may not necessarily require a securing part, depending on the design of the board. Further, the body of the reinforcing element can be made from any effective rigidity material or shape. Further still, the board may comprise more than one of the cavities for holding respective reinforcing elements.
[0033] These and other modifications may be made without departing from the scope of the invention, which is defined in the claims and summary.
[0034] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.
[0035] It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country. | A body board ( 1 ) is provided having a cavity ( 2 ) into which reinforcing elements ( 4 ) may be interchangeably inserted through an opening ( 3 ) by the user to vary the flexing characteristics of the board. The reinforcing elements may be provided with securing parts adapted to engage with a retainer in the board to securely hold the reinforcing element in place. | 1 |
This application is a division of application Ser. No. 11/322,987 filed Dec. 30, 2005 now U.S. Pat. No. 7,638,160. Fibrous glass insulation (“fiberglass” or “glass fiber” insulation) products generally comprise matted glass fibers bonded together by a binder that is often a cured thermoset polymeric material. Molten streams of glass are drawn into fibers of random lengths and blown into a forming chamber where they are randomly deposited as a mat onto a traveling conveyor. The fibers, while in transit in the forming chamber, and while often still hot from the drawing operation are sprayed with the binder. The coated fibrous mat is transferred to a curing oven where heated air, for example, is blown through the mat to cure the binder and rigidly bond the glass fibers together.
BACKGROUND
Fiberglass binders have a variety of uses ranging from stiffening applications where the binder is applied to woven or non-woven fiberglass sheet goods and cured, producing a stiffer product; thermo-forming applications wherein the binder resin is applied to sheet or lofty fibrous product following which it is dried and optionally B-staged to form an intermediate but yet curable product; and to fully cured systems such as building insulation.
Binders useful in fiberglass insulation products generally require a low viscosity in the uncured state, yet characteristics so as to form a rigid thermoset polymeric mat for the glass fibers when cured. A binder which forms a rigid matrix when cured is required so that a finished fiberglass thermal insulation product, when compressed for packaging and shipping, will recover to its specified vertical dimension when installed in a building.
From among the many thermosetting polymers, numerous candidates for suitable thermosetting fiber-glass binder resins exist. However, binder-coated fiberglass products are often of the commodity type, and thus cost becomes a driving factor, generally ruling out such resins as thermosetting polyurethanes, epoxies, and others. Due to their excellent cost/performance ratio, the resins of choice in the past have been phenol/formaldehyde resins. Phenol/formaldehyde resins can be economically produced, and can be extended with urea prior to use as a binder in many applications. Such urea-extended phenol/formaldehyde binders have been the mainstay of the fiberglass insulation industry for years.
Over the past several decades, however, minimization of volatile organic compound emissions (VOCs) both on the part of the industry desiring to provide a cleaner environment, as well as by Federal regulation, has led to extensive investigations into not only reducing emissions from the current formaldehyde-based binders, but also reducing the amount of binder used in production. Increasing stringent Federal regulations has lead to greater attention to alternative binder systems which are free from formaldehyde.
One particularly useful formaldehyde-free binder system employs a binder comprising a polycarboxy polymer and a polyol. Formaldehyde-free resins are those which are not made with formaldehyde or formaldehyde-generating compounds. Formaldehyde-free resins, such as acrylic resins, do not emit appreciable levels of formaldehyde during the insulation manufacturing process and do not emit formaldehyde under normal service conditions. Use of this binder system in conjunction with a catalyst, such as an alkaline metal salt of a phosphorous-containing organic acid, results in glass fiber products that exhibit excellent recovery and rigidity properties.
Fiberglass products, such as fiberglass insulation, are exposed to a variety of environmental conditions that can adversely affect the performance of the product. Overall rigidity and recovery of the product are typical measures of performance.
Curing of the fiberglass products is essential to proper product performance. Factors that contribute to the curing process, and the ultimate performance of the fiberglass product, include many variables, and ultimate product performance is often unpredictable.
There is a need for reducing the quantity of acrylic resin used in binder systems during the manufacture of fiber glass insulation products without negatively impacting the curing process or the overall performance of the product.
The foregoing examples of the related art and limitations related therewith are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.
SUMMARY
The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools, and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other improvements.
The method provides for reducing the amount of acrylic binder or resin used in glass fiber manufacturing while maintaining product performance. One method for reducing the amount of acrylic resin used in glass fiber manufacturing maximizes ramp moisture, operating between 5 and 20 percent. Another method for reducing the amount of acrylic resin used in glass fiber manufacturing maximizes the use of silane, operating between 0.019% and 0.350% solid per weight of glass (between 0.20% and 3.64% per weight resin solids). Most preferably, a method for reducing the amount of acrylic resin used in glass fiber manufacturing maximizes the use of silane, operating between 0.70% and 0.26% solid per weight of glass (between 0.8% and 2.7% per weight resin solids). Increasing ramp moisture and increasing silane levels in the binder were discovered to reduce the amount of acrylic-based binder required to manufacture glass fiber material while maintaining or improving product performance. Relatedly, increasing either ramp moisture or silane levels were discovered to reduce the amount of acrylic-based binder required to produce glass fiber material while maintaining product performance.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the methods and compositions disclosed herein will be described hereinafter which form the subject of the claims of the invention. It should be appreciated that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the methods and compositions disclosed herein. It should also be realized that such equivalent constructions do not depart from the methods and compositions disclosed herein. The novel features which are believed to be characteristic of the methods and compositions disclosed herein, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description.
In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and tables and by study of the following descriptions.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments are illustrated in the referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than limiting.
FIG. 1 is an analysis of variance representing measurements of the rigidity of a product manufactured according to a method disclosed herein.
FIG. 2 is a reduced model for rigidity measurements of a product manufactured according to a method disclosed herein. The response surface regression of FIG. 2 plots QKdrp vs. ramp moisture, resin flow, and silane flow.
FIG. 3A is a contour plot of product rigidity for resin flow (y-axis) (L/min) vs. ramp moisture (x-axis) (%).
FIG. 3B is a contour plot of product rigidity for silane flow (y-axis) (L/min) vs. ramp moisture (x-axis) (%).
FIG. 3C is a contour plot of product rigidity for silane flow (y-axis) (L/min) vs. resin flow (y-axis) (L/min).
FIG. 4 is an analysis of variance for product rigidity following seven (7) days of aging at 90° F. and 90% humidity.
FIG. 5A is a contour plot of product rigidity following seven (7) days of aging at 90° F. and 90% humidity for resin flow (y-axis) (L/min) vs. ramp moisture (x-axis) (%).
FIG. 5B is a contour plot of product rigidity following seven (7) days of aging at 90° F. and 90% humidity for silane flow (y-axis) (L/min) vs. ramp moisture (x-axis) (%).
FIG. 5C is a contour plot of product rigidity following seven (7) days of aging at 90° F. and 90% humidity for silane flow (y-axis) (L/min) vs. resin flow (y-axis) (L/min).
DETAILED DESCRIPTION
It has been discovered that fiber glass insulation product properties may be improved or maintained when manufactured under conditions of increased overall ramp moisture and/or increased silane content, while reducing amounts of resin or binder. The improvement in rigidity after aging of the fiber glass insulation product manufactured with increased silane flow as described herein was unexpected.
Structural integrity and physical properties of glass fiber products overall are related to, amongst other things, curing of binders or resins which hold the glass fibers together and provide stiffness and resiliency to the products. The effectiveness of the binder composition is due in large measure to how well the binder is cured. This is particularly true for novel formaldehyde-free binder compositions that are currently being used by fiberglass manufacturers. Physical properties of manufactured glass fiber products are dependant upon, amongst other things, the temperature of the binder resin during the curing step, the length of time that the temperature is maintained, and the silane content of the binder.
The methods and compositions described herein are particularly useful for ensuring that properties of manufactured glass fiber products are maintained or improved when using formaldehyde-free binders, including, but not limited to, acrylic thermoset binders, while reducing the amount of binder used in the manufacturing process. The formaldehyde-free binders useful in the practice of the methods and compositions disclosed herein are typically prepared from resins comprising poly-carboxy polymers such as acrylic resins, although other formaldehyde-free resins may be employed. As used herein, the term “formaldehyde-free” or “FF” means that the resin or binder composition is substantially free of formaldehyde and/or does not liberate formaldehyde as a result of curing or drying. FF binders and resins generally have a molecular weight of less than about 10,000, preferably less than about 5,000.
In one embodiment, the polycarboxy polymer used in the formaldehyde-free binder comprises an organic polymer or oligomer containing more than one pendant carboxy group. The polycarboxy polymer may be a homopolymer or copolymer prepared from unsaturated carboxylic acids including, but not necessarily limited to, acrylic acid, methacrylic acid, crotonic acid, isocrotonic acid, maleic acid, cinnamic acid, 2-methylmaleic acid, itaconic acid, 2-methylitaeonic acid, α-β-methyleneglutaric acid, and the like. Alternatively, the polycarboxy polymer may be prepared from unsaturated anhydrides including, but not necessarily limited to, maleic anhydride, methacrylic anhydride, and the like, as well as mixtures thereof. Methods for polymerizing these acids and anhydrides are well-known in the chemical art.
In one embodiment, the formaldehyde-free curable aqueous binder composition also contains a polyol containing at least two hydroxyl groups. The polyol must be sufficiently nonvolatile such that it will substantially remain available for reaction with the polyacid in the composition during heating and curing operations. The polyol may be a compound with a molecular weight less than about 1000 bearing at least two hydroxyl groups such as, for example, ethylene glycol, glycerol, pentaerythritol, trimethylol propane, sorbitol, sucrose, glucose, resorcinol, catechol, pyrogallol, glycollated ureas, 1,4-cyclohexane diol, diethanolamine, triethanolamine, and certain reactive polyols such as, for example, β-hydroxyalkylamides such as, for example, bis[N,N-di(β-hydroxyethyl)]adipamide, as may be prepared according to the teachings of U.S. Pat. No. 4,076,917, incorporated herein by reference, or it may be an addition polymer containing at least two hydroxyl groups such as, for example, polyvinyl alcohol, partially hydrolyzed polyvinyl acetate, and homopolymers or copolymers of hydroxyethyl(meth)acrylate, hydroxypropyl(meth)acrylate, and the like. The most preferred polyol for the purposes of the present invention is triethanolamine (TEA), or mixtures of DEA and TEA.
The ratio of the number of equivalents of carboxy, anhydride, or salts thereof of the polyacid to the number of equivalents of hydroxyl in the polyol is from about 1/0.01 to about 1/3. An excess of equivalents of carboxy, anhydride, or salts thereof of the polyacid to the equivalents of hydroxyl in the polyol is preferred. The more preferred ratio of the number of equivalents of carboxy, anhydride, or salts thereof in the polyacid to the number of equivalents of hydroxyl in the polyol is from about 1/0.4 to about 1/1. The most preferred ratio of the number of equivalents of carboxy, anhydride, or salts thereof in the polyacid to the number of equivalents of hydroxyl in the polyol is from about 1/0.6 to about 1/0.8, and most preferably from 1/0.65 to 1/0.75. A low ratio, approaching 0.7:1, has been found to be of particular advantage in the present invention, when combined with a low molecular weight polycarboxy polymer and the low pH binder.
The formaldehyde-free curable aqueous binder composition may also contain a catalyst, such as, for example, a phosphorous-containing accelerator which may be a compound with a molecular weight less than about 1000 such as, for example, an alkali metal polyphosphate, an alkali metal dihydrogen phosphate, a polyphosphoric acid, and an alkyl phosphinic acid or it may be an oligomer or polymer bearing phosphorous-containing groups such as, for example, addition polymers of acrylic and/or maleic acids formed in the presence of sodium hypophosphite, addition polymers prepared from ethylenically unsaturated monomers in the presence of phosphorous salt chain transfer agents or terminators, and addition polymers containing acid-functional monomer residues such as, for example, copolymerized phosphoethyl methacrylate, and like phosphonic acid esters, and copolymerized vinyl sulfonic acid monomers, and their salts. Such a phosphorous-containing accelerator may be used at a level of from about 1% to about 40%, by weight based on the combined weight of the polyacid and the polyol.
The binder compositions described herein are usually supplied as an aqueous suspension containing about 48 to 53 wt % solids and are prepared by first further diluting the binder to a point where the composition contains from about 1 to about 10 percent solids.
Acid is then added to the aqueous binder composition to reduce the pH to a less than about 3.5, preferably less than 3.0, much preferably less than 2.5. Low pH has been found to be important in ensuring proper application and curing of the binder composition.
Curing of the binders is most often accomplished by heating the binder coated fibers in a curing oven. Curing ovens typically are arranged with one or more temperature zones of varying ramp moistures. In each zone, the binder-coated fibers are subjected to a temperature in the range of 150° C. to 325° C. with from 180 to 250° C. preferred. Air is also forced through the fiberglass product by fans associated with each zone to ensure uniform heating of the fiberglass product.
Use of silane adhesion promoters often is utilized when employing a binder for a glass mat. Identifying appropriate adhesion promoters for thermosetting acrylic resin-based binder compositions might also be helpful in delivering a more useful fiberglass binder. The presence of the ethoxysilane has been found to impart good hydrolytic stability to the binder, and hence the fiberglass mat to which the binder is applied. As well, the use of an ethoxysilane, as opposed to other silanes, avoids harmful emissions such as methanol, which is recognized as a HAP (hazardous air pollutant). As a result, fiberglass products such as insulation made with the binder of the methods and compositions disclosed herein provide a competitive advantage as the products will meet advertised thickness so as to make the required R value, and also have good recovery and rigidity properties, and good hydrolytic stability, and a reduction in the amount of resin or binder used in the manufacturing process. The use of various silanes as adhesion promoters in binders used in the production of glass fiber-based materials is discussed by Guy Clamen, et al., “Acrylic Thermosets: A Green Chemistry Alternative to Formaldehyde Resins,” International Nonwovens Technical Conference, Baltimore, Md., Sep. 15-18, 2003.
Silanes are monomeric silicon compounds with four substituent groups attached to the silicon atom and are commercially available from chemical companies such as Dow Corning and GE Silicones. Silane compounds are believed to act as an adhesion promoter of the binder to the fiberglass by a coupling mechanism. Silane reacts with the thermoset polycarboxy molecule and attaches to the glass fiber substrate. If an appropriate silane is chosen, it has been found that the properties of the polycarboxy based binder, and hence the fiberglass product, can be enhanced.
The silanes of the methods and compositions disclosed herein are ethoxysilanes. The ethoxysilanes generally do not contain a vinyl group, and preferably contain an epoxy or glycidoxy group. A mixture of ethoxysilanes can be employed. Among the most preferred ethoxysilanes are the diethoxysilanes such as, glycidoxy or epoxydiethoxysilane, and triethoxysilane, which have been found to provide good results when used in combination with a polycarboxy/polyol binder system. A polycarboxy based binder system containing an ethoxysilane also has the advantage of good hydrolytic stability under hot, humid conditions. Thus, the good physical performance of such binders can be realized regardless of the environmental conditions, which provides a real competitive advantage. The ethoxysilanes used in the binder compositions of the methods and compositions disclosed herein also result in no harmful emissions, as none of the emissions are considered a HAP (hazardous air pollutant). The combination of good physical properties and environmental acceptability offered by the use of ethoxysilanes in the binder compositions of the methods and compositions disclosed herein is truly advantageous to the industry. Further reducing the amount of binder composition used in the manufacturing process is also advantageous.
The formaldehyde-free curable aqueous binder composition may contain, in addition, conventional treatment components such as, for example, emulsifiers, pigments, filler, anti-migration aids, curing agents, coalescents, wetting agents, biocides, plasticizers, anti-foaming agents, colorants, waxes, and anti-oxidants.
The formaldehyde-free curable aqueous binder composition may be prepared by admixing the polyacid, the polyol, and the phosphorous-containing accelerator using conventional mixing techniques. In another embodiment, a carboxyl- or anhydride-containing addition polymer and a polyol may be present in the same addition polymer, which addition polymer would contain both carboxyl, anhydride, or salts thereof functionality and hydroxyl functionality. In another embodiment, the salts of the carboxy-group are salts of functional alkanolamines with at least two hydroxyl groups such as, for example, diethanolamine, triethanolamine, dipropanolamine, and di-isopropanolamine. In an additional embodiment, the polyol and the phosphorous-containing accelerator may be present in the same addition polymer, which addition polymer may be mixed with a polyacid. In yet another embodiment the carboxyl- or anhydride-containing addition polymer, the polyol, and the phosphorous-containing accelerator may be present in the same addition polymer. Other embodiments will be apparent to one skilled in the art. As disclosed herein-above, the carboxyl groups of the polyacid may be neutralized to an extent of less than about 35% with a fixed base before, during, or after the mixing to provide the aqueous composition. Neutralization may be partially effected during the formation of the polyacid.
Once the composition of the polyacid and the polyol has been prepared, the ethoxysilane can then be mixed in with or simply added to the composition to form the final binder composition to be sprayed on the fiberglass. The ethoxysilane is therefore basically an important additive to conventional polycarboxy binder systems, such as that described in U.S. Pat. No. 6,331,350, which is hereby expressly incorporated by reference in its entirety. As molten streams of glass are drawn into fibers of random lengths and blown into a forming chamber where they are randomly deposited as a mat onto a traveling conveyor, the fibers, while in transit in the forming chamber, are sprayed with the aqueous binder composition of the methods and compositions disclosed herein, which includes the ethoxysilane.
More particularly, in the preparation of fiberglass insulation products, the products can be prepared using conventional techniques. As is well known, a porous mat of fibrous glass can be produced by fiberizing molten glass and immediately forming a fibrous glass mat on a moving conveyor. The expanded mat is then conveyed to and through a curing oven wherein heated air is passed through the mat to cure the resin. The mat is slightly compressed to give the finished product a predetermined thickness and surface finish. Typically, the curing oven is operated at a temperature from about 150° C. to about 325° C. Preferably, the temperature ranges from about 180 to about 225° C. Generally, the mat resides within the oven for a period of time from about ½ minute to about 3 minutes. For the manufacture of conventional thermal or acoustical insulation products, the time ranges from about ¾ minute to about 2 minutes. The fibrous glass having a cured, rigid binder matrix emerges from the oven in the form of a bat or roll which may be compressed for packaging and shipping and which will thereafter substantially recover its thickness when unconstrained.
The formaldehyde-free curable aqueous composition may also be applied to an already formed nonwoven by conventional techniques such as, for example, air or airless spraying, padding, saturating, roll coating, curtain coating, beater deposition, coagulation, or the like.
The waterborne formaldehyde-free silane-containing composition, after it is applied to a nonwoven, is heated to effect drying and curing. The duration and temperature of heating will affect the rate of drying, ramp moisture, processability and handleability, and property development of the treated substrate. Heat treatment at about 120° C., to about 400° C., for a period of time between about 3 seconds to about 15 minutes may be carried out; treatment at about 150° C., to about 250° C., is preferred. The drying and curing functions may be effected in two or more distinct steps, if desired. For example, the composition may be first heated at a temperature and for a time sufficient to substantially dry but not to substantially cure the composition and then heated for a second time at a higher temperature and/or for a longer period of time to effect curing. Such a procedure, referred to as “B-staging,” may be used to provide binder-treated nonwoven, for example, in roll form, which may at a later stage be cured, with or without forming or molding into a particular configuration, concurrent with the curing process.
The heat-resistant nonwovens may be used for applications such as, for example, insulation batts or rolls, as reinforcing mat for roofing or flooring applications, as roving, as microglass-based substrate for printed circuit boards or battery separators, as filter stock, as tape stock, as tape board for office partitions, in duct liners or duct board, and as reinforcement scrim in cementitious and non-cementitious coatings for masonry. Due to the good hydrolytic stability of the binders and good humid aging performance, products prepared using the methods disclosed herein can be used under varying environmental conditions.
Measurement of rigidity generally involves preparing a specimen of fiberglass product for testing, placing the specimen in contact with water and determining the water resistance of the specimen. The water resistance can be determined by either qualitative or quantitative techniques. Measurement of rigidity can be used to evaluate the water resistance of fiberglass products where its ability to resist water affects the products performance. Methods for evaluating the water resistance of binder-coated fiberglass products are disclosed in co-pending U.S. application Ser. No. 10/887,023, filed by Ward Hobert et al., on Jul. 9, 2004, and incorporated by reference herein in its entirety.
We conclude that resin usage can be reduced in a manufacturing process that increases silane and/or ramp moisture. These increases in ramp moisture and/or silane flow will enable reduced costs in a fiberglass manufacturing system. It is important to note that the effect of silane is improved product durability. It is possible to reduce resin usage significantly while maintaining equal or improved product performance. By maximizing ramp moisture, operating between 5 and 20 percent, we can reduce resin usage while improving product performance. By maximizing the use of silane, operating between 0.019% and 0.350% solid per weight of glass (between 0.20% and 3.64% per weight resin solids), and most preferably, between 0.70% and 0.26% solid per weight of glass (between 0.8% and 2.7% per weight resin solids), we can reduce the amount of acrylic resin used in glass fiber manufacturing while maintaining or improving product performance.
EXAMPLES
The following is offered as an example of the invention and should not be construed as limiting the invention.
Through the use of a designed experiment and subsequent product aging and testing, an opportunity was observed that will reduce resin system cost in plants operating on the acrylic resin systems. Based upon the product rigidity measurements for both quick (in-plant) and following 7 days of aging at 90° F. and 90% humidity, increases in ramp moisture and/or silane usage provided an opportunity to reduce resin usage and therefore product cost. Product recovery met or exceeded label thickness throughout the trial for both the quick and aged products and was not found to be significant to any of the process variables manipulated.
Trials were performed at one or more manufacturing plant with a design to improve the cost and performance of insulation products manufactured with formaldehyde-free binders. The trials disclosed herein focused on three (3) factors identified as having the significance to product performance. Manipulation of ramp moisture, resin flow and silane flow were investigated using a central-composite designed experiment. During the execution of the trial the product performance varied significantly with the process adjustments. FIG. 1 represents an analysis of variance (“ANOVA”) of the quick rigidity measurements by run.
As observed in the ANOVA results, there were significant differences between product runs. Also, runs 2 and 15 were center points for the experiment and are statistically identical suggesting no drifting occurred during the 8 hour trial. Analysis of the experiment suggested that three factors (ramp moisture, silane flow, and resin flow) were significant to product performance. A reduced model of quick rigidity is presented in FIG. 2 . The analysis suggests that all three factors are significant to quick rigidity. FIG. 3 represents a contour plot of quick rigidity for each of the three combinations of factors.
Interpretation of FIG. 3 leads to a conclusion that increased ramp moisture and/or silane flow will allow for reductions in resin flow while maintaining acceptable product performance. The results of the trials suggest that there is opportunity to reduce resin usage provided that silane levels are increased while maintaining or increasing ramp moisture. The reduced model depicted in FIG. 3 , and shown in FIG. 2 , predicted product rigidity with and RSQ of 90.8%.
Similar to the quick product performance analysis, an ANOVA was performed for rigidity following 7 days of sag room aging. FIG. 4 represents the output for the ANOVA performed on product aged 7 days at 90° F. and 90% humidity. As was observed in the quick product performance, the product aged 7 days also showed significant differences based on the process settings. Also, similar to the quick performance, runs 2 and 15 were statistically the same suggesting a minimum amount of process drift occurred during the 8-hour trial. Recovery for the products at both quick and 7 days of sag room aging met or exceeded label thickness and were not found to be significant to any of the factors manipulated in the experiment.
Following the ANOVA analysis shown in FIG. 4 , analysis of the experiment was performed. FIG. 5 represents a contour plot for the reduced model. As with quick rigidity, all factors were significant to product performance following 7 days at 90° F. and 90% humidity.
Through interpretation of FIG. 5 , we conclude that resin usage can be reduced in a manufacturing process that increases silane flow and/or ramp moisture. These increases in ramp moisture and/or silane flow will enable a reduced manufacturing system cost. It is important to note that the effect of silane is improved product durability when reduced amounts of acrylic-based binder are used.
Through the analysis of the responses displayed above, we conclude that it is possible to reduce resin usage significantly while maintaining equal or improved product performance. By maximizing ramp moisture, operating between 5 and 20 percent we can reduce resin usage while improving product performance. By maximizing the use of silane, operating between 0.019% and 0.350% solid per weight of glass (between 0.20% and 3.64% per weight resin solids), and most preferably, between 0.70% and 0.26% solid per weight of glass (between 0.8% and 2.7% per weight resin solids), we can reduce the amount of acrylic resin used in glass fiber manufacturing by up to 30% while maintaining or improving product performance.
While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions, and subcombinations thereof. It is therefore intended that claims hereafter introduced are interpreted to include all such modifications, permutations, additions, and sub-combinations as are within their spirit and scope. | A method for reducing the amount of binder or resin used in glass fiber manufacturing while maintaining product performance is disclosed. The method generally reduces the amount of binder or resin used in a manufacturing process by adjusting other factors in the manufacturing process. Specifically, ramp moisture and/or silane content are factors that are adjusted to achieve the results of the disclosed method. Additionally, glass fiber compositions resulting from the method are disclosed. | 3 |
[0001] The present invention is directed to electrospun fibers, and more particularly to electrospun fibers and a method of making the same which electrospun fibers include one or more functional actives
BACKGROUND OF THE INVENTION
[0002] The practice of electrospinning fibers from a polymer is still a relatively new practice. The electrospinning process has been used to form various types of polymers into fibers having a diameter of several nanometers. These small-diameter fibers have been found to have a large specific surface area relative to fibers, thus enabling the production of fibers having a high porosity.
[0003] Several processes for forming electrospun fibers, which can be used in the present invention, are disclosed in two articles entitled “Electrospinning Process and Applications of Electrospun Fibers” by Doshi and Reneker (J. Electrostatics, 35, 151 (1995)); and “Beaded nanofibers formed during electrospinning” by H. Fong (Polymer, 40, 4585 (1999)); PCT Application Serial Nos. WO 2004/074559; WO 2005/004768; WO 2005/005696; WO 2005/005704; WO 2007/002478; U.S. Pat. Nos. 6,106,913; 6,955,775; 6,991,702; 7,229,944; and U.S. Patent Publication Nos. 20020100725; 2002/0173213; 2003/0215624; 2005/0224998; all of which are incorporated by reference in their entirety.
[0004] The general process for forming a nanofiber includes pumping, extruding, etc. a polymer solution through one or more small openings and subjecting the polymer solution to an electric field to form nanofibers fibers that are collected on the surface of a collector. The process results in the conversion of a polymer solution into solid polymer fibers. The process can be used to control the fiber diameter (i.e., from several nanometers to several thousand nanometers), and to control the size of the pores in the fibers to produce a porous polymer fiber.
[0005] Due to the unique properties of electrospun fibers, it is believed that such electrospun fibers could be used for various types of cleaning applications. As such, it would be advantageous to use the porous polymer fiber to form a cleaning implement. It would also be advantageous to include one or more functional actives in the porous polymer fibers so as to enhance the cleaning, sanitizing and/or disinfecting properties of the porous polymer fibers. In view of the current state of the art regarding polymer electrospun fibers, there is a need for polymer electrospun fibers that include one or more functional actives, and which polymer electrospun fibers can be used in various types of cleaning scours and cleaning implements.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to polymer electrospun fibers that include one or more functional actives. These electrospun fibers can be used in a variety of applications, all of which are included in the present invention. In one non-limiting application, the polymer electrospun fibers can be included in a variety of cleaning implements. Such cleaning implements can include, but are not limited to, sponges, brushes, foam pads, scouring pads, cleansing pads, dusters, wipes, mop heads, mop head wipes, rags, towels (e.g., paper, fabric, etc.), napkins (e.g., paper, fabric, etc.), tissues, toilet paper, etc. The polymer electrospun fibers can form the complete cleaning implement, or only form a part of the cleaning implement. When the polymer electrospun fibers only forms part of the cleaning implement, the polymer electrospun fibers can be bonded (e.g., adhesive, heat melted, lamination, etc.) to one or more other materials of the cleaning implement, interwoven with one or more other materials of the cleaning implement, needle punched to one or more other materials of the cleaning implement, mechanically connected to one or more other materials of the cleaning implement, or some combinations of such processes. As can be appreciated, other or additional arrangements can be used to incorporate the polymer electrospun fibers with one or more of the other materials of the cleaning implement. Although the polymer electrospun fibers are well suited for use in various types of cleaning implements and will be described with particular reference thereto, it will be appreciated that the polymer electrospun fibers can be used in other applications (e.g., gloves, clothing, masks, filters, carpet, upholstery, tablecloths, place mats, food and/or container mats, sheets, pillow cases, quilts, blankets, wash and bath towels, etc.).
[0007] In one non-limiting aspect of the present invention, the polymer electrospun fibers are formed from one or more polymers. In one non-limiting embodiment of the present invention, at least one of the polymers used in the polymer electrospun fibers is an at least partially water-soluble polymer, an at least partially alcohol-soluble polymer, an at least partially glycerol-soluble polymer, and/or at least glycol-soluble polymer. In one non-limiting aspect of this embodiment, all of the polymers used in the polymer electrospun fibers are at least partially water-soluble and/or alcohol soluble polymers. In another and/or alternative non-limiting aspect of this embodiment, all of the polymers used in the polymer electrospun fibers are at least partially water-soluble polymers. In yet another and/or alternative non-limiting aspect of this embodiment, all of the polymers used in the polymer electrospun fibers are water-soluble polymers. In still another and/or alternative non-limiting aspect of this embodiment, the polymer electrospun fibers are formed from a single polymer. In yet another and/or alternative non-limiting aspect of this embodiment, the polymer electrospun fibers are formed from two or more different polymers. In still yet another and/or alternative non-limiting aspect of this embodiment, all of the polymers used in the polymer electrospun fibers are alcohol-soluble polymers. The one or more polymers used in the polymer electrospun fibers can be a natural polymer and/or synthetic polymer. In another and/or alternative one non-limiting embodiment of the present invention, at least one of the polymers used in the polymer electrospun fibers is a synthetic polymer. In yet another and/or alternative one non-limiting embodiment of the present invention, at least one of the polymers used in the polymer electrospun fibers includes a poly vinyl polymer. In one non-limiting aspect of this embodiment, the poly vinyl polymer includes polymers of vinyl derivatives of pyrrolidone. Non-limiting examples of such vinyl derivatives of pyrrolidone include polyvinylpyrrolidone and poly(1-vinyl-2-pyrrolidone). As can be appreciated, other or additional polymers can be used in the present invention.
[0008] In another and/or alternative non-limiting aspect of the present invention, the one or more polymers used to form the polymer electrospun fibers are mixed with one or more functional actives prior to forming the polymer electrospun fibers so as to form electrospun fibers that facilitate in cleaning, sanitizing, disinfecting, and/or sterilizing a surface. As used herein, “functional active” refers to a substance, other than a surfactant, which reacts or interacts with a surface to clean, sanitize, disinfect, sterilize, bleach, remove stains, etc. such surface. As used herein, the term “disinfect” shall mean the elimination of many or all pathogenic microorganisms on surfaces with the exception of bacterial endospores. As used herein, the term “sanitize” shall mean the reduction of contaminants in the inanimate environment to levels considered safe according to public health ordinance, or that reduces the bacterial population by significant numbers where public health requirements have not been established. At least a 99% reduction in bacterial population within a 24 hour time period is deemed “significant.” As used herein, the term “sterilize” shall mean the substantially complete elimination or destruction of all forms of microbial life and which is authorized under the applicable regulatory laws to make legal claims as a “Sterilant” or to have sterilizing properties or qualities. Many different functional actives can be added to the one or more polymers. In one non-limiting embodiment of the invention, the polymer electrospun fibers of the present invention are formed from a single functional active. In another and/or alternative non-limiting embodiment of the invention, the polymer electrospun fibers of the present invention are formed from two or more different functional actives. In still another and/or alternative non-limiting embodiment of the invention, one or more of the functional actives that can be mixed with the one or more polymers include, but are not limited to, bleaching agents (e.g., peracids, perborates, percarbonates, chlorine-generating substances [e.g., chloroisocyanurates hypohalite sources], sodium hypochlorite, calcium hypochlorite, hydrogen peroxide, and/or sources of peroxides) and/or commercially formulated liquid cleaners that include one or more bleaching agents. As can be appreciated, other or additional functional actives can be used. In another and/or alternative non-limiting embodiment of the invention, many different types of commercial cleaners that include one or more bleaching agents can be used as the source of one or more functional actives. Non-limiting examples of commercial cleaners that can be used include, but are not limited to, several commercial products by The Clorox Company, namely Clorox® High Efficiency Bleach Cleaner, Clorox® Outdoor Bleach Cleaner, Clorox® Regular Bleach, Clorox® Scented Liquid Bleach, Clorox® Splash-Less Liquid Gel Bleach, and Clorox® Ultimate Care™ Premium Bleach. As can be appreciated, other or additional commercial products can be used. As can also be appreciated, two or more commercial cleaners can be mixed with one or more polymers to form the polymer electrospun fibers of the present invention. As can further be appreciated, one or more commercial cleaners can be combined with one or more functional actives from a non-commercial cleaner source and be mixed with one or more polymers to form the polymer electrospun fibers of the present invention. Also, it will be appreciated that the one or more functional actives which can be mixed with one or more polymers to form the polymer electrospun fibers of the present invention can be from a non-commercial cleaner source. In a further and/or alternative non-limiting embodiment of the invention, the polymer electrospun fibers can be formed from a mixture of one or more water-soluble bleaching agent compatible polymers and one or more bleaching actives (e.g, peracids, perborates, percarbonates, chlorine-generating substances [e.g., chloroisocyanurates hypohalite sources], sodium hypochlorite, calcium hypochlorite, hydrogen peroxide, and/or sources of peroxides, etc.).
[0009] In still another and/or alternative non-limiting aspect of the present invention, the one or more polymers and the one or more functional actives can be at least partially reacted or bonded together prior to forming the polymer electrospun fibers. In one non-limiting example, a vinyl derivative of pyrrolidone could be reacted with a peroxide or peroxide containing compound to form a peroxide derivative of the vinyl derivative of pyrrolidone. As can be appreciated, many other or additional derivatives can be formed for use in forming the polymer electrospun fibers. One non-limiting commercial available polymer that can be used in the present invention is Peroxydone® that is available from ISP. In this particular example, a single compound is used to form the mixture of polymer and functional active that is used in forming the polymer electrospun fibers. As such, as defined in the present invention, a single compound that includes a polymer and a functional active that is bonded to the polymer is considered a mixture of at least one polymer and at least one functional active when the single compound is at least partially dissolved in a solvent. As can be appreciated, additional polymers and/or functional actives could be mixed with a single compound that includes a polymer and functional active, wherein such mixture can be used in forming the polymer electrospun fibers; however, this is not required.
[0010] In yet another and/or alternative non-limiting aspect of the present invention, the one or more polymers and the one or more functional actives should be able to form a generally stable and homogeneous mixture. It has been found that when a generally stable and homogeneous mixture is not formed prior to the mixture being subjected to an electric field, few, if any, fibers are formed. As defined herein, a generally stable and homogeneous mixture is a polymer and functional active mixture that maintains its homogenous form for at least about 1 minute after being mixed for at least about 10 minutes. In one non-limiting embodiment of the invention, one or more polymers and one or more functional actives are selected such that a generally homogenous mixture is formed for at least about 5 minutes after being mixed for at least about 10 minutes. In another and/or alternative non-limiting embodiment of the invention, one or more polymers and one or more functional actives are selected such that a generally homogenous mixture is formed for at least about 15 minutes after being mixed for at least about 10 minutes. In still another and/or alternative non-limiting embodiment of the invention, one or more polymers and one or more functional actives are selected such that a generally homogenous mixture is formed for at least about 30 minutes after being mixed for at least about 10 minutes. In yet another and/or alternative non-limiting embodiment of the invention, one or more polymers and one or more functional actives are selected such that a generally homogenous mixture is formed for at least about 60 minutes after being mixed for at least about 10 minutes.
[0011] In still another and/or alternative non-limiting aspect of the present invention, at least one of the polymers used to form polymer electrospun fibers degrades or dissolves at a slower rate than at least one of the functional actives used to form the polymer electrospun fibers; however, this is not required. It is believed that an extended time of release of the one or more functional actives can be achieved during the use of the polymer electrospun fibers when at least one of the polymers used to form polymer electrospun fibers degrades or dissolves at a slower rate than at least one of the functional actives. As such, the usable life of the polymer electrospun fibers can be extended by this selection of polymer and functional active. In one non-limiting embodiment of the invention, all of the polymers in the polymer electrospun fibers degrade or dissolve at a slower rate than at least one of the functional actives in the polymer electrospun fibers. In another and/or alternative non-limiting embodiment of the invention, all of the polymers in the polymer electrospun fibers degrade or dissolve at a slower rate than all of the functional actives in the polymer electrospun fibers. In still another and/or alternative non-limiting embodiment of the invention, the time ratio that at least one of the polymers in the polymer electrospun fibers degrades or dissolves relative to at least one of the functional actives in the polymer electrospun fibers is at least about 1.05:1. As such, in this particular embodiment, if the functional active dissolved in 10 minutes, the polymer would dissolve in a time no earlier than 10.5 minutes. In yet another and/or alternative non-limiting embodiment of the invention, the time ratio that at least one of the polymers in the polymer electrospun fibers degrades or dissolves relative to at least one of the functional actives in the polymer electrospun fibers is at least about 1.25:1. In yet another and/or alternative non-limiting embodiment of the invention, the time ratio that at least one of the polymers in the polymer electrospun fibers degrades or dissolves relative to at least one of the functional actives in the polymer electrospun fibers is at least about 1.5:1. In still yet another and/or alternative non-limiting embodiment of the invention, the time ratio that at least one of the polymers in the polymer electrospun fibers degrades or dissolves relative to at least one of the functional actives in the polymer electrospun fibers is at least about 2:1. In another and/or alternative non-limiting embodiment of the invention, the time ratio that at least one of the polymers in the polymer electrospun fibers degrades or dissolves relative to at least one of the functional actives in the polymer electrospun fibers is about 2-10:1. As can be appreciated, other time ratios for dissolving rate of the functional active relative to the polymer can be used. In still another and/or alternative non-limiting embodiment of the invention, at least one of the polymers in the polymer electrospun fibers and at least one of the functional actives in the polymer electrospun fibers are designed to dissolve when exposed to water and/or alcohol. In one aspect of this embodiment, all of the polymers in the polymer electrospun fibers and all of the functional actives in the polymer electrospun fibers are designed to dissolve when exposed to water and/or alcohol.
[0012] In another and/or alternative non-limiting aspect of the present invention, when the polymer electrospun fibers are formed from one or more polymers that include a functional active bonded to the polymer, the functional active on the polymer is generally designed to disassociate from the polymer at a rate that is faster than the dissolving of the polymer when the electrospun fibers are exposed to water and/or an alcohol; however, this is not required. By selecting a polymer that dissolves at a slower rate than the rate at which the functional active disassociates from the polymer, the integrity of the electrospun fibers can be maintained while the functional active is controllably and/or uncontrollably released from the electrospun fibers. In one non-limiting embodiment of the invention, the time ratio that at least one of the polymers in the polymer electrospun fibers begins to dissolve relative to the time at least one of the functional actives disassociates from the polymer in the polymer electrospun fibers is at least about 2:1. As such, in this particular embodiment, if the functional active begins disassociating from the polymer in 5 seconds, the polymer would begin to dissolve in a time no earlier than 10 seconds. In another and/or alternative non-limiting embodiment of the invention, the time ratio that at least one of the polymers in the polymer electrospun fibers begins to dissolve relative to the time at least one of the functional actives disassociates from the polymer in the polymer electrospun fibers is at least about 5:1. In still another and/or alternative non-limiting embodiment of the invention, the time ratio that at least one of the polymers in the polymer electrospun fibers begins to dissolve relative to the time at least one of the functional actives disassociates from the polymer in the polymer electrospun fibers is at least about 20:1. In yet another and/or alternative non-limiting embodiment of the invention, the time ratio that at least one of the polymers in the polymer electrospun fibers begins to dissolve relative to the time at least one of the functional actives disassociates from the polymer in the polymer electrospun fibers is at least about 100:1. As can be appreciated, other time ratios for at least one of the polymers in the polymer electrospun fibers to begin dissolving relative to the time at least one of the functional actives disassociates from the polymer in the polymer electrospun fibers can be used.
[0013] In another and/or alternative non-limiting aspect of the present invention, the viscosity of the mixture of the at least one polymer and the at least one functional active prior to the mixture being subjected to an electric field is at least about 500 cps at 25° C. It has been found that viscosities that are lower than about 500 cps at 25° C. will not properly form polymer electrospun fibers, or not form any polymer electrospun fibers. The viscosity of the mixture of the at least one polymer and the at least one functional active prior to the mixture being subjected to an electric field is also less than about 100000 cps at 25° C. It has been found that viscosities that are greater than about 100000 cps at 25° C. also will not properly form polymer electrospun fibers, or not form any polymer electrospun fibers. In one non-limiting embodiment of the invention, the viscosity of the mixture of the at least one polymer and the at least one functional active prior to the mixture being subjected to an electric field is at least about 750 cps at 25° C. In another and/or alternative non-limiting embodiment of the invention, the viscosity of the mixture of the at least one polymer and the at least one functional active prior to the mixture being subjected to an electric field is at least about 1000 cps at 25° C. In still another and/or alternative non-limiting embodiment of the invention, the viscosity of the mixture of the at least one polymer and the at least one functional active prior to the mixture being subjected to an electric field is no greater than about 25000 cps at 25° C. In still another and/or alternative non-limiting embodiment of the invention, the viscosity of the mixture of the at least one polymer and the at least one functional active prior to the mixture being subjected to an electric field is no greater than about 10000 cps at 25° C. In yet another and/or alternative non-limiting embodiment of the invention, the viscosity of the mixture of the at least one polymer and the at least one functional active prior to the mixture being subjected to an electric field is about 1500-8000 cps at 25° C. In still yet another and/or alternative non-limiting embodiment of the invention, the viscosity of the mixture of the at least one polymer and the at least one functional active prior to the mixture being subjected to an electric field is about 2000-7000 cps at 25° C. As can be appreciated, other viscosities for the mixture can be used.
[0014] In still another and/or alternative non-limiting aspect of the present invention, the process parameters regarding flow rate of the polymer-functional additive mixture, strength of electric field and distance mixture travels through electric field are controlled to obtain the polymer electrospun fibers. It has been found that by controlling these parameters, a desired thin fiber-structured polymer material can be formed in accordance with the present invention. In one non-limiting embodiment of the invention, the flow rate of the mixture the polymer-functional additive mixture through each nozzle is at least about 0.1 microliter per minute and less than about 100 microliters per minute. It has been found that faster or slower flow rates for the mixture through each nozzle will produce little, if any, polymer electrospun fibers. In one non-limiting aspect of this embodiment, the flow rate of the mixture the polymer-functional additive mixture through each nozzle is at least about 5 microliters per minute. In another and/or alternative non-limiting aspect of this embodiment, the flow rate of the mixture the polymer-functional additive mixture through each nozzle is at least about 7 microliters per minute. In still another and/or alternative non-limiting aspect of this embodiment, the flow rate of the mixture the polymer-functional additive mixture through each nozzle is at least about 10 microliters per minute. In yet another and/or alternative non-limiting aspect of this embodiment, the flow rate of the mixture the polymer-functional additive mixture through each nozzle is no greater that about 60 microliters per minute. In still yet another and/or alternative non-limiting aspect of this embodiment, the flow rate of the mixture the polymer-functional additive mixture through each nozzle is no greater that about 40 microliters per minute. In another and/or alternative non-limiting aspect of this embodiment, the flow rate of the mixture the polymer-functional additive mixture through each nozzle is no greater that about 30 microliters per minute. As can be appreciated, other or additional flow rates for the mixture can be used. In another and/or alternative non-limiting embodiment of the invention, the strength of the electric field through which the mixture travels as the mixture is transformed into polymer electrospun fibers is at least about 0.5 kV and less than about 200 kV. It has been found that an electric field that is less than 0.5 kV will not form polymer electrospun fibers. Likewise, it has been found that an electric field that is 200 kV or more also will not form polymer electrospun fibers. In one non-limiting aspect of this embodiment, the electric field through which the mixture travels as the mixture is transformed into polymer electrospun fibers is at least about 1 kV. In another and/or alternative non-limiting aspect of this embodiment, the electric field through which the mixture travels as the mixture is transformed into polymer electrospun fibers is at least about 2 kV. In still another and/or alternative non-limiting aspect of this embodiment, the electric field through which the mixture travels as the mixture is transformed into polymer electrospun fibers is up to about 100 kV. In yet another and/or alternative non-limiting aspect of this embodiment, the electric field through which the mixture travels as the mixture is transformed into polymer electrospun fibers is about 2-20 kV. In still yet another and/or alternative non-limiting aspect of this embodiment, the electric field through which the mixture travels as the mixture is transformed into polymer electrospun fibers is about 2-12 kV. In another and/or alternative non-limiting aspect of this embodiment, the electric field through which the mixture travels as the mixture is transformed into polymer electrospun fibers is about 2-10 kV. As can be appreciated, other or additional values for the electric field can be used. In still another and/or alternative non-limiting embodiment of the invention, the distance that the mixture of polymer and functional active travels through the electric field during the transformation from a liquid mixture to polymer electrospun fibers is at least about 1 cm and typically less than about 100 cm. It has been found that distances of travel of less than 1 cm are insufficient to form polymer electrospun fibers. Distances of travel of greater than 100 cm are not required since the polymer electrospun fibers have been fully created long before traveling of such distances. In one non-limiting aspect of this embodiment, the distance that the mixture of polymer and functional active travels through the electric field during the transformation from a liquid mixture to polymer electrospun fibers is at least about 2 cm. In another non-limiting aspect of this embodiment, the distance that the mixture of polymer and functional active travels through the electric field during the transformation from a liquid mixture to polymer electrospun fibers is up to about 40 cm. In still another non-limiting aspect of this embodiment, the distance that the mixture of polymer and functional active travels through the electric field during the transformation from a liquid mixture to polymer electrospun fibers is up to about 20 cm. In yet another non-limiting aspect of this embodiment, the distance that the mixture of polymer and functional active travels through the electric field during the transformation from a liquid mixture to polymer electrospun fibers is about 2-10 cm. As can be appreciated, other or additional distances of travel can be used.
[0015] In yet another and/or alternative non-limiting aspect of the present invention, the polymer electrospun fibers are nanofibers. As defined herein, a nanofiber is a fiber that has an average diameter of no more than 1000 nanometers. In one non-limiting embodiment of the invention, the polymer electrospun fibers have an average diameter of no more than about 500 nanometers. In another and/or alternative non-limiting embodiment of the invention, the polymer electrospun fibers have an average diameter of no more than about 200 nanometers. In still another and/or alternative non-limiting embodiment of the invention, the polymer electrospun fibers have an average diameter of no more than about 100 nanometers. In yet another and/or alternative non-limiting embodiment of the invention, the polymer electrospun fibers have an average diameter of at least about 0.1 nanometers. In still yet another and/or alternative non-limiting embodiment of the invention, the polymer electrospun fibers have an average diameter of at least about 0.5 nanometers. In another and/or alternative non-limiting embodiment of the invention, the polymer electrospun fibers have an average diameter of at least about 1 nanometers.
[0016] In still yet another and/or alternative non-limiting aspect of the present invention, the polymer electrospun fibers can include one or more additives; however, this is not required. Such one or more additives, when used, can include, but are not limited to, abrasive materials, anti-corrosion materials, anti-redeposition materials, anti-static agents, anti-sticking agents, buffering and pH adjusting agents, chelating agents, colorants and/or dyes, defoamers, elastomers, enzymes, filler materials, foamers, fragrances or perfumes, heat generating materials, hydrotropes, sequestration agents, softening agents, soil release agents, solubilizing materials, stabilizers, surfactants, sudsing control agents, thickeners, wetting agents, and/or UV protectors. As can be appreciated, other or additional additives can be used.
[0017] It is one non-limiting object of the present invention to form polymer electrospun fibers from a mixture that includes at least one polymer and at least one bleaching active.
[0018] It is another and/or alternative object of the present invention to form polymer electrospun fibers from a modified polymer that includes at least one bleaching agent.
[0019] It is still another and/or alternative object of the present invention to form polymer electrospun fibers from at least one water-soluble and/or alcohol soluble polymer that includes at least one bleaching agent.
[0020] It is still yet another and/or alternative object of the present invention to form polymer electrospun fibers having a high surface area to weight ratio.
[0021] These and other objects and advantages will become apparent to those skilled in the art upon reading and following the description of the invention taken together with the accompanied drawings.
BRIEF DESCRIPTION OF THE DRAWING
[0022] Reference may now be made to the drawings, which illustrates various attributes of the invention wherein;
[0023] a. FIG. 1 is a schematic illustration of a conventional electrospinning arrangement.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] Referring now to the drawings wherein the showings are for the purpose of illustrating preferred embodiments of the invention only and not for the purpose of limiting same, FIG. 1 illustrates a schematic illustration of a conventional electrospray/electrospinning apparatus 10 for producing fibers and/or fibrous materials. As used herein, the term fibrous materials denotes material both electrosprayed as short fibers and material electrospun into longer continuous fibers. In accordance with one non-limiting embodiment of the present invention, a spray head 20 includes an electrode 30 that is connected to the spray head. The spray head 20 includes at least one spray nozzle 22 . Generally, nozzle 22 is a spinning nozzle. The spray head is connected to a pipe or tube 40 in communication with a supply of electrospray medium A. The electrospray medium is an extrudable mixture that includes at least one polymer and at least one functional active.
[0025] An electric potential across to the electrodes 30 and 50 that is generated by a high voltage source 60 creates an electric field E which extends through and beyond nozzle 22 of the spray head 20 to the exterior electrode 50 . The geometrical arrangement of the electrode 30 and the exterior electrode 50 configures the electric field strength and distribution. The electrospray medium, upon extrusion from the spray head, is guided along a direction of the electric field E toward the exterior electrode 50 . Electrode 50 is generally connected to a plate or moving conveyor that is used to collect the formed electrospun fibers.
[0026] The flowrate at which the electrospray medium flows through the nozzle of the spray head can be at least partially controlled by the size of the nozzle and the pressure generated exerted on the electrospray medium by pump P. One non-limiting pump that can be used is a NE-1000 programmable syringe pump. As can be appreciated, many arrangements for forming the electrospun fibers can be used. The electrospray medium is formulated to form fibers that have a large surface area to weight ratio. The fibers of the present invention generally have an average diameter of less than about 1000 nanometers. These types of fibers can be useful in various types of cleaning applications. For example, the cleaning efficacy of various types of cleaning implements (e.g., wipes, sponges, towels, mops, brushes, etc.) can be improved by incorporating the fibers of the present invention into such cleaning implements, without having to increase the volume of functional actives in the cleaning implement. The large surface area of the fibers of the present invention can be used to inhibit excess amount of cleaning agents from becoming diluted and/or flushed from the cleaning implement by water, at the point that the cleaning implement contacts a surface to be cleaned. The fibers of the present invention can be incorporated into non-woven cleaning implements (e.g, sponges, foam pads, wipes, etc.), laminated and/or adhesively connected to various types of cleaning implements, etc. The fibers of the present invention can be used to deliver low-levels of a functional active in a controlled or uncontrolled release profile. The fibers of the present invention can be used to stabilize and/or strengthen a functional active that is incorporated in the fiber. As such, the fibers can be used to deliver functional active to a desired surface which was in the past a normally difficult functional active to deliver at a point of use.
[0027] A non-limiting example for forming fibers of the present invention will now be set forth. The fibers in this non-limiting example were formed from a mixture of a water soluble polymer that has been modified to include a bleaching agent.
[0028] A solution of polyvinylpyrrolidone is reacted with a peroxide compound to incorporate peroxide compound as a functional group on the polyvinylpyrrolidone. The peroxide bonded complex of polyvinylpyrrolidone is a water-soluble polymer. The peroxide bonded complex of polyvinylpyrrolidone is dissolved in water to form the electrospray medium. The viscosity of the solution as maintained between 2000-7000 cps at 25° C. The electrospray medium is a stable and homogenous phase so that the mixture could be electrospun.
[0029] The polyvinylpyrrolidone polymer used in the electrospray medium dissolves more slowly than the time period it takes the peroxide group to disassociate from the polyvinylpyrrolidone.
[0030] The solution was slowly pumped through a spinning nozzle at a volume of about 5-30 microliters/minute. The solution exiting the spinning nozzle was exposed to an electric field of about 10-20 kV. The solution traveled a distance of about 5-20 cm from the spinning nozzle to a collector which collected the formed fibers. The average diameter of the formed fibers was about 100-500 nanometers. The formed fibers produced a porous web of a high porosity.
[0031] It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained, and since certain changes may be made in the constructions set forth without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. The invention has been described with reference to preferred and alternate embodiments. Modifications and alterations will become apparent to those skilled in the art upon reading and understanding the detailed discussion of the invention provided herein. This invention is intended to include all such modifications and alterations insofar as they come within the scope of the present invention. It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention, which, as a matter of language, might be said to fall therebetween. | The invention comprises a method of forming functionally active fibers and substrates comprising functionally active fibers. The method includes forming a mixture of at least one poly vinyl polymer and at least one bleaching active. The mixture is then injected at a controlled flow rate into an electric field to cause the mixture to at least partially form fine fibers that have an average diameter of less than about 1000 nanometers. | 3 |
TECHNICAL FIELD
This invention is generally related to the field of devices to prevent contamination of an incision area during a surgical procedure. The invention more specifically, however, relates to a disposable surgical drape with a pull-tab, having a portion overlying an adhesive surrounding a window in the drape, of a length to enable remote removal of the portion overlying the adhesive surface proximate the window, so that the drape can be secured to the patient's body without contamination.
BACKGROUND OF THE INVENTION
Surgical drapes made of cloth have been in use for a number of years. These cloth surgical drapes are reusable, however they require laundering and careful sterilization after previously being used.
The heavy weight of cloth drapes can cause the drape to slide, if imbalanced, away from the incision area. The size and weight of cloth surgical drapes can make them difficult to position and to secure in position once it is attained. This tendency of a cloth drape to slip from its position and the requirement for means for fastening the drape to the patient's body are distinct disadvantages of such a drape. Additionally, significant expense can be involved in sterilization.
Disposable surgical drapes have also been employed and are known in the prior art. Because they are disposable, the need for sterilization after use is obviated. The need remains, of course, for the maintaining of their sterility prior to their use.
Disposable surgical drapes have been difficult to maintain in place due to a lack of weight. As a result, the drape might be permitted to slip away from the incision area. The area is, thereby, exposed to contamination. Use of heavier disposable drapes would help minimize this problem, however they would decrease the economic advantages associated with disposability.
The introduction of adhesive backing to disposable drapes has helped to eliminate the slippage problem. Prior art devices employ peel-off paper backing for exposing the adhesive on the under-side of the surgical drape to the patient's body.
A problem with the prior adhesive backed disposable surgical drapes has been the potential for contamination which results from the need for human intervention to peel off the paper backing. Contamination of the surgical site can occur during the taking of this action.
Positioning of adhesive on the surgical drape is important. Where the disposable surgical drape has the adhesive, peel-off backing in the center of the drape, optimal use cannot be made of the drape. Application of the adhesive substance to the periphery of a window formed in the surgical drape allows for the secure positioning of the drape with the window at the incision area.
In the prior art, drainage troughs were employed for removal of bodily fluids from the incision area. Such removal was effected by osmosis and interior tubing in combination with a suction device.
Prior surgical drapery has, primarily, been flat sheets of either cloth or paper. When the incision area has been on a patient's limb, the drape material was arranged as well as it could be around the generally cylindrical body limb.
Another problem in the prior art is providing the ability to convey bodily fluids secreted at the incision area away from that area as quickly and as sanitarily as possible. Absent adequate provision for conveying means, such fluids tend to saturate the area and provide a growth medium for bacteriologicial growth.
The present invention addresses these problems associated with the prior art and provides for a new and improved tubular-shaped, disposable surgical drape with a pull-tab covered adhesive for securing the drape to the patient's body. Additionally, it provides a conduit for removal of bodily fluids from the incision area.
SUMMARY OF THE INVENTION
The present invention is a surgical drape for deterring contamination of the incision area during a surgical procedure. It includes a protective film for covering the patient's body or anatomical portion during the surgical procedure, means for adhering the film to the patient's body, and means for remotely exposing the adhering means to permit securing the protective film to the patient at a desired location without contamination of the sterilized incision area.
The protective film can be formed into a tubular shape for ease in draping a patient's limb. Additionally, the tubular-shaped drape can be flared at one end for ease in fitting it to the patient's torso adjacent the limb to be operated upon.
A window is formed in the protective film for exposing a body part to be operated upon; for example, when a knee is to receive orthoscopic surgery. Adhesive is carried by a side of the drape, encircling the window to allow for the securing of the drape to the body part. A pull-tab can be peeled off the adhesive to expose the adhesive. This permits for the facile positioning of the drape prior to it being secured to the patient's body.
The pull-tab can comprise an adhesive protective portion which is withdrawn from around the window from a position remote from the incision area to allow for the exposure of the adhering means. After the pull-tab is withdrawn, the adhering means encircling the window can be engaged with the patient's skin at the incision area and pressed down to maintain the drape at the desired location.
In a preferred embodiment, the tubular drape can be constructed so that a bodily fluid disposal channel is integrally formed therein. Two circumferentially spaced portions of the wall of the drape can be fused together by heat sealing one portion to another. The channels thereby created can be disparate in size, a smaller of the channels functioning as a fluid conducting conduit.
The seam formed by the heat sealing process insulates each of the channels from each other. A perforated line can be formed in the seam so that, if desired, the bodily fluid conveying channel can be diverted from the drape proper.
A pouch or pouches can also be provided and can be configured for disposition proximate the window in the drape so that bodily fluids secreted from the incision will flow into the pouch or pouches. If desired, means can be provided for establishing fluid communication between the pouch or pouches and the fluid disposal channel formed integrally in the drape.
Various advantages and features of novelty which characterize the invention are pointed out with particularlity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and objects attained by its use, reference should be had to the drawing which forms a further part hereof, and to the accompanying descriptive matter, in which there are illustrated and described certain embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a surgical drape in accordance with the present invention;
FIG. 2 is a perspective view of the surgical drape of FIG. 1 drawn over a patient's limb with the adhesive area around the window within the drape being partially exposed to the patient's limb;
FIG. 3 is a sectional view taken generally along the line of 3--3 of FIG. 2;
FIG. 4 is a perspective view of a second embodiment of the present invention wherein no window is formed in the drape;
FIG. 5 is a perspective view of the embodiment of FIG. 4 illustrating the surgeon using a scalpel to incise the drape and make entry to the patient's body;
FIG. 6 is a perspective view of the embodiment of FIG. 1 illustrating the drape in use in combination with a saddlebag-type pouch arrangement; and
FIG. 7 is an enlarged perspective view from the direction indicated by arrow 7 in FIG. 6.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings wherein like reference numerals denote like elements throughout the several views, FIG. 1 generally illustrates a disposable surgical drape 10 in accordance with the present invention. The drape 10 is in tubular form.
The drape 10 has an unsealed flared end 12 to facilitate fitting around a patient's limb at the joinder of the limb to the patient's torso. Such fitting is illustrated in FIGS. 2, 4, 5 and 6.
The drape 10 comprises a protective film 14. By means of heat sealing, a seam 15 is formed to define a channel 16. Channel 16, with the addition of a drain or a pump(not shown) can be used to remove fluid from the area at which incision is to be made.
The tubular shape of the instant invention allows for the fitting of the drape to the individual patient's limb 22, which is shown in phantom in FIGS. 2, 4, 5 and 6. FIG. 2 illustrates the drape with a window aperture 18 formed therein. Window aperture 18 provides access to the proposed incision area.
Adhesive, seen in cross-section in FIG. 3, is a layer 20 of any appropriate substance applied to the inside of the protective film 14. Adhesive layer 20 functions to facilitate application of the surgical drape 10 with the window 18 formed therein to the specific location of the patient's body desired. Adhesive layer 20 permits the surgical drape 10 to be securely positioned and maintained in position during the surgical procedure without the necessity of skin clamps or sutures or other fastening means.
Adhesive layer 20 can be exposed to the patient's limb 22, without the risk of contamination, by withdrawing a pull-tab 24 of a length sufficient to enable removal from a position overlying adhesive layer 20, from a location remote from the surgical site. FIG. 2 illustrates the application of the surgical drape 10 to the patient's body part 22 with the pull-tab 24 being removed to, thereby, expose the adhesive layer 20.
As seen in the figures, and particularly FIG. 1, the pull-tab 24 has a protective portion 25 which overlies adhesive layer 20 surrounding window 18, and a tab portion 23 which is folded back on the protective portion 25 and extends toward the flared end 12 of the surgical drape 10. The distal end of the tab portion 23 projects, in its normal position, beyond an edge of the protective portion 25 most closely proximate the flared end 12 of the drape 10.
As can be seen in view of this disclosure, after the drape 10 is maneuvered so that the patien's limb 22 is in position therewithin, a nurse can reach into the drape 10 from the flared end 12 and grab the protruding tab portion 23 of the pull-tab 24. Because of the disposition of the tab portion 23, his or her hand will never achieve a position immediately proximate the window 18. Consequently, the immediate incision area will not become contaminated by any bacteria associated with the nurse's hand. The pull-tab 24 can, thereafter, be drawn to remove it from the area around the window 18.
FIGS. 4 and 5 illustrate a second embodiment of the invention. Illustrated is a tubular shaped drape 26 which has no aperture therein, although a transparent window 18 can be provided. The surgical drape 26 of this embodiment functions, therefore, as an incise drape; that is, the incision is made through the drape material itself.
In FIGS. 4 and 5, as in FIG. 2, the patient body 22 part is shown in phantom encased within the tubular drape 26. The pull-tab 24 is withdrawn from the drape 26 in the same way as in the original embodiment to thereby expose the adhesive layer 20 to the patient's limb 22. Since the transparent window 18 would, most likely, have adhesive applied over its full under-surface, the protective portion 25 of pull-tab 24 would, therefore, be continuous to cover the full window 18. FIG. 5 illustrates the drape 26 in place with the adhesive layer 20 adhering the drape to the patient's body 22 to stabilize the drape 26 and maintain it in position. FIG. 5 also illustrates the surgeon's hand 30 holding scalpel 32 and making incision 28 through the drape 26.
FIG. 6 illustrates a surgical drape showing a flared tubular-shaped surgical drape 10 with a window aperture 18 formed therein. FIG. 6 also illustrates a saddlebag-type structure 34 having a pair of pouches 36, one at each of opposite ends thereof. When the assembly 34 is straddling the draped limb 22, these pouches 36 receive fluids as they drain from the incision area.
The pouches 36 can collect the fluids or, in conjunction with tubing 44 which communicates through tap fittings 40 with the pouches 36, and through fittings 42 with channel 16, act as a conduit to remove fluids. In this manner, fluids can be drained from the surgical site through the pouches 36 and the associated tubing 44 to the channel 16, and thus away from the surgical site for disposal.
FIG. 7 is an enlarged view illustrating the channel 16 and heat seal 15. The channel 16 is shown partially separated from the protective film 14 along a line of perforations 46 formed within the heat seal 15 defining channel 16.
Numerous characteristics and advantages of the invention covered by this document have been set forth in the foregoing description. It will be understood, however, that this disclosure is, in many respects, only illustrative. Changes may be made in details, particularly in matters of shape, size, and arrangement of parts without exceeding the scope of the invention. The invention's scope is, of course, defined in the language in which the appended claims are expressed. | A disposable surgical drape (10). It includes a tubular-shaped protective film (14) with a pull-tab (24) which lends itself to remote removal from an adhesive layer (20) on the protective film (14) so that the drape can be secured to a patient (22) without contamination of the incision area. An embodiment of the drape (10) comprises a protective film (14) which, when circumferentially spaced portions thereof are bonded together by, for example, a heat seal (15), defines a channel (16) which can function as a fluid conduit to remove bodily fluids from the surgical incision area. | 0 |
FIELD OF THE INVENTION
The present invention relates to a cap for use in neurosurgery. In particular, it relates to a sealing cap that provides a sealable channel through which one or more neurosurgical instruments can be passed.
BACKGROUND
There are many situations where there is a requirement to deliver therapeutic agents to specific targets within the brain parenchyma via implanted catheters. Furthermore, many of these therapeutic agents will cause unwanted side effects if delivered to healthy parts of the brain. Examples of treating abnormalities of brain function include the acute infusion of Gamma-aminobutyric-acid agonists into an epileptic focus or pathway to block transmission, and the chronic delivery of opiates or other analgesics to the periaqueductal grey matter or to thalamic targets for the treatment of intractable pain. Also, cytotoxic agents can be delivered directly into a brain tumour, intraparenchymal infusion can also be used to deliver therapeutic agents to brain targets that can not be delivered systemically because they will not cross the blood-brain barrier. For example, the treatment of patients with Parkinson's disease, Alzheimer's disease, head injury, stroke and multiple sclerosis maybe carried out by the infusion of neurotrophic factors to protect and repair failing or damaged nerve cells. Neurotrophins may also be infused to support neural grafts transplanted into damaged or malfunctioning areas of the brain in order to restore function. It is also known to insert instruments other than catheters, such as electrodes, directly in the brain parenchyma. For example, stimulating and lesioning electrodes are used in a variety of surgical procedures, including deep brain stimulation (DBS) electrodes. A surgeon wishing to stimulate or lesion a particular area of nervous tissue can target the end of an electrode to the target site so that a desired electrical current can be delivered.
Once a catheter or electrode has been inserted into the target area, it may need to remain in place for some time. It would be useful to be able to substantially seal the channel through which the instrument has been passed, so as to reduce the likelihood of the ingress of micro-organisms etc. it would also be advantageous to be able to remove the instrument without opening the seal. In addition, it is often necessary to administer a course of treatment to the same area repeatedly and so a surgeon may need to access the patient's brain through the same channel on a number of occasions. It would be helpful to be able to do this, without repeated opening of the channel surgically.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention, there is provided a cap for closing a communication channel in a patient's skull. The cap comprises a body that is attachable to the skull of a subject over a preformed hole in the skull, the body defining a channel through which one or more neurosurgical instruments can be passed, and an openable seal for sealing the channel.
The present invention thus provides a cap that can be located within or over an aperture or hole formed in the skull of a subject. The cap comprises an openable sealed access channel or passageway, through which a neurosurgical instrument, such as a tube or a wire, can be passed, allowing communication between the outer surface of a patient's skull and the patient's brain cavity.
The body of the cap preferably comprises means for allowing the body to be attached to the patient's skull. In particular, such means are likely to be one or more, preferably at least two, more preferably three or four holes through which a screw may be passed and screwed into the patient's skull, thereby anchoring the body to the skull.
The body may be of any appropriate shape to allow attachment to the patient's skull and to define at least one channel. The channel defined by the body may be selected in size and shape to correspond to a hole drilled in a patient's skull. The channel is preferably circular. The channel may be any size, but is preferably less than 8 mm in diameter, more preferably less than 6 mm in diameter.
The cap comprises at least one sealing element to seal the passageway or channel into the patient's brain. A variety of sealing elements may be used. Preferably, the sealing element is a septum seal or similar seal that defines at least one channel through which a neurosurgical device can be passed, the channel being self sealing, that is to say will close substantially when the device is removed. The septum seal may take the form of a membrane or a bung, for example. The septum seal may also define more than one channel through which a neurosurgical instrument may be passed.
As indicated above, a number of shapes of body are envisaged. In a preferred embodiment, the body sits on the surface of the patient's skull. In that embodiment, the body has a lower contact surface that is preferably arranged to sit on the surface of the patient's head, an upper surface and a side wall. The lower contact surface may be substantially flat. The diameter of the body is larger than the hole in the patient's skull and the surface wall is shallow, being approximately 1 to 5 mm in height. The body may be any shape, but is preferably generally annular.
With a body of this nature, a number of septum seals may be used. The seal may be a flat, membrane like seal that extends across the body channel. Alternatively, the seal may be a deeper, bung like seal that not only seals the body channel, but also extends into the hole made in the patient's skull. Such a seal may be cylindrical or have the shape of an inverted cone.
When the septum seal extends into the hole provided in the patient's skull, the cap may also comprise a seal housing, which is arranged to extend into the hole in the patient's skull and to be located between the seal and the patient's skull bone.
Alternatively, part of the body may be arranged to be located within the hole made in the patient's skull, thereby providing an integrally formed housing for the septum seal. In that second embodiment, the body is preferably cylindrical in shape and has a substantially annular shoulder, the cylindrical body extending into the hole in the skull and the shoulder sitting on the surface of the patient's head. The means for allowing attachment of the body are preferably found on the annular shoulder.
The body of the skull mount may be made from a material that is appropriate to remain in situ for an extended period of time. Preferably the material chosen is reasonably rigid, so as to avoid the body changing shape or deforming substantially if a force is applied. However, in order to allow a skull mount according to the invention to be attached to a patient's skull at any one of a number of different locations on the patient's head, it is important that the body of the skull mount has some flexibility. This allows the body to conform to the shape of the patient's skull. This flexibility may be provided by weakening areas of the body in the region of the means for allowing attachment. For example, a number of lines of weakness may be formed on the annular body or on the annular shoulder of the cylindrical body. The body is able to flex along these lines of weakness, so that it will conform to the shape of the patient's head.
To aid positioning and removal of an instrument used with the cap, the cap is preferably provided with at least one instrument exit point. Preferably, the body has a plurality of exit points to allow either a plurality of instruments, especially catheters to be used simultaneously or to the position of one instrument to be selected from a number of options. The exit points may be formed in the body, in the seal, or both. Each exit point may comprise a channel, passageway, trench or a groove in the body or seal, through which the instrument may be passed. Further, each exit point may be provided with a locking means to hold an instrument in place once inserted. For example, where the exit point is a groove or recess, the exit point may be sized such that the instrument fits snugly within the groove or recess. Part of the groove or recess may be locally narrowed, so that the instrument can still be inserted into the narrowed part, but once inserted is held in place. The exit point allows the instrument to be removed from the patient, by a surgeon or suitably trained clinician, simply pulling the instrument out, whilst preventing the end of the instrument from straying significantly from its inserted trajectory.
To further assist in sealing the hole in the patient's skull, the cap may also comprise a cap seal. The cap seal is arranged to be positioned over the septum seal when the instrument has been inserted. The cap seal provides further sealing around the area of insertion of the instrument. The cap seal and septum seal are preferably shaped to fit together snugly. The cap seal may comprise an instrument guide, such as a channel or groove, through which the instrument can pass, again to improve the fit between the cap and septum seal. Additionally the instrument guide may coordinate with the instrument exit point.
The septum seal is preferably made, at least partially, of a soft elastomer to allow the seal to deform slightly when the instrument is introduced. The cap seal may also be made of a soft elastomer, allowing it to deform around the instrument and maintain a close seal.
Further, the cap may be provided with a cap top which fits over the cap body. When a cap top is used, the body may have an annular groove around side wall of the body or of the shoulder. The cap top fits on to the body and the sides of the top preferably snap fit into the annular groove. To aid this snap fit, the underside of the cap top may be shaped to fit into the groove. For example, the cap top may comprise an O ring near to the edge of the underside of the cap top. In addition, the edge of the cap may be provided with a deformable skirt which fits closely with the patient's head but deforms to allow an instrument to exit from the cap body under the skirt. On the underside of the cap, a second O ring may also be provided. The second O ring fits on top of the cap seal, holding the cap seal in place and providing further sealing. Alternatively, the cap may be used without a cap top. In that case, in use, the body may be covered with bone wax.
In an alternative embodiment, the cap seal may be temporarily replaced by a septum guide.
As noted above, the cap is advantageously suitable for long term, percutaneous, implantation within a subject. Long term implantation may mean the skull mount remaining with the body for weeks, months or even years at a time; i.e. long after the initial surgical intervention. In such a case, the cap is conveniently formed from materials that are suitable for long term implantation within the body. For example, the cap body may be formed from titanium or a plastic material such as Barex (Trademark), PEEK (Polyaryletheretherketone) or a thermoplastic polyurethane elastomer (TPU) such as Carbothane (Trademark). The cap is conveniently fabricated from a material that is opaque to x-rays or is detectable using MRI so that it can be readily identified after implantation. Conveniently, the cap comprises only non-magnetic material so that a patient with the cap implanted therein can be safely subjected to an MRI scan. As outlined in more detail below, the implanted cap maybe provided as part of a long term implanted drug delivery or deep brain stimulation system.
Also provided by the invention is a method for inserting a neurosurgical instrument comprising the steps of (i) attaching the body from a cap according to the invention to the patient's skull, over a hole in the patient's skull, the body of the cap being sealed by a body seal; (ii) passing an instrument through the body seal; and (iii) placing the instrument into the exit point in the cap body.
The method may also include one or both of the steps of (iv) placing a cap seal onto the cap; and (v) placing a cap top onto the cap.
The cap of the invention may be used with a guide or skull mount, such as that described in UK Patent Application No. 0723880.1 and applications claiming priority therefrom.
DETAILED DESCRIPTION OF THE INVENTION
The cap according to the invention will now be described in detail, by way of example only, with reference to the drawings in which:
FIGS. 1 to 4 show a first embodiment of the cap; FIG. 1 showing a top view assembly (A) and a bottom view assembly (B), FIG. 2 showing an exploded top view of the component parts, FIG. 3 showing a section of the assembly, FIG. 4 showing a bottom exploded view of the component parts;
FIG. 5 shows an exploded view of a second embodiment of the cap;
FIG. 6 shows a bottom view of the second embodiment (A) and a section of the second embodiment (B);
FIG. 7 shows a partial section of a third embodiment;
FIG. 8 shows a section of a fourth embodiment;
FIG. 9 shows a sectioned view (A) and a top view (B) of a fifth embodiment including a septum guide;
FIG. 10 shows top (A) and bottom (B) exploded views of the components of a sixth embodiment.
In a first embodiment, as shown in FIGS. 1 to 4 , the cap 10 comprises a body 12 , that is generally annular in shape. The body defines a channel, 14 , through which surgical instruments may be passed. Extending from the annular body are three arms, each having an aperture 16 through which a bone screw may be passed to attach the body to a patient's skull. In order to allow the body to conform to the shape of the surface of the patient's skull, the body is provided with flexion regions, 17 which are lines of weakness, along which the body can flex.
The cap body is used with a seal housing 18 . The seal housing is cylindrical, and is provided with a lip 20 . The housing fits into the hole in the patient's skull, beneath the cap body, the lip resting on the surface of the patient's head. A body seal 22 , fits inside the housing, sealing the channel in the body. The body seal itself has a preformed channel through which an instrument can be passed. The body seal is formed from an elastomeric material that may be deformed by the instrument to allow insertion.
The body and the body seal cooperate to provide a path for the inserted instrument. The seal and upper surface of the body are curved 24 , to provide a smooth path for the instrument. Also, the body is provided with three instrument exit points 26 , through which the inserted instrument can exit the cap. Corresponding exit guides 28 are provided on the body seal. In this embodiment, the exit points are channels in the cap body.
The cap further comprises a cap seal 30 shaped to fit into the top of the body seal.
Finally, there is a cap top 32 which fits over the other components of the cap. The cap top snap fits onto the cap body, the edge 34 of the body snapping into a groove 36 in the wall of the body. The edge of the cap top is provided with openings to allow easy exit of the instrument.
FIG. 3 shows the assembled cap. The housing 18 is inserted into the hole in the patient's skull and the body seal placed inside the housing. The body is placed over the housing and screwed into place. The instrument, such as a catheter, is inserted through the instrument path in the body seal and follows the curved surface of the body seal. This prevents kinking of the instrument and minimises stress during implantation or removal. The instrument exits the cap via the exit guide and exit point. The cap seal is then placed on top of the body seal. The cap seal and body seal are made of an elastomeric material and deform around the instrument, improving the seal. The cap top is then placed on top of the body. The edge of the cap top snaps into the groove around the wall of the body.
When wishing to remove the instrument, a surgeon or other medical practitioner does not need to remove the cap top or cap seal. The surgeon can simply pull the instrument from the cap. To aid a steady removal, the surgeon can apply pressure to the cap top. The curved surface of the body seal, combined with the exit guide and exit points provides a smooth path through which the instrument passes. As it is removed, the instrument remains on its inserted trajectory, so as not to cause damage to the brain tissue.
In a second embodiment, as shown in FIGS. 5 and 6 , the cap comprises four components, an annular body 40 defining a channel which can be attached to the patient's skull using screws that fit through apertures 42 in the body. The cap also comprises a body seal 44 , which fits through the body channel into the patient's brain cavity. The body seal defines an instrument channel having a curved path, through which an instrument may be passed. The curved path of the instrument channel has a large radius, allowing for a wide range of instrument trajectories. The body seal may take the form of a duck seal or a polyp seal which may be self sealing on the removal of the instrument. Alternatively, the seal can be manually activated via the scalp or cap top. The instrument exits the seal via an exit guide 46 which fits into a corresponding exit point 48 in the cap body. To maintain the position of the instrument in the exit guide, the cap also comprises a cap seal 50 , which fits into the body seal, over the instrument. The cap top 52 is fitted over the body and seals to hold the components in place. The edge of the cap top snaps into a groove in the edge of the body. The cap top may comprise two separate parts, a main part 52 a , which can remain on the cap whilst the instrument is inserted, and a secondary part, 52 b , which may be removed to insert the instrument. The cap top in this embodiment is annular and has a central aperture. This aperture can be filled by a further cap top portion or seal to provide additional sealing, if required.
In third and fourth embodiments, as shown in FIGS. 7 and 8 , the cap body 54 has a cylindrical portion or boss 56 , from which an annular shoulder 58 extends. The cylindrical portion fits into a hole in the patient's skull. The body can be attached to the skull using screws inserted through apertures in the shoulder. Slots in the underside of the annular portion allow the annular portion to conform to the patient's skull shape. A body seal 60 is found in the lower end of the cylindrical portion. The body and body seal are provided with a corresponding groove and ridge which fit together to hold the body seal in place. The cap further comprises an integrated cap seal and cap top 62 which fits into the cylindrical portion above the body seal. Again, the cap seal and body may be provided with a corresponding lip and groove to hold the cap seal in place. The body seal, cap seal and body combine to provide a passageway through which an instrument can be inserted. A substantially straight channel 64 is provided in the body seal. The cap seal comprises a curved channel 66 and, in its upper region, comprises an exit guide 68 which combines with an exit point 70 in the body to form the passageway. The passageway is curved and has large controlled radii, which prevents kinking of the instrument and aids removal. The exit point 70 on the body is made up of a groove in the body. In the fourth embodiment, the exit point also include a hook 71 or lip which clips over the instrument to aid positioning, hold the instrument in place and aid removal. The edge of the cap top comprises a flap 72 which seals the exit point after the instrument is removed. The third and fourth embodiments may also include a mesh reinforcement plug 74 between the body seal and cap seal. The plug may be made, for example, from cellulose. It provides additional support for the instrument and can act as a saline reservoir to prevent infection and to aid lubrication on removal of the instrument.
In the fifth embodiment, the body and body seal are similarly arranged to the third and fourth embodiments. This embodiment can also be used with a cap top or cap seal. As an alternative; however, the cap seal may be replaced with a septum guide 76 and a piercing cannula 78 , as shown in FIG. 9 . The septum guide comprises an elongate guide component that fits into the cap body. A piercing cannula can be passed through a central hole in the septum guide and through the septum and dura of the patient's brain. The cannula may then be removed and a desired instrument inserted. Use of the piercing cannula helps to prevent deflection from the trajectory angle. The caps described herein may usually be used for a range of trajectory angles, that is with insertion trajectories that are not parallel to the cap trajectory. The septum guide may be pivoted within the body in order to set the trajectory angle. The septum guide may then be held in place by an external clamp. Alternatively, when the insertion trajectory is parallel to the cap trajectory, the septum guide may be locked into the cap body, the septum guide being provided with a ridge or groove which locks with a corresponding groove or ridge on the cap body.
A sixth embodiment is shown in FIG. 10 . The embodiment comprises an annular body 80 having three holes 82 through which screws may be inserted to attach the body to the patient's skull. The body defines a channel 84 , through which an instrument may be passed. The edge of the channel is rounded, to provide a smooth passage for the instrument. The body comprises flexion regions 85 weakened regions along which the body may flex to allow the body to conform to the shape of the patient's skull. The cap also comprises a septum seal 88 , which also comprises holes 90 through which the skull screws pass, fixing both the seal and the body to the skull. In use, the instrument is passed through the channel and septum seal. The instrument is then bent over and placed into the exit point 92 , a slot in the body. The instrument may be locked in place as the slot is narrowed so that the instrument fits snugly within it. The instrument may be removed by pulling it through the slot. To aid in the safe removal of the catheter, the embodiment further comprises an instrument guide which fits on top of the seal. The instrument guide comprises an exit guide 94 which fits over the instrument and directs it into the exit point. The instrument guide protects the instrument from being crushed by load applied to the cap. The cap also comprises a cap top 96 . The cap top comprises a central O ring 98 that fits onto the instrument guide and holds it in place, and a peripheral O 100 ring which fits into a groove 102 around the side wall of the body and provides additional sealing. At the periphery of the cap, there is a deformable skirt 104 which moulds around the exiting instrument and which returns to its original position once the instrument has been removed to maintain sealing.
The use of the sixth embodiment will now be described. It will be appreciated that the use of the other embodiments will follow a similar work flow. The site for a burr hole is localised on the skull. A burr hole of approximately 8 mm is drilled in the skull. The dura depth is determined and a guiding device aligned (for example, stereotactically). The depth of the target is determined and the cap aligned with the burr hole, an aperture created in the dura, and the device placed and screwed into position. A catheter or other instrument is selected and the target depth marked on the catheter. The catheter is then implanted using the guiding device. Following implantation, the guiding device is removed and the catheter folded and positioned in the exit point slot. The instrument guide (or cap seal) is then placed over the catheter. The cap top is then placed over the cap, a tunnel created and the catheter externalised.
Whilst a variety of features have been described in the different embodiments, it should be appreciated that features from different embodiments can be combined. | The invention relates to a cap for use in neurosurgery. The cap may be applied to a bore hole in a patient's skull, allowing the entry and removal of neurosurgical instruments, while providing an openable seal over the bore hole. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
Beverage can containers, more specifically a beverage can container for providing easy access to the beverage cans contained therein.
2. Background Information
Beverages, such as soda or beer, often come in cylindrical, aluminum, typically 12 oz. cans. Traditionally, one could buy a single can or a “six pack.” The six pack is simply six cans contained in a typically rectangular paper container or hung on interconnected plastic rings.
More recently, cans of soda and beer have become available in packs of twelve cans. The twelve pack is typically rectangular cardboard with the cans, usually in a 4×3 matrix arrangement, stacked closely next to one another. The twelve pack has walls typically constructed of light cardboard or thick paperboard, being thicker than writing stock paper but not as robust or thick as corrugated cardboard. These twelve packs presently enjoy popularity with use by Coca-Cola and Pepsi-Cola, the two leading providers of soda as well as by many major domestic beer companies.
The twelve pack containers provide a convenient means to carry the beverage cans but are not handy for dispensing the cans. Typically, the consumer will purchase the twelve pack, bring it home, tear the pack open and pull out the cans to stack them in the refrigerator, discarding the container. Applicant provides, however, for a modification to the currently available twelve pack to convert the carrying container to a dispensing container. That is, the cans will remain within the carrying container, the container acting, as modified by applicant as a beverage can dispenser.
An object of Applicant's present invention is to provide for a container for beverage cans which will allow easy access to the beverage cans for easy removal but will also hold the beverage cans therein.
It is also an object of Applicant's present invention to provide a modification to currently existing beverage can containers so that the containers, as modified, will provide easy access to the cans therein.
This and other objects are provided for in a generally rectangular, paper beverage can container with a corner removed on a diagonal line across the two side walls, the line running from a front wall to the adjacent top wall.
There are a number of benefits with Applicant's novel beverage container with a dispensing cutout therein. These include ease of access. This is obtained by placing the twelve pack container on edge with a cutout in the upper corner. Easy and fast accessibility to the cold beverage cans will increase consumption and sales of the product.
Applicant's invention also provides for gravity feed to enhance access to the beverage cans. This is created by the weight of the cans when the beverage container is placed in a vertical position. This position naturally pushes the cans, under the influence of gravity, towards the front wall of the container. The cutout location is designed to take maximum advantage of this gravity feed.
Another advantage of Applicant's invention is the ability to effectively utilize space, especially in a refrigerator or kitchen cabinet. By placement of the cutout in the position indicated, the container may be placed vertically to save space.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the preferred embodiment of applicants invention.
FIG. 1A is side view of a 12 oz. beverage can.
FIG. 1B is a perspective view of the beverage container modified accordingly to Applicant's invention.
FIG. 2 is a side elevational view of the preferred embodiment of applicants invention.
FIG. 3 is a side elevational view of an embodiment of Applicants invention.
FIG. 4 a two dimensional pattern of a typical paper twelve pack container illustrating the area removed to provide for applicants unique dispenser.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Line 12 A shows the position of a line on the front wall of a beverage container from one side wall to the next, the line being straight and meeting the edge between the front wall and the side wall at a 90° angle. The line 12 D shows the position of a diagonal line across each of the two side walls between the front wall and the top wall, lines 12 D, at 12 B and 12 C showing a preferred range of the position of line 12 D with respect to the top wall. Line 12 E is a line across the top wall, one side wall to the next and perpendicular to the edges of the top wall. The beverage container will be cut through along lines 12 A, 12 D and 12 E to remove section 12 from the rest of the container (See FIG. 1 B). The position of lines 12 A, 12 D and 12 E may be premarked, scored (or otherwise weaken) by the manufacturer of the beverage container so as to direct the consumer to the position for cutting and removing portion 12 .
FIG. 1 is a perspective view of a modified twelve pack container 10 with cylindrical aluminum 12 oz. beverage cans A packed inside in a 4×3 arrangement and designating two side walls S/W, a top wall T/W, a bottom wall B/W, a front wall F/W and a rear wall R/W. It is noted that the two side walls have the greatest surface area, the top and bottom walls having a surface area between the two side walls and the front and rear walls, which have the least surface area. A support surface, such as a refrigerator shelf, is designated SS. The top, bottom, front and rear walls are defined when the container is placed on a support surface, as illustrated in FIG. 1, with the F/W chosen to provide for the most convenient access. FIG. 1 also illustrates Applicant's modification, being a cut or removed portion 12 , the removed portion being a comer of the container where the front wall meets the top wall and defined by a diagonal line across the two sidewalls between the front wall and the top wall, and a line across the top wall and across the front wall, this line along which the removed portion is defined designated 12 A.
FIG. 2 illustrates a side elevational view of the twelve pack of FIG. 1 wherein the dimension designated D is the approximate diameter of a 12 oz. aluminum beverage can, typically about 6.6 centimeters. As can be seen in FIGS. 1 and 2 the typical twelve pack beverage container is a little over 4 diameters long (about 26 cms) and about 3 “diameters” high (about 20 cms) to enclose therein, in a 3×4 matrix, twelve cans. Furthermore it sometimes includes a handle 14 thereon, the handle typically being walls defining a cut out in the top wall for the receipt of a hand thereinto. The height (H) of a typical 12 oz. metal beverage can is about 12.6 cm.
In FIG. 2 it is seen that Applicant modifies the standard heavy paper wall twelve pack container by cutting off the corner created by the joinder of the front wall and top wall. This is preferably done in the manner illustrated in FIGS. 1 and 2. The preferred height of the front wall defined after the cut across the front wall is less than two diameters but greater than one diameter, more preferably between 1.50 and 1.80 times D. Indeed, the most preferred height of the front wall defining the cut to remove portion 12 is between 1¼ diameter and 1¾ diameter. Such dimension allows easy receipt of the second course of cans but is high enough to prevent the second course of cans from falling out when there are still 3 courses in the container.
The preferred length of the top wall defined after the cut is between 1 and 3 diameters, preferably between 1 and 2 diameters. These cut dimensions are illustrated by lines 12 B and 12 C set forth in FIG. 2 .
Cuts along the lines 12 A, 12 D and 12 E may be made with a knife, razor or any other suitable instrument. When the cuts are made as set forth in FIGS. 1 and 2, portion 12 can be removed (See FIG. 1B) and the single can at the top comer will then be removed and the container placed in the position illustrated in FIG. 1 for easy dispensing of the remaining cans.
FIG. 3 provides for a diagonal cut 12 C across the side walls S/W's that terminates adjacent handle 14 . Handle 14 , in a 4×3 twelve pack is usually at 2 diameters from a top edge (half way across top wall T/W) to provide for proper balance.
FIG. 4 illustrates a flattened twelve pack pattern 16 which will fold together to provide for a typical twelve pack with dimension. Handle 14 is illustrated. Scored line 18 is made as part of the process of constructing the container, typically after the outer perimeter 20 defining the pattern 16 of the box is formed. Scored line 18 may be grooves, scratches or notches, or any other means known in the trade to weaken the paperboard such that it is easier for the user to remove portion twelve. Indeed, with proper scoring in ways known in the trade, it is fairly easy to remove portion twelve without a cutting instrument. Note in FIG. 4 that folding the pattern 16 will provide for the twelve pack illustrated in FIGS. 1-3 with the diagonal line 12 D running across the side walls from the front wall F/W to the top wall T/W.
In an alternate preferred embodiment Applicant provides a twelve pack container with a line marked on the front wall F/W at between 1 D and 2 D, on the top wall T/W between 1 D and 3 D and across the two side walls S/W's to define the pattern for removal of a corner 12 of a twelve pack container as illustrated in FIGS. 1-4 to show a consumer that they may cut the container along the line to convert it into the Applicants novel dispenser container as illustrated.
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limited sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the inventions will become apparent to persons skilled in the art upon the reference to the description of the invention. It is, therefore, contemplated that the appended claims will cover such modifications that fall within the scope of the invention. | A container having a multiplicity of cans therein. The container disclosed is modified from a rectangular, closed wall container to a container with part of the walls removed, thereby allowing easy access to the cans of the container. Applicant discloses a unique relationship between the walls of the opened container and the size of the beverage cans. Applicant also discloses a method for constructing a closed container that may be easily modified to remove the cans of the container. | 1 |
This application claims the benefit of U.S. Provision Application Ser. No. 60/036,113 filed Jan. 15, 1997.
FIELD OF THE INVENTION
The present invention relates to collating apparatus for collating loose articles and more particularly, the present invention relates to an apparatus for arranging and/or collating articles into a neat orderly array and a method of employing the apparatus.
BACKGROUND OF THE INVENTION
Many different forms of collating arrangements are known in the art and one of the chief drawbacks of those existing arrangements is realized with the degree of labour intensity. Generally speaking, several personnel are involved in handling the articles to eventually be packaged and this often leads to difficulties in terms of damaged goods as well as complications with respect to health standards. Further limitations revolve around the fact that the additional personnel add labour costs to the overall process.
It would be desirable if there were a method for collating loose articles into an orderly array which is significantly less labour intensive and which reduces the contact between the product and the personnel packaging the product.
The present invention is directed to solving the difficulties as set forth herein.
SUMMARY OF THE INVENTION
One object of the present invention is to provide an improved method and apparatus for collating loose articles into an orderly array.
A further object of the present invention is to provide an apparatus suitable for orienting articles, comprising:
a plurality of channel means, the channel means each having a receiving end for receiving the articles and a discharge end for discharging the articles, the channel means for slidably receiving the articles, each channel of the channel means having a width dimension, the width dimension progressively decreasing from the receiving end to the discharge end, the receiving end being at a higher elevation than the discharge end, whereby when the articles are received in a relatively random form at the receiving end and are slidably transported to the discharge end, the channels orient the articles from a relatively disordered form with respect to one another to an ordered array with respect to one another.
Any number of channels may be employed in the arrangement and this will depend upon the volume of article to be packaged among other factors. The channel may be formed of any suitable material having a low coefficient of friction in order to ensure quick transportation of the product from the receiving end of the apparatus to a discharge end. To this end, the receiving end will be elevated relative to the discharge end in order to provide a "ramp effect" and thus facilitate sliding of the article down the channel. Suitable materials for construction of the channels include aluminum, Teflon™ suitable plastics or other suitable metals acceptable to the food industry and also providing the necessary degree of friction. As a further feature, the temperature of the channels may be controlled (heated, cooled) depending upon the type of product to be collated.
A further object of the present invention is to provide an apparatus for sorting and packaging articles, comprising, in combination:
conveyor means for conveying the article;
orienting means for orienting the articles from an unordered state wherein the articles are randomly positioned relative to one another to an ordered state where the articles are in a regular array, the orienting means comprising:
a plurality of separate channels each channel of the channels having a receiving end for receiving the articles and an opposed discharge end for discharging articles in an array, the channels for slidably receiving the articles, each channel having a width dimension, the width dimension progressively decreasing from the receiving end to the discharge end, the receiving end being elevated with respect to the discharge end; and
packaging means for packaging an array of oriented articles.
The channels may include pegs, cams or some additional element on the top edges in order to reposition, for example, a potato patty from a generally horizontal position relative to the channel to a position where the patty is vertically oriented within the channel. This may also be achieved by providing a texture on the top edge of the channels or simply having different material on adjacent top edges to provide a different coefficient of friction. This will ensure that any randomness in the orientation of the product is eliminated by the edging to reposition the article. In this manner, the channels provide a self-aligning feature for the articles contacting them.
A further object of the present invention is to provide a method of collating loose articles from a relatively disordered state, comprising the steps of:
providing a plurality of channels for slidably receiving the articles, the channels tapering in width from a receiving end to a discharge end, the receiving end being elevated relative to the discharge end;
introducing the articles at the receiving end at any orientation relative to the channels, sliding the articles down a respective channel to progressively orient the articles; and
discharging the articles in an ordered array.
Having thus described the invention, reference will now be made to the accompanying drawings illustrating preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overall schematic illustration depicting a sorting, collecting and packaging procedure;
FIG. 2 is a top plan view of the apparatus according to one embodiment;
FIG. 3 is a sectional view along line 3--3 of FIG. 2; and
FIG. 4 is a section along line 4--4 of FIG. 2.
Similar numerals in the figures denote similar elements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, FIG. 1 broadly illustrates a sorting, collecting and packaging system in schematic form.
The articles, in this example, patties, may be ovular or rectangular, are typically discharged into a freeze tunnel conveyor from previous processing operations (not shown). The freeze tunnel is broadly denoted by numeral 10. From the freeze tunnel 10, the articles are passed on to a dispensing conveyor 12 which orients the patties from travelling widthwise to a lengthwise arrangement. Inspectors 14, in the conveyor line 12, typically examine the patties for quality assurance purposes and remove any broken or otherwise inferior patties. The patties are then passed on to the collating apparatus, broadly denoted by numeral 16 to be discussed hereinafter in much greater detail. From the collating apparatus 16, the patties are then conveyed via conveyor 18 to a packaging machine 20, which receives trays 22 in timed sequence in order to charge a tray 22 with patties. The charged trays 24 are then passed on to, for example, a shrink wrap machine 26. Having thus generally described the overall process sequence, reference will now be made in greater detail to the collating apparatus 16 shown best in FIGS. 2, 3 and 4.
FIG. 2 illustrates a top plan view of the collating apparatus 16 with parts removed for clarity. As is illustrated, the collating apparatus includes a receiving end 30 and a discharge end opposed therefrom and denoted by numeral 32. The collating apparatus 16 includes a plurality of discrete channels 34 regularly spaced from one another and extending from the receiving end 30 to the discharge end 32. Channels 34 each have a width dimension broadly denoted by numeral 36 in FIG. 2, which width dimension progressively decreases from the receiving end 30 to the discharge end 32 such that the overall apparatus 16 converges from the receiving end to the discharge end. In this convergent pattern, the width dimension within any channel remains constant relative to an adjacent channel.
FIG. 3 illustrates a section along line 3--3 of FIG. 2 which depicts the channels 34 in a generally sawtooth formation. As is illustrated, each channel includes a first substantially vertical wall 38 and a diagonally oriented wall 40, the orientation being relative to the vertical wall 38. Diagonal wall 40 terminates in a substantially horizontal base wall segment 42 and further includes a second vertical wall 44, which is at approximately 90° relative to partial wall 42 and in a parallel and spaced relationship with wall 38. In this manner, at least at the receiving end and somewhat spaced therefrom, the channels start with a straight wall 38144 and an inclined wall 40. The spacing between the channels 34 is less than the length of the patty P, but greater than the width of the patty P.
Generally proximate end 32, the inclined wall 40 in each channel 34 is substantially vertical. This is illustrated in FIG. 4. The transition from an angular wall 40 to its substantially vertical orientation is progressive along the length of channel 16 as is illustrated in FIG. 2. In this manner, the patty P moves along the collating apparatus 16, it is moved from a generally inclined form to a vertically oriented disposition. This facilitates arranging the patty P into an orderly array at end 32 for subsequent charging into a tray 22 as broadly illustrated in FIG. 1.
In order to achieve this, the collating apparatus 16 and more particularly, the end 30, is elevated somewhat relative to end 32. The elevation may be from about 20° to about 40° or greater relative to the horizontal. By providing the elevation, this facilitates sliding of the patties P down the channels from end 30 to 32.
In operation, the patties P generally enter the receiving end of the apparatus 16 at the various orientations relative to one another. This is typically random and is illustrated in FIG. 2 where one patty is between channels 34 whereas the other is disposed in a cross channel form. By providing the arrangement of the channels 34 as illustrated in FIG. 3, this random disposition is solved simply by having the patty P fall into the channel 34. It is then automatically turned on its side by virtue of the configuration of the channel 34 as it travels down the inclined apparatus 16. In order to ensure that the cross channel patties positively are oriented on a side such as that shown in FIG. 3, small pegs 46 may be employed at the crest or the juncture of walls 38 and 40. By providing pegs 46, if the article is cross channel or riding the crests, the pegs ensure reorientation or repositioning to the form shown in FIG. 3, i.e. the patty is on an edge within the channel 34.
It is clearly envisioned in the absence of pegs 46, the top edges of channels 34 may be composed of materials having different coefficients in order to induce the proper disposition of the patty P into the channel 34. Other forms of locating may be employed such as means for vibrating the channels 34, cammed internal surfaces inter alia.
FIG. 3 shows in chain line, the gradual change in attitude of the patty P as the same travels the course of the channel 34.
The present invention thus alleviates the need superfluous personnel in the packaging procedure and further avoids excessive handling by personnel of the product to be packaged.
It will be appreciated by those skilled that although potato patties have been indicated to be the article, the apparatus and methodology are amenable to any article that may be packaged.
Although embodiments of the invention have been described above, it is not limited thereto and it will be apparent to those skilled in the art that numerous modifications form part of the present invention insofar as they do not depart from the spirit, nature and scope of the claimed and described invention. | A foodstuff collating apparatus having a plurality of discrete channels within which foodstuffs are collated. The apparatus is elevated at one end to provide a slide for the foodstuff with the channels converging from one end of the apparatus to the other. As the foodstuff slides down a channel, the former is oriented from a random position to an ordered vertical disposition. | 1 |
FIELD OF THE INVENTION
[0001] This invention is generally in the field of manufacturing of multi-layer structures, such as semiconductor wafers and integrated circuits, and relates to an optical measuring method and system for control of layers alignment.
BACKGROUND OF THE INVENTION
[0002] Integrated circuits are multi-layer structures produced by applying a sequence of deposition-lithography-etching steps to a semiconductor wafer. In such structures layers have to be precisely aligned with each other, which is controlled by the so-called “overlay measurement”. This measurement is usually accomplished using a box-within-a-box technique consisting of the following. A rectangular frame-like structure is formed in a test site of each layer, and two adjacent layers are considered as being correctly aligned if a specific alignment between the frames on these layers is provided. Overlay defining the alignment is measured by comparing the shifts between the frames at opposite sides: determining whether the frames are precisely concentric, the smaller frame being inside the larger one (in projection).
[0003] The above technique is carried out by an ordinary optical microscope, which is capable of measuring line width with a resolution limited by resolution of optical imaging systems, usually not less than several nanometers. The current high-performance semiconductor devices, however, have features' dimensions of 0.13 μm and less, and require measurements of overlay registration with the resolution of less than 1 nm.
[0004] A different alignment technique is disclosed in the U.S. Pat. No. 5,216,257. According to this technique, two grating structures of different periodicity are deposited on two adjacent layers in a multi-layer structure, and a change in a moire fringe pattern caused by the superposition of two gratings is detected, being indicative of a grating alignment error.
SUMMARY OF THE INVENTION
[0005] There is a need in the art to facilitate overlay measurements for the purpose of correct alignment of layers in a multi-layer sample (e.g., integrated circuit), by providing a novel optical method and system.
[0006] The main idea of the present invention is based on the fact that the diffraction of incident radiation from a pair gratings (or any other diffractive structures), located one on top of the other is affected by all geometrical aspects of the gratings, namely, both the parameters of each separate grating and their location relative to each other (i.e., lateral shift). According to the present invention, the lateral shift between two layers is determined by analyzing electromagnetic radiation (light) diffracted from gratings (patterned structure) of substantially the same periodicity, which are specifically arranged within a site formed by regions of two layers. To this end, scatterometry (measuring diffraction efficiency as a function of wavelength and/or angle of incidence) or ellipsometry (measuring both change of polarization amplitude and phase of the diffracted light) can be utilized. These techniques are based on the detection of the so-called “diffraction signature” of two gratings one on top of the other.
[0007] Thus, according to the invention, an effect of radiation diffraction from two patterned structures (gratings) of known periodicity located one on top of the other, caused by a lateral shift between the two patterned structures, is detected and analyzed to determine an alignment error. The patterned structures are located within a site formed by two regions of two layers, respectively. Preferably, two patterned structures (gratings) of substantially the same periodicity are used.
[0008] According to different embodiments of the invention, the following methods are used: a so-called “direct method”, a method based on reference sites, and a method based on simple calibration. The direct method is based on the initial calculations of a diffraction signature using certain well-defined models. The reference sites method is based on the comparison between diffraction signatures measured in different sub-regions of the site. The simple calibration based method utilizes certain reference data previously obtained by any suitable tool to be indicative of various diffraction signatures corresponding to respective lateral shifts. These different methods require different sites prepared on the layers of a multi-layer sample.
[0009] The term “site” used herein signifies a location in a multi-layer sample that includes two regions one on top of the other. Such a site may be a test site located outside the features containing area if a sample.
[0010] If layers' shift along more than one axis in the sample plane is to be determined, the test site (generally, grating containing site) includes two main regions, one containing a grating structure aligned along the X-axis of the sample and the other along the Y-axis of the sample. Each region may contain several different sub-regions having different nominal shifts between the gratings. The term “nominal” signifies a shift of the masks used for layer manufacturing, assuming perfect masks production and zero alignment error.
[0011] Another embodiment of the test structure may contain a two-dimensional grating enabling the measurement of the X and the Y components of the lateral shift at the same site. In order to avoid the possibility to confuse between the X and the Y components several methods may be used: (a) Produce a test site whose period in the Y-axis is significantly different than the period in the X-axis (b) measure the same site several times using different polarizations (in case of polarized reflectometry) (c) measure the same site from different directions. All the above methods result in different changes to the diffraction signatures due to shifts in different directions, thus avoiding confusion.
[0012] According to another embodiment of the test structure, the diffractive structures of one of at least two pairs are shifted with respect to each other along the X-axis by a distance +ΔX and the diffractive structures of the other of the at least two pairs are shifted with respect to each other along the X-axis by a distance (−ΔX).
[0013] According to another embodiment of the test structure, the diffractive structures of one of the at least two pairs are shifted with respect to each other along the X-axis by a distance (+ΔX), and the diffractive structures of the other of the at least two pairs are shifted with respect to each other along the X-axis by a distance (−ΔX±NΔx), where Δx<<ΔX and N is an integer number.
[0014] According to another embodiment of the test structure, the two diffractive structures of at least one pair have patterns of features of different periodicities.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] In order to understand the invention and to see how it may be carried out in practice, a preferred embodiment will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:
[0016] FIG. 1 is a schematic illustration of a cross-section of a site in a semiconductor wafer;
[0017] FIGS. 2A and 2B illustrate the principles of a direct method according to the invention;
[0018] FIG. 2C shows diffractive structures having two-dimensional patterns of features.
[0019] FIG. 3 illustrates the principles of a reference sites based method according to the present invention;
[0020] FIGS. 4-6 illustrate different simulation results of the sensitivity test as functions of grating parameters; and
[0021] FIG. 7 illustrates the effect of an overlay error on a scatterometry signal (diffraction efficiency) as measured on the optimal structure.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Referring to FIG. 1 , there is schematically illustrated a cross-section of a test site 10 in a semiconductor wafer suitable for use in the present invention. The site 10 contains two gratings (patterned structures) 12 and 14 of certain known periodicity located one above the other. In the present example, the gratings 12 and 14 have substantially the same period P. In the present example, the top grating 12 presents a pattern of spaced-apart photoresist-containing regions R PR , and the underneath grating 14 presents a pattern of spaced-apart aluminum-containing region R Al . In this specific example, the gratings 12 and 14 have different duty cycles defined by features critical dimensions CD PR and CD AL , respectively. It should, however, be noted that this condition is not a requirement for the technique of the present invention, but provides for a better sensitivity of the method. As further shown in the figure, the gratings 12 and 14 are shifted along the X-axis with respect to each other a distance S, which is measured as a distance between the centers of the two locally adjacent regions (lines) R PR and R Al .
[0023] In order to find the conditions under which the method of the present invention is most effective, and show how the method is practical, the sensitivity of the method has been studied for a specific configuration of the site structure exemplified in FIG. 1 . The site structure 10 is typical for the overlay problem in photoresist-on-aluminum layer structure. The pattern in the aluminum (Al) layer is typically defined by layers underneath the aluminum layer, and the photoresist (PR) layer is patterned by a lithography processing. In this specific example, the PR lines are modeled to be on top of the Al lines. It should, however, be understood, that this is not essential for the present invention, and PR lines may be located between the Al lines, as well. For simplicity, both gratings 12 and 14 have a square profile. The measurement technique used for this analysis is the normal incidence polarized spectrophotometry. According to this technique, the normal incidence reflectivity spectrum is measured with selective polarization direction of the incident light relative to the grating (TM polarization mode in this specific example). Other optical techniques, such as spectral ellipsometry, angular scatterometry, etc. may be used as well.
[0024] The sensitivity of the spectrum (measured by the technique of the present invention, which will be described more specifically further below) to a change in the lateral shift S between the gratings 12 and 14 has been studied. The ratio between the mean change in the spectrum (defined as the root of the mean of the square differences between spectra with and without a change in the shift) caused by a change in the shift value S of 1 nm has been defined as the sensitivity test T, wherein S is the nominal shift.
[0025] The simulation results have shown that T depends on all the parameters of the test structure. Values of T are almost always monotonously increasing with the values of S. This general rule holds as much as T can be increased, i.e., until the edge of the PR line “falling off” from the Al line. It is thus evident that the measurement is more sensitive for an asymmetrical structure.
[0026] As for the other parameters of the test site, such as the period P, the CD PR and CD Al (generally, the duty cycles of gratings) and the heights H PH and H Al of the two gratings, they usually affect the sensitivity test T in an oscillatory manner. It is thus necessary to find such a set of gratings parameters, that T is maximized while being least sensitive to the exact values of these parameters. For example, the value of T equal to 8·10 −3 is obtained with the following set of gratings' parameters: P=600 nm, CD PR =300 nm, CD AL =150 nm, H PR =600 nm, and H AL =100 nm.
[0027] In one embodiment of the invention, the direct method is used. In this method exact simulation methods, such as RCWT (Rigorous Couple Wave Theory), are used to simulate the diffraction signature(s) from the test site. In the simplest case there is not any prior knowledge of the exact grating properties on either layers. In this case the experimentally measured dif fraction from the test site is fitted to simulation fitting at the same time for both CD's, grating heights and additional parameters characterizing the individual gratings in the two layers and the shift as an additional fitting parameter.
[0028] FIGS. 2A and 2B exemplify the principles underlying the design of a test site 20 suitable to be used for another embodiment of the present invention. FIG. 2C illustrates diffractive structures having two-dimensional patterns of features. The test site 20 is formed by regions 24 and 26 located one on top of the other in layers L 1 and L 2 , respectively. As shown in FIG. 2B , the two regions 24 and 26 define together four different pairs of sub-regions: A 1 -A 2 , B 1 -B 2 , C 1 -C 2 and D 1 -D 2 , wherein sub-regions A 2 , B 2 , C 2 and D 2 are located on top of sub-regions A 1 , B 1 , C 1 and D 1 , respectively. In the pair A 1 -A 2 , sub-regions A 1 and A 2 are different in that region A 1 contains a grating G A1 and sub-region A 2 has no grating at all, and in the pair D 1 -D 2 —vice versa. Gratings G B1 and G B2 of sub-regions B 1 and B 2 , respectively, are shifted with respect to each other along the X-axis a distance +Δx (i.e., in the positive X-direction), and gratings G C1 and G C2 are shifted with respect to each other a distance −Δx (negative X-direction). In this embodiment information is gained from measuring the single-grating sites (sub regions A 1 -A 2 and D 1 -D 2 ) in order to simplify the fitting in the dual-grating sites (sub regions B 1 -B 2 and C 1 -C 2 ). The measurement is done in two steps. In the first step the single-grating sites are measured and the grating characteristics in those sites, including for example CD, height wall angle etc., are measured by fitting to simulation, as in normal scatterometry. In the second step the measurements of the dual-grating sites are fitted to simulation using all or part of the grating parameters that have been measured in Step 1 and fitting for the shift between the gratings. It should be noted that at least those gratings which are located in a common layer must be are identical, i.e., have the same period, duty cycle, and height.
[0029] Notice that for the case of perfect alignment the measurements of sites B and C should be identical, thus a significant difference between the two measurements may indicate an alignment error. The difference between the two signals obtained from sub-region pairs B 1 -B 2 and C 1 -C 2 , respectively, may be utilized in order to increase the sensitivity and reduce systematic measurement errors. This can be done by fitting the difference of simulated signatures to the difference of the measurements in the two sites. This procedure may be used in order to filter out changes in the spectrum that are not related to the shift S, thus enhancing the sensitivity and the robustness of the measuring technique.
[0030] In another embodiment of the invention, the reference site method is used. FIG. 3 illustrates the main principles underlying this method. Here, a test site 30 , which is formed by two regions one above the other in layers L 1 and L 2 , is composed of a so-called “measurement site” 32 and a so-called “reference site” 34 spaced-apart from each other along the X-axis. Gratings in these sites are not specifically illustrated, but is should be understood that both the measurement and the reference sites include sub-region pairs arranged as described above. In this method, the measurement site 32 has one grating-pair characterized by a nominal shift (+ΔX) between the gratings, and the reference site 34 has several grating-pairs located in sub-region pairs, respectively, aligned in a spaced-apart relationship along the X-axis and characterized by the following nominal shifts: −ΔX−3Δx, −ΔX−2Δx, −ΔX−Δx, −ΔX, −ΔX+Δx, −ΔX+2Δx, −ΔX+3Δx, . . . etc., Δx is typically much smaller than ΔX and is of the same order of magnitude as the required resolution in the lateral shift measurement. In this method, it is assumed that the grating profiles are sufficiently symmetric and unaffected by the ex act shift, and therefore symmetric shifts between the gratings (upper grating shifted to either right or left of the lower grating) will result in the identical diffraction signatures.
[0031] When the two layers are printed with an alignment error (+ξ), the actual shifts between the gratings of the measurement site will be: (+ΔX+ξ) and for the reference sites the shifts will be as follows
[0000] (−ΔX−3Δx+ξ); (−ΔX−2Δx+ξ); (−ΔX−Δx+ξ); (−ΔX+ξ); (−ΔX+Δx+ξ); (−ΔX+2Δx+ξ); etc.
[0032] In order to measure the alignment error ξ, the diffraction signatures from all the sub-region pairs are measured using one of the above mentioned measurement techniques. Then, the signature from the measurement site is compared to the signatures from all the sub-region pairs in the reference site, looking for the best match. If the best match is found for the (+N)′ th sub-region pair, for which the nominal shift is (−ΔX+NΔx), than we have:
[0000] (+Δ Xr +ξ)≈−(−Δ Xr+NΔx+ξ )
[0000] and therefore:
[0000] ξ≈(− NΔx )/2
[0033] Hence, the shift with the resolution of Δx/2 can be found by simply finding the best matching signature from the set.
[0034] If a significant range of shifts is to be covered by a small number of sub-region pairs in the reference site, Δx should be selected to be significantly larger than the required resolution. In this case, some interpolation method can be used in order to find the shift with improved accuracy. Interpolation can be done, for example, by calculating the RMS (root mean square) of the difference between the measurement site signature and all reference site signatures, fitting all or part of the results to a polynomial function of the shift and finding the shift providing minimum RMS difference in signatures. Another optional interpolation method is using a learning system, which is trained using the reference site data to return the shift, and measurement site data is used as input for interpretation. Comparing the reference site method to the direct method, the reference site method is advantageously self-calibrating, i.e., there is no need to realize the potentially complex details about how the diffraction signature was created, including materials properties and exact geometry (e.g. CD, line profile), as long as these are constant for all involved sites. The reference site method, however, requires a larger area on the sample occupied by a test site and a larger number of measurements, requiring more time.
[0035] In yet another embodiment of the invention, a calibration method may be used. In this method, a test site similar to the test site 20 of FIGS. 2A and 2B (suitable to be used for direct method) but including only two grating-containing sub-region pairs B 1 -B 2 and C 1 -C 2 is used. Here, similarly to the direct method, the difference between the diffraction signatures measured on both sub-region pairs is determined, but, in distinction to the direct method, the resulting signature is not fitted to a theoretical signature, but is rather interpreted using a previously performed calibration stage. In the calibration stage, the signature (or only some sensitive e points thereof) is determined as a function of alignment error values, being measured by a suitable reference tool (e.g., ordinary microscope). To this end, a test sample (e.g., semiconductor wafer) is specifically prepared with several alignment shifts, and measured off-line to make a record of the calibration results and keep it as reference data.
[0036] In accordance with still another embodiment of the test structure may contain a two-dimensional grating enabling the measurement of the X and the Y components of the lateral shift at the same site. In that case, in order to avoid the possibility to confuse between the X and the Y components further several methods may be used. In accordance with one embodiment, test site is prepared, comprising two dimension grating with a period in the Y-axis significantly different than the period in the X-axis. In accordance with another embodiment polarized reflectometry technique may be used to measure the same site several times with different polarizations. Finally, the same site may be measured from different directions (with different orientation). All the above methods result in different changes to the diffraction signatures due to shifts in different directions, thus avoiding confusion.
[0037] Reference is now made to FIGS. 4-6 showing different simulation results of the sensitivity test as functions of grating parameters. FIG. 4 illustrates the sensitivity test as a function of Al grating depth (H Al ) and shift S using the test structure of FIG. 1 with the following parameters: CD PR =150 nm, CD Al =300 nm, P=800 nm and H PR =600 nm. FIG. 5 illustrates the sensitivity test as a function of Al grating depth (H Al ) and grating period P using the test structure of the following parameters: CD PR =150 nm, CD Al =300 nm, H PR =600 nm and S=75 nm. FIG. 6 illustrates the sensitivity test as a function of Al grating depth using the test structure of the following parameters: CD PR =150 nm, CD Al =300 nm, P=600 nm and H PR =600 nm. Two graphs R 1 and R 2 are shown corresponding, respectively, to TM and TE polarization modes of incident radiation relative to the grating orientation.
[0038] FIG. 7 illustrates the effect of a 5 nm overlay error on a scatterometry signal (diffraction efficiency) measured on the optimal structure with the TM polarization mode. Two diffraction signatures SG 1 and SG 2 are shown corresponding, respectively, to a sample with no lateral shift between the layers (i.e., overlay is zero) and to a sample with a 5 nm overlay error.
[0039] Obviously, many modifications and variations of the present invention are possible in the light of the above teachings. For example, in the reference site based method grating-pairs located in sub-region pairs may be characterized by pre-determined arbitrary nominal shifts.
[0040] Those skilled in the art will readily appreciate that many modifications and changes may be applied to the invention as hereinbefore exemplified without departing from its scope, as defined in and by the appended claims. | Alignment of layers during manufacture of a multi-layer sample is controlled by applying optical measurements to a measurement site in the sample. The measurement site includes two diffractive structures located one above the other in two different layers, respectively. The optical measurements include at least two measurements with different polarization states of incident light, each measurement including illuminating the measurement site so as to illuminate one of the diffractive structures through the other. The diffraction properties of the measurement site are indicative of a lateral shift between the diffractive structures. The diffraction properties detected are analyzed for the different polarization states of the incident light to determine an existing lateral shift between the layers. | 6 |
This is a continuation-in-part of application Ser. No. 776,758, filed Mar. 11, 1977, and now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates generally to a transmissive body of high density polycrystalline alumina exhibiting improved total optical transmission as well as in-line transmission. A tubular form of the optically improved material when used as the light transmissive envelope for the high intensity electric discharge lamp provides higher light output than can generally be obtained with conventional polycrystalline alumina material. Such improvement is attributable to uniformity in the size and shape of the individual alumina grains along with substantial absence of pores and any secondary phase at the grain boundaries in said material.
The polycrystalline alumina material made in accordance with U.S. Pat. No. 3,026,210- Coble, assigned to the assignee of the present invention, has proven generally useful for the light transmissive envelope in high intensity electric discharge lamps. This polycrystalline alumina material is characterized by relatively uniform large grain size and can be prepared with a minimum of secondary phase magnesia-alumina spinel at the grain boundaries in order to provide optimum in-line transmission. A number of further modified polycrystalline alumina materials are also known which are said to exhibit improved in-line transmission attributable to either an addition of various grain-growth inhibiting agents in the powdered alumina mixture along with magnesia or other wise varying the method of preparation. For example, a uniform grain structure of reduced size is said to be achieved in U.S. Pat. No. 3,711,585 and No. 3,792,142 by adding lanthana and/or yttria along with magnesia to the pure alumina powder to provide combined in-line transmission improvement and greater mechanical strength. A different approach which does not include any addition of grain-growth inhibiting oxides other than magnesia to achieve the same kind of improvement is described in U.S. Pat. No. 3,311,482 where a small size and uniform grain structure is said to be obtained by modifying the sintering conditions. All said variations do not eliminate secondary phase in the final sintered product, however, which contributes to reduce in-line transmission by reason of differences in refractive index between alumina and the secondary phase material.
It has further long been recognized in U.S. Pat. No. 3,026,177, assigned to the present assignee, that residual pore in the final sintered product must also be suppressed for optimum in-line transmission. A recent investigation finds that a pore volume fraction as small as 10 -2 -10 -3 can be primarily responsible for light scattering in polycrystalline alumina material and thereby have more of a detrimental effect that either grain boundary or secondary phase scattering. The means utilized to reduce porosity in accordance with this patented method of preparation features no use of a grain growth inhibiting additive in the powdered alumina starting material in combination with a two-stage sintering technique said to enhance removal of residual trapped pores. Such necessity for double sintering under special conditions and the attendant cost involved, however, has not lead to significant commercialization of said method.
The light output or luminuous output of high intensity electric discharge lamps, especially sodium vapor lamps, depends upon the optical transmission of the light transmissive envelope wherein the arc discharge is generated. More particularly, the in-line transmission characteristics of said envelope are especially critical since passage of the emitted radiation without internal reflection has important advantages. Internal reflection of the generated radiation within said lamp envelope can result in significant absorption of the reflected radiation by the arc discharge. Passage of the generated radiation through the lamp envelope walls without reflection also affects heat flow and temperature distribution for the lamp in a desirable manner. By minimizing such internal reflection for improved in-line transmission, it has been found that the lamp envelope walls run significantly cooler which can permit lamp redesign to run the arc discharge at higher temperatures for both greater efficiency and a more desirable whiter color of lamp emission. Consequently, there is a continuing need to provide still greater in-line transmission for polycrystalline alumina material and in a manner which does not require costly modification of existing commercial manufacture.
SUMMARY OF THE INVENTION
It has been found, surprisingly, that in-line transmission of polycrystalline alumina material can be significantly increased to such a degree that the light output characteristics of high intensity electric discharge lamps utilizing the improved material reflects this change. Such improvement results from an increase in total optical transmission between about 0.5 to 1 percent which is further accompanied by a two- to three-fold increase in the in-line transmission of the improved material compared to the previously manufactured product. specifically, these improvements are attributable to utilizing a sintered body of polycrystalline alumina material consisting essentially of relatively uniform size equiaxed grains of alumina containing no more than about 150 parts per million of magnesium but essentially devoid of both secondary phase and residual pores. The total optical transmission of the improved material has been found to be at least 93 percent at a 0.75 mm sample thickness for the entire visible wavelength range. As a still further improvement, it has also been found that the flux polishing treatment of said material taught in U.S. Pat. No. 3,935,495 produces additional increase of in-line transmission for the flux polished material. The flux polishing can be further characterized as a reduction of the high spots on the individual surface alumina grains without materially etching the grain boundaries. A method of preparing the improved material that provides an average grain size of approximately 26 microns diameter and where substantially all grains have an average diameter in the range extending from about 20 microns diameter up to about 35 microns diameter is hereinafter described for the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a jacketed high pressure sodium vapor lamp embodying the improved polycrystalline alumina material of the present invention; and
FIG. 2 is a sectional view of an electrode configuration for the lamp depicted in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A high intensity sodium vapor discharge lamp in which the invention may be embodied as illustrated at 1 in FIG. 1 and comprises an outer vitreous envelope or jacket 2 of elongated ovoid shape. The neck 3 of the jacket is closed by a re-entrance stem 4 having a press seal 5 through which extends stiff in-lead wires 6 and 7 which are connected at their outer ends to the threaded shell 8 and center contact 9 of a conventional screw base. The inner envelope or arc tube 11 is made with sintered high density polycrystalline alumina material of the present invention to provide increased in-line optical transmission to a degree more fully explained hereinafter. The ends of the tube are closed by thimblelike niobium metal end caps 12 and 13 which have been hermetically sealed to the improved alumina arc tube by means of a glass sealing composition which is shown exaggerated in thickness at 14 in FIG. 2.
Thermionic electrodes 15 are mounted on the ends of the improved arc tube. As best seen in FIG. 2, the electrode comprises an inner tungsten wire coil 16 which is wound over tungsten shank 17 crimped or welded in the end of a niobium tube 18 welded to the end cap. The central turns of the inner coil 16 are spread apart and the outer tungsten wire coil 19 is screwed over the inner coil. A suitable electron emissive mix may be applied to the electrode coils by painting or alternatively by dipping the coils in the emissive mix suspension. The material is retained primarily in the interstices between the turns of outer and inner coil and of inner coil and shank.
Lower tube 18 is pierced through at 21 and is used as an exhaust tube during manufacture of said lamp. After the gas filling sodium mercury amalgam has been introduced into the arc tube, exhaust tube 18 is hermetically pinched off by a cold weld indicated at 22 and serves thereafter as a reservoir for condensed sodium mercury amalgam. Upper tube 18' has no opening in the arc tube and is used to contain a small amount of yttrium metal (not shown) which serves as a getter; the end of the tube is closed by a pinch 23 which forms a hermetic seal. The illustrated lamp is limited to a base-down operation wherein the longer exhaust tube 18, which must be the coolest portion of the arc tube for the amalgam to condense therein, is located lowermost.
The arc tube is supported within the outer envelope by means of a mount comprising a single rod 25 which extends the length of the envelope from in-lead 7 at the stem end to a dimple 26 at the dome end to which it is anchored by a resilient clamp 27. End cap 13 of the improved arc tube is connected to the frame by band 29 while end cap 12 is connected to in-lead 6 through band 30 and support rod 31. The inter-envelope space is desirably evacuated in order to conserve heat; that is done prior to sealing off the outer jacket. A getter, suitably barium-aluminum alloy powder pressed into channeled rings 32 is flashed after sealing in order to insure a high vacuum. A method of manufacturing this type lamp construction is further disclosed in U.S. Pat. No. 3,708,710, hence need not be repeated in connection with the present invention.
Basically, the present improved polycrystalline alumina material is prepared in accordance with the general method taught in the aforementioned Coble patent. Said known method sinters a pressed compact of finely divided alumina powder containing from a small but effective amount up to 0.5 weight percent of finely divided magnesia at elevated temperatures in the range 1700°-1950° C. in an environment selected from the group consisting of vacuum and hydrogen for a sufficient time period to produce a sintered alumina grain structure which desirably retains little or essentially no secondary magnesia alumina 99 phase at the grain boundaries. As further disclosed in said reference patent, the purity of the alumina starting material in said powdered mixture is maintaining about 99 percent purity in order to reduce the amount of secondary phase formation that adversely affects transparency of the final body, especially the in-line transmission through excessive light scattering. Along with said general method of sintering preparation, ther is also disclosed in said Coble patent the general technique for measuring total and in-line optical transmission of the sintered body of polycrystalline alumina material which makes it unnecessary to repeat such details in the present specification.
As regards the present departure from the prior art teachings of Coble, however, a particularly reactive alumina starting material has been selected which can be characterized by an even lower level of impurities and more uniform particle size distribution than heretofore used. The present starting material is 99.99 percent pure alumina which is substantially devoid of any grain-growth promoting impurities such as sodium and iron. The present starting alumina material is further characterized by a relatively uniform particle size of submicron diameter which excludes any agglomerates in size exceeding about 10 microns diameter and further demonstrates a relatively uniform surface area of approximately 8-9 square meters per gram. Additionally, the magnesia content in the starting alumina powder mixture is also maintained at 0.1% by weight or less to insure no secondary magnesia alumina spinel phase in the final sintered product. In the preferred method of preparation, a conventional binder and lubricant is incorporated in said powder mixture to permit extrusion of a pressed compact in the form of tubing and which further requires a presintering step as disclosed in the aforementioned Coble reference in order to remove these further additives prior to sintering. Accordingly, such presintering is carried out in an oxygen containing atmosphere at a temperature from about 950° C. to about 1200° C. before the final sintering operation. The pressed compact has a green density of at least 30 percent of the theoretical density for a single crystal of alumina and about 15 percent shrinkage of said compact occurs during the aforementioned presintering step. A detailed example for the preferred method of preparation is give to more fully described practice of the present invention.
EXAMPLE
Approximately 8.75 kilograms of high purity alumina powder having the particle size distribution and impurities level above set forth was dry milled for approximately 70 minutes in a vibratory mill after admixture with approximately 8.75 grams of finely divided magnesia. Said admixture was then blended with about 2200 grams of a liquid binder suspension (3 percent by weight organic binder) and 425 grams of a stearate lubricant to prepare a blended admixture suitable for extruding the material in tubular form. The blended admixture was then compacted in an extruder in conventional fashion at a total force in the range 20-35 tons to form the desired shape of pressed compact. The green density of the tubing prepared in this manner reached at least 30-35 percent of the theoretical density for a single crystal of alumina. The green tubing was next presintered in a conventional resistance element furnace utilizing an air atmosphere and heated to about 950°-1000° C. The presintering schedule being employed held the material at said elevated temperatures for approximately 4-6 hours and was further accompanied by slow rates of heating and cooling to avoid adverse temperature effects. The final sintering schedule consisted of firing the presintered material at approximately 1900° C. for about 4 hours in an electric furnace provided with a hydrogen atmosphere.
The optical transmission characteristics of the final sintered product prepared in the foregoing manner were measured employing the same general measurement technique described in the aforementioned Coble patent. Unpolished tubing samples having an approximate 0.75 mm wall thickness were measured. These transmission values were also compared with a sintered polycrystalline alumina product obtained by the same method of preparation above described but utilizing conventional alumina powder in the starting admixture. The conventional sintered product exhibited a total transmission over the visible wavelength spectral region of 92.3 percent as compared with 93.5 percent for the sintered product of the present invention. Correspondingly, the present sintered product exhibited in-line transmission values of 43 and 67 (in arbitrary units) as compared with in-line transmission values of 23.6 and 36.5 for the conventional product over a wavelength region extending from 0.2 micron wavelength to 4.0 microns wavelength.
Further visual comparison of the above respective sintered products was conducted to provide better understanding of the surprising optical transmission improvements exhibited by the present product. While both sintered materials were found to have an average grain size of approximately 26 microns diameter and a relatively uniform equiaxed grain size distribution extending from about 20 microns diameter up to about 35 microns diameter, there was found a notable difference between said materials as regards the nature of optical discontinuities existing at the grain boundaries. The present material was found to be substantially devoid of both pores and secondary phase inclusions at the grain boundaries whereas the conventional product contained a far greater number of residual pores. From this difference combined with a further observation that the conventional product did not contain any large concentration of secondary phase inclusions at the grain boundaries, it can be concluded that residual porosity is the primary cause of lower in-line transmission for sintered polycrystalline alumina having no more than about 150 ppm residual magnesium content in the sintered product. It can further be concluded from said observations that a porosity volume fraction as little as 0.01-0.001 can be responsible for substantially lower in-line transmission so that reducing the residual porosity to a 10 -4 volume fraction level should provide in-line transmission comparable to that obtained with a single crystal of alumina. | Increased optical transmission is provided for a body of light transmissive polycrystalline alumina having relatively uniform size equiaxed grains of alumina and which is essentially free of porosity and secondary phase material. A tube of the improved optical material can be used as the light transmissive envelope for high intensity discharge lamps especially sodium and other metal vapor lamps exhibiting increased light output as a result of said improved optical transmission. A method of producing the improved optical material is also disclosed. | 7 |
RELATED APPLICATION
[0001] This application claims the priority benefit of European Patent Application 12177506.8 filed on Jul. 23, 2012, the entirety of which is hereby incorporated by reference.
TECHNICAL FIELD
[0002] The present disclosure relates to methods for controlling a laundry drying machine with a heat pump system comprising a process air circuit including a rotating drum, a blower and a heater; a refrigerant circuit including a compressor, a condenser, an expansion device, an evaporator, the condenser and evaporator being in heat exchange relationship with the process air circuit, and an auxiliary condenser cooled by an air flow driven by a fan; and at least two temperature sensors placed respectively in the process air circuit and in the refrigerant circuit.
BACKGROUND
[0003] The so called “hybrid” heat pump dryers, in which the process air is heated either by the condenser of a refrigerant circuit and by an auxiliary heater are well known in the art. Moreover, a hybrid heat pump dryer having an auxiliary condenser with an auxiliary fan (cooled by ambient air) is known from European Patent Application EP 999302.
[0004] Usually such hybrid heat pump dryers, despite being very efficient in term of use of energy, offer to the user only a quite limited range of choices for the drying process, for instance degree of final humidity content of laundry, or long or short drying cycle. Such few and simple choices can on one hand limit the operational ranges of the machine, and on the other hand limit the possible choices of the users which may depend on several factors.
SUMMARY
[0005] The purpose of this disclosure is therefore a goal oriented control method, which increases the choices of the user, and which can particularly optimize a choice on low energy consumption, on cycle overall time, or on fabric care of a hybrid heat pump household tumble dryer, with an optimized balance between heating and cooling power.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Further advantages and features of the disclosed methods and laundry dryers according to the disclosure will become clear from the following detailed description, with reference to the attached drawings in which:
[0007] FIG. 1 is a schematic view of a hybrid heat pump tumble dryer;
[0008] FIG. 2 is a block diagram showing a dual loop control architecture according to the disclosure;
[0009] FIGS. 3-5 are examples of control implementations according to different choices of the user based on energy strategy, time strategy and fabric care strategy, respectively;
[0010] FIG. 6 is a block diagram showing a prior-art control loop;
[0011] FIG. 7 is a diagram showing the temperature and residual moisture content behavior in a dryer using the prior-art control system of FIG. 6 ; and
[0012] FIGS. 8-10 are diagrams showing example energy optimized cycle temperature behaviors, time optimized cycle temperature behaviors and fabric care optimized cycle temperature behaviors, respectively.
DETAILED DESCRIPTION
[0013] With reference to FIG. 1 , the process air circuit is the one that involves the evaporation of the water retained by the fabric and it is made up of a rotating drum 10 actuated by an electric motor and containing a certain amount of clothes, a process air blower 12 that sets the circuit process airflow, a condenser 14 and an heating element 16 that heat the air going inside the drum 10 , an evaporator 18 where the moisture contained in the process air can condense, an auxiliary condenser 20 (sub-cooler), a compressor 22 , an expansion tube 23 , and a fan 26 for cooling the auxiliary condenser 20 with ambient air.
[0014] The clothes dryer comprises also a NTC temperature sensor T 1 placed on the process air exhaust from the drum 10 , and a NTC sensor T 2 placed in the refrigerant circuit downstream from the compressor 22 , the temperature sensors T 1 and T 2 being connected to a control process unit 28 that drives all components of the clothes dryer according to certain processes.
[0015] The clothes dryer can also include also other components, for example, an accumulator upstream of the compressor 22 , which is not shown in FIG. 1 for sake of clarity.
[0016] An air channel conveys the process air to the evaporator 18 , where the vapor contained in the air condenses due to the low temperature.
[0017] The heat pump circuit is the one that involves the refrigerant that with its phase variation transfers heat to the air circuit. The temperature sensor T 2 that measures the refrigerant temperature may alternatively be placed in a position different from compressor outlet, for instance in the capillary tube or other places. The auxiliary fan 26 increases the heat exchange on the auxiliary condenser 20 .
[0018] Also the temperature sensor T 1 may be placed in a different position than the one shown in FIG. 1 , but in any case it is placed in the moist air circuit, by the drum outlet, the blower 12 or the evaporator 18 .
[0019] The second temperature sensor T 2 , instead of being placed in the refrigerant circuit, may alternatively be placed in the moist air circuit in a position different from the first sensor T 1 , for instance by the heater 16 , the condenser 14 , or the auxiliary condenser 20 .
[0020] The controllable variables of the system, which may be continuously adjusted or simply ON/OFF, are the compressor speed, the process air blower speed, the heating element power and the auxiliary fan speed.
[0021] Those variables are controlled in order to provide and remove the right quantity of energy respectively by means of the condenser 14 plus the heating element 16 and the evaporator 18 , by compromising between evaporation and condensation.
[0022] In the most of the cases, to reduce the cost of the system, the motors of the compressor 22 and the process air blower 12 are constant speed motors, therefore it is not possible to change their speeds.
[0023] According to a common practice of controlling the clothes dryer, the compressor 22 is kept on for the entire drying cycle while the heater 16 switches on/off in order to manage the temperature of the tumble dryer by feeding back the drum exhaust temperature measured by sensor T 1 . Indeed, the drum output temperature is usually a good approximation of the clothes temperature which is therefore kept under control.
[0024] Since it is required that the compressor stay on, due to inefficiency in turning off and on the heat pump system, and to prevent shifting in the working point of the system that would result in less energy removed in the evaporator 18 , thus less condensation and overheating of the compressor 22 , its temperature has to be controlled. Therefore when the temperature of the compressor 22 , sensed by sensor T 2 , reaches a certain value close to the high limit temperature switch off, the auxiliary fan 26 is turned on.
[0025] The feedback is usually made through hysteresis control, i.e. the heater 16 and the auxiliary fan 26 are switched on when the feedback temperature is below a predefined threshold and switched off when it is above a second predefined threshold.
[0026] Up to now we have described a dryer which can be controlled either according to prior art or according to the disclosure. As a matter of fact the main drawback of the known control system is the difficulty in creating a customized appliance behavior aiming to optimize system performances according to customer choices, who may desire to save energy, to save time or alternately to prefer a more gentle treatment of clothes, for instance by keeping the drying temperatures lower.
[0027] The methods according to the disclosure can control every component of the clothes dryer, and preferably both the auxiliary cooling fan 26 and the heater 16 of a tumble hybrid heat pump dryer, optimizing alternatively energy consumption, drying time or fabric care according to a selection made by the user by means of a user interface 30 . This selection can be done through a button, touch display, cycle selection, etc.
[0028] Once the user has made his/her selection, the system temperatures can be controlled by means of several actuators for the auxiliary cooling fan 26 , the heater 16 , the compressor 22 , and the process air blower 12 . The way all these actuators are used affects the overall system performances in terms of energy consumption, cycle duration, water extraction efficiency, final moisture retention at the end of the cycle, fabric care (wrinkles, shrinkage, etc.), etc..
[0029] The present disclosure provides therefore methods of choosing how to use these actuators in the different parts of a drying cycle.
[0030] The disclosure is effective even in the case of one or more of the actuators cannot be continuously controlled, e.g. fixed speed compressor, fixed speed fan, etc.
[0031] According to the disclosure, the drying cycle is conceptually divided in three phases of variable duration: warm up (WU), mid phase (MP) and cool down (CD). In the following descriptions, the three phases will be identified by means of two temperature measurements and cycle length.
[0032] In particular, naming:
[0033] t 0 =0 the beginning of the cycle,
[0034] t end the time at the end of the cycle,
[0035] t 20 =0.2*t end ,
[0036] t 50 =0.5*t end ,
[0037] t 70 =0.7* tend ,
[0038] t 80 =0.8*t end ,
[0039] T 1 — start the value of temperature T 1 measured at time t 0 ,
[0040] T 1 — mid the maximum value of temperature T 1 measured from t 0 to t 50 ,
[0041] T 1 — threshold =(T 1 — mid −T 1 — start )*0.8+T 1 — start ,
[0042] t r1 the first time at which the temperature T 1 is greater than T 1 — threshold ,
[0043] T 2 — start the value of temperature T 2 measured at time t 0 ,
[0044] T 2 — mid the maximum value of temperature T 2 measured from t 0 to t 50 ,
[0045] T 2 — threshold =(T 2 — mid −T 2 — start )*0.8+T 2 — start ,
[0046] t r2 the first time at which the temperature T 2 is greater than T 2 — threshold ,
[0047] t WU =min(t20, tr1, tr2)
[0048] t MP — start=max(t 20 , t WU *1.2)
[0049] t MP _end=t 70
[0050] tCD — start =t 80
[0051] The following definitions of the three phases of the cycle are given:
[0052] Warm up (WU): starts at time t 0 and ends at time t WU
[0053] Mid phase (MP): starts at time t MP — start and ends at time t MP — end
[0054] Cool down (CD): starts at time t CD — start and ends at time t end
[0055] Moreover, naming:
[0056] P WU the average power absorbed by the heating element during WU phase
[0057] P MP the average power absorbed by the heating element during MP phase
[0058] P CD the average power absorbed by the heating element during CD phase
[0059] S F — WU the average speed of the auxiliary fan during WU phase
[0060] S F — MP the average speed of the auxiliary fan during MP phase
[0061] S F — CD the average speed of the auxiliary fan during CD phase
[0062] S C — WU the average speed of the compressor during WU phase
[0063] S C — MP the average speed of the compressor during MP phase
[0064] S C — CD the average speed of the compressor during CD phase
[0065] S B — WU the average speed of the process air blower fan during WU phase
[0066] S B — MP the average speed of the process air blower fan during MP phase
[0067] S FB — CD the average speed of the process air blower fan during CD phase
[0068] In case of discrete control the averages are computed taking in account 0 as OFF and 1 as ON.
[0069] The disclosed controller 28 will be provided with the possibility to operate in at least two of the following cycles based on a selection made via the user interface 30 , to which the following values of parameters apply:
[0070] Energy Optimized Cycle, characterized by having:
[0000] P MP <0.2*P WU , P CD <0.2*P WU
[0000] S f — WU <0.25*S F — MP, S f — CD >S F — WU
[0000] S C — CD =<S C — MP, S C — CD =<S C — WU
[0000] S B — WU =<S B — MP =<S B — CD
[0071] Time Optimized Cycle, characterized by having:
[0000] 0.5*P WU <P MP <1.2*P WU , P CD <1.2*P WU
[0000] S f — WU <0.25*S F — MP , S f —CD >S F — WU
[0000] S C — CD =<S C — MP , S C — CD =<S C — WU
[0000] S B — WU =<S B — MP =<S B — CD
[0072] Fabric Care Optimized Cycle, characterized by having:
[0000] 0.2*P WU <P MP <0.5*P WU ,PCD<0.25*P WU
[0000] S f — WU <0.25*S F — MP , S f — CD >S F — WU
[0000] S C — CD =<S C — MP , S C — CD =<S C — WU
[0000] S B — WU =<S B — MP =<S B — CD
[0073] Of course the above parameter values are only examples and they can change depending on the actual dryer in which the methods according to the disclosure are implemented.
[0074] A conceptual scheme which is shown in FIG. 2 , changes both auxiliary fan motor speed and heating power according to two temperature measurements by the sensors T 1 and T 2 , thus controlling the energy delivered to the load inside the drum 10 and the energy removed from the refrigerant giving the possibility to optimize different system performance objectives.
[0075] One example of the possible implementations of the control strategy shown in FIG. 2 , considering for sake of simplicity that the process air blower 12 and compressor 22 are maintained at a constant speed during the cycle, for the energy, the time and the fabric care strategy are respectively drawn in the FIGS. 3-5 . In the examples of FIGS. 3-5 , the temperature sensed by sensor T 1 is the drum outlet temperature while the temperature sensed by sensor T 2 is the capillary temperature of the refrigerant circuit.
[0076] The control strategy according to the disclosure has been compared with a simple known strategy in which the hysteresis on T 1 controls the heater actuation while the hysteresis on T 2 controls the fan actuation, as shown in FIG. 6 , referred to a drying cycle of a 4 kg load.
[0077] With the control system shown in FIG. 6 , example results are shown in FIG. 7 , which shows an energy consumption of 1.69 kWh and a drying time around 92 minutes. In the diagrams, reference A indicates the temperature of process air entering the drum 10 , reference B indicates the temperature of air measured at the exhaust of the drum 10 , reference C indicates the capillary temperature of the refrigerant circuit, and reference D indicates the residual moisture content of the fabric inside the drum 10 .
[0078] The example energy optimized cycle shown in FIG. 8 (corresponding to the example control scheme of FIG. 3 ), reveals a lower energy consumption around 1.54 kWh (−9%) and a drying time around 98 minutes (+8%) compared to the control system of FIGS. 6 and 7 .
[0079] The example time optimized cycle shown in FIGS. 4 and 9 has a comparable energy consumption 1.72 kWh (+2%) and a comparable drying time, around 90 minutes (−1%).
[0080] The example fabric optimized cycle shown in FIGS. 5 and 10 keeps the fabric temperature low and avoids the temperature increase at the cycle end and therefore reduces the stress on the fabric. In terms of performances, the energy absorbed is slightly below the reference cycle of FIGS. 6 and 7 , i.e. 1.6 kWh (−5%) but the drying time is increased lasting 118 minutes (+29%). | A laundry drying machine with a heat pump system comprises a process air circuit including a rotating drum, a blower and a heater, a refrigerant circuit including a compressor, a condenser, an expansion device, an evaporator, the condenser and evaporator being in heat exchange relationship with the process air circuit, an auxiliary condenser cooled by an air flow driven by a fan, and at least two temperature sensors placed in the process air circuit and/or in the refrigerant circuit. A method for controlling the laundry drying machine includes receiving an input indicating a desired behavior of the laundry drying machine selected from the group consisting of optimized use of energy, overall drying time and fabric care, and controlling components of the machine according to signals from the two temperature sensors and according to the desired behavior. | 3 |
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DESCRIPTION OF PRIOR ART
Several containers have been provided in former art which present with collapsible walls. Examples of prior art which present with collapsible midsections include U.S. Pat. No. 4,775,564, which was issued Oct. 4, 1998 to Shriver, Clinton, Richeson, Canton, Vogliano, Tallmage, U.S. Pat. No. 36,377, which was reissued Nov. 9, 1999 to Neil Y. Gilbert, and U.S. Pat. No. 5,174,458, which was issued Dec. 29, 1992, Umberto D. I. Segati. In each example the inventions are improved upon in that the disclosed invention provides a means of handling the container, provides for axial support of the container in expanded form, and provides for a means of supporting and retaining the container in collapsed form. These improvements are attributable to a handle which is affixed to create a graspable, rigid spine when the container is in the expanded form. This also discloses the handle wherein it is affixed to prevent the axial expansion of the container when it is in its collapsed form.
Another form of collapsible container is disclosed in U.S. Pat. No. 6,047,848, which was issued Apr. 11, 2000 to Rex C. Davis. That patent disclosed a container with a collapsible midsection and a locking means to retain the container in the collapsed form. As in the case of the other examples of prior art, the retention of the Davis invention in its expanded form is directly dependent on the material of the flexible walls of the container having a thickness to normally enable self support of the container. The disclosed invention improves on the Davis invention in that the support of the container is supplemented by the disclosed handle. This provision allows for flexibility in materials used in construction and a reduction in wall thickness in appropriate instances.
Another improvement noted over the Davis invention in that the position of the handle in the disclosed invention provides for increased ease of handling of the container when dispensing solutions.
The disclosed invention presents with a flush profile of its top portion when in its fully collapsed and secured form. This flush profile is an improvement on the Davis invention in that projections, such as the securing cap, U-shaped top channel clamp, and vent cap disclosed in the David invention, are eliminated. The elimination of these projections increases packaging efficiency in stacking and storing units during transport, while the containers are being displayed for sale, and while being stored by the end user. An additional improvement attributable to the flush top surface of the disclosed invention is the provision for usable space on which product information can be placed without the need for secondary packaging.
Yet another improvement on prior art which this invention provides for is an increased level of product and consumer protection. The inadvertent displacement of a storage container's closure device is the most common mode of introducing contaminants into a container. In addition to providing a grasping means for the user, and a rigid support for the container is in its fully expanded form, this invention's handle secures the container closed in such a way as to fully protect the container's closure cap. The potential inadvertent displacement of the closure device from the container, and the introduction of contaminants through this route, is thereby substantially reduced.
Examples of prior art, which support methods of production for the disclosed main body of the invention, include U.S. Pat. No. 4,187,960, which was issued Feb. 12, 1980 to Bonk, and U.S. Pat. No. 4,213,933, which was issued Jul. 22, 1980 to Cambio. In both examples, a blow molding technique for plastics is disclosed. The main body of the disclosed invention may be produced in a plural cavity, two sided, blow mold format as referred to in U.S. Pat. No. 4,213,933, June 1980, Cambio.
BACKGROUND OF THE INVENTION
This invention relates to a collapsible container which is used for storing products requiring the addition of liquids prior to use. The collapsible container presents in two functional states. In a fully collapsed form, the collapsible container is used for the storage of evaporated, powdered, condensed, or concentrated products. In a fully expanded form, the collapsible container stores the evaporated, powdered, condensed, or concentrated products in a solution form. In addition, in a fully expanded form, the collapsible container functions as the mixing device and dispensing container for the products in solution form.
The packaging of products in evaporated, powdered, condensed, and concentrated forms provides for increased efficiency in the storage and distribution of the products. The increased storage and distribution efficiency is predominantly associated with decrease container size requirements. Additional benefits noted relate to increased product shelf life, and maintained product quality associated with evaporated, powdered, condensed, and concentrated products.
The preparation of the evaporated, powdered, condensed, and concentrated products to a usable form typically involves the use of secondary containers into which the products are dispensed, appropriate liquids are added, in which the products and liquids are brought into solution, and from which the liquids are dispensed. To bring the products and the added liquids into a usable solution, supplemental mixing devices, such as spatulas or long handled mixing spoons, are often required.
This invention eliminates the need for secondary containers and supplemental mixing devices while improving upon present packaging for evaporated, powdered, condensed, and concentrated products.
The invention eliminates the need for secondary storage and dispensing containers, as the collapsible container forms a functional pitcher-like storage and dispensing container when in its fully expanded form. The ability of the collapsible container to expand is attributable to the undulating accordion style walls or corragated walls of the collapsible container's midsection and to the material type used. A pitcher-like form is attained when opposing forces are placed along the long axis of the container. The opposing forces lead to the elongation of the midsection and a corresponding increase of the container's overall vertical dimension. The material types which would allow for this action and associated forces may be selected from metal foils, polymers, elastomers, plastics, and paper based products. When the inventions multi-functional U-shaped handle is attached, the collapsible container takes on the form of a functional pitcher.
Supplemental mixing devices are eliminated as mixing of the added liquids and evaporated, powdered, condensed, or concentrated products is undertaken by briskly shaking the container until the desired solution consistency is reached. The undulating accordion style walls of the container's collapsible midsection assists with the incorporation of the added liquid and the stored product by acting as a resistance form.
Consumers appreciate time, money, and energy savings as the need to purchase, use, store and clean secondary storage containers and supplemental mixing devices is eliminated.
In its fully collapsed form the invention is generally cubical in nature. This feature provides for increased efficiency in storage and bulk packaging of multiple units both from a manufacturing and retail standpoint when compared to exiting packaging forms.
A specific example where the general cubical configuration of the collapsible container will be a distinct improvement is in its use with frozen juice concentrates. Present container systems for frozen juice concentrate are typically cylindrical. The cylindrical shapes of the existing containers are inefficient in terms of space use, are unstable when stacked, and are difficult to handle. The generally cubical nature of this invention provides for efficient space use as the containers may be placed in direct contact with one another in a consistent manner. In addition, this invention provides for stability when stacking, and the physical handling characteristics are far greater than those of cylindrical form.
When compared to the cylindrical container form of frozen juice concentrate containers, an additional benefit attributable to the generally cubical form comes in the form of an increase in readily visible surface area. This feature allows for additional surface area for the presentation of product information and display advertising by the manufacturer.
This invention's most unique feature, when compared to existing storage devices and previous art, is its U-shaped handle. The U-shaped handle performs the function of being a means by which secure the container closed and protect its closure cap, provides a method by which to grasp the container, and is the dominant means by which the container is supported both in its fully expanded and fully collapsed forms.
In its fully expanded form, the U-shaped handle forms a rigid supporting spine. This feature improves upon existing storage devices and existing art in that the retention of the expanded form is no longer strictly dependent on the self-supporting characteristic of the materials used to form the walls of the container. The handle's U-shaped action as a supporting spine or bight therefore allows for a diversity in materials types and material thickness to be used in construction of the container's body. In addition to forming a rigid supporting spine, or bight the U-shaped handle acts as a functional means by which to grasp the container when the container is in its fully expanded form.
Yet another improvement on existing storage devices and prior art which this product provides for is an increased level of product and consumer protection. The inadvertent displacement of a storage container's closure device is the most common mode of introducing contaminants into a container. When the invention's U-shaped handle secures the container in its fully collapsed form, the container's closure cap is fully covered by the U-shaped handle, making access to the closure cap possible only upon displacement of the handle. The potential inadvertent displacement of the closure device from the container, and the introduction of contaminants through this route, is substantially reduced.
In its fully collapsed form, the collapsible container is inherently rigid and can withstand stresses which surpass existing single walled, non-collapsible container types. In its collapsed forms the undulating walls of accordion style or corrugated style compress to form a wall which is the thickness of one plain of the accordion fold. With the accordion folds starked upon one another, the sides of the container are particularly resistant to damage from lateral impacts. While in its fully collapsed form the U-shaped handle acts to further protect the container from lateral impact and provides a resistance form to vertical compression.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 . is a side schematic elevated view of the container in its fully expanded form. Shown are the following components: rectangular top portion ( 1 ); collapsible rectangular midsection in its fully expanded form ( 2 ); rectangular base portion ( 3 ); U-shaped handle ( 4 ) locked into rear of the top rectangular portion ( 1 ) and into the rear of the rectangular base portion ( 2 ) to accommodate securing the container in its fully expanded form; threaded cap ( 5 ) secured in place; U-shaped handle inset or recess ( 11 ); cap inset or recess 12 .
FIG. 2 . is a side schematic elevated view of the container in its fully collapsed form. Shown are the following components: top rectangular portion ( 1 ); collapsible rectangular midsection in its fully collapsed form ( 2 ); rectangular base portion ( 3 ); U-shaped handle ( 4 ) locked in place to accommodate securing the container in its fully collapsed form.
FIG. 3 . is a cross-sectional schematic view of the side of the presently preferred embodiment of the storage container; the cross-section passes along the middle plane from the back through the front of the container. The collapsible container is shown in its fully expanded form wherein the U-shaped handle ( 4 ) is connected via the male handle connector mechanism or bead on the handle base ( 7 ) to the female handle connector mechanism or groove on the base portion rear side ( 8 ). In addition, the male handle connector mechanism or bead on the handle top ( 9 ) is attached to the female handle connector mechanism or groove on the top portion rear side ( 10 ). The threaded cap ( 5 ) is shown detached from the threaded inlet ( 6 ). Other components shown are include: rectangular top portion ( 1 ); collapsible midsection in its fully expanded form ( 2 ); rectangular base portion ( 3 ); handle inset or recess ( 11 ); cap inset or recess ( 12 ); female handle connector mechanism or groove on the base portion front side ( 13 ).
FIG. 4 . is a cross-sectional schematic view of the side of the presently preferred embodiment of the storage container; the cross-section passes along the middle plane from the back through the front of the container. The collapsible container is shown in its fully collapsed form wherein the U-shaped handle ( 4 ) is connected via the male handle connector mechanism or bead on the handle base ( 7 ) to the female handle connector mechanism or groove on the base portion rear side ( 8 ). In addition, the male handle connector mechanism on the handle top ( 9 ) is attached to the female handle connector mechanism on the base portion front side ( 13 ). The threaded cap ( 5 ) is shown attached to the threaded inlet ( 6 ). The U-shaped handle ( 4 ) is shown resting in the handle inset or recess ( 11 ). Other components shown are: rectangular top portion ( 1 ); collapsible rectangular midsection ( 2 ); rectangular base portion ( 3 ); cap inset or recess ( 12 ); female handle connector mechanism or groove on the rectangular top portion rear side ( 10 ).
DESCRIPTION OF PREFERRED EMBODIMENT
The presently preferred best mode for carrying out the present invention is illustrated by way of FIGS. 1 to 4 .
The best mode of carrying out the invention would present with a main body, as illustrated in FIG. 1, which consists of a top rectangular portion ( 1 ), a collapsible rectangular midsection ( 2 ), and a base rectangular portion ( 3 ). The top portion ( 1 ), collapsible midsection ( 2 ), and base portion ( 3 ,) form a hollow, four-walled container with a base and a top. The top portion ( 1 ) has solid walls, which continue to the collapsible midsection ( 2 ), which in turn continues to form the base portion ( 3 ), which then terminates in a solid walled base.
The collapsible container presents with a fully collapsible and fully expandable form. The collapsible midsection, formed of undulating walls of accordion style, provides for both forms. Referring to FIG. 1, the collapsible container is presented in its fully expanded form, wherein the collapsible midsection ( 2 ) is in its fully expanded form. Referring to FIG. 2, the container is in its fully collapsed form wherein the collapsible midsection ( 2 ) is in its fully collapsed form.
The ability of the collapsible midsection to transform from a fully collapsed state to a fully expanded state is attributable to the mechanical characteristics of the undulating walls of accordion style and material types used in construction. The material type used in the construction of the midsection must therefore possess the characteristics of being reasonably able to withstand stresses associated with the axial mechanical expansion and compression forces necessary to transform from one to the other state. Material types which would accommodate this requirement may be selected from metal foils, polymers, elastomers, plastics, and paper based products.
In its use as a storage container for solutions, the characteristics of the main body of the container would include a reasonable degree of fluid impermeability. The material type used in construction of the container will vary to accommodate the storage requirements of the stored products in their evaporated, powdered, condensed, and concentrated forms as wells as in their respective final solution forms. Material types which would accommodate this requirement may be selected from metals, metal foils, polymers, elastomers, plastics, and paper based products. The ideal material type to be used would have the additional characteristic of being recyclable.
To minimize material waste in the construction of the collapsible container the overall size of the container will vary to accommodate product requirements. Referring to FIG. 1, the base portion ( 3 ) of the product is sized to minimally contain products in their evaporated, powdered, condensed, and concentrated forms. The collapsible midsection ( 2 ) is sized to minimally to contain the added liquid to bring the above mention products in solution. The top portion ( 1 ) is designed to provide housing of the handle ( 4 ) and the threaded cap ( 5 ). The container is designed to provide a minimal profile both in its fully collapsed and fully expanded forms.
The transformation of the collapsible container from its fully collapsed form, as shown in FIG. 2, to its fully expanded form, as shown in FIG. 1, is best illustrated in the following manner:
Referring to FIG. 4, detach the male handle connector mechanism or bead on the handle top ( 9 ) from the female handle connector mechanism or groove on the base portion front side ( 13 ); swing the handle ( 4 ) over the top portion ( 1 ) such the handle clears the top portion ( 1 ); partially detach the threaded cap ( 5 ) from the threaded inlet ( 6 ) to allow for relief of the vacuum within the container; place simultaneous opposing forces on the top portion ( 1 ) and the base portion ( 3 ) of the container such that the expansion of the expandable midsection ( 2 ) occurs until the collapsible midsection ( 2 ) is expanded to the form shown in FIG. 1 . Referring to FIG. 3, attach the male handle connector mechanism or bead on the handle top ( 9 ) to the female handle connector mechanism or groove on the top portion rear side ( 10 ). Reversing this process would allow for the collapse of the container from its fully expanded form as shown in FIG. 1, to its fully collapsed form as shown in FIG. 4 .
Once in its expanded form as shown in FIG. 3, the threaded cap ( 5 ) is removed from the threaded inlet ( 6 ) and the added liquid is dispensed into the collapsible container through the threaded inlet ( 6 ). The threaded cap ( 5 ) is then replaced and the user shakes the container to bring the added liquid and the evaporated, powdered, condensed, and concentrated product into solution. The solution may then be dispensed for use from the threaded inlet ( 6 ).
The user may remix the solution as necessary by shaking the container appropriately. The container may be used for alternative storage purposes post dispensing of the original solution. The container is ideally disposed of for recycling in its fully collapsed form. This minimizes recyclable product storage space requirements for the user and recycling facilities.
The best mode of carrying out the invention would be to utilize a blow molding process of a Food and Drug Administration approved, recyclable plastic, which would included attributes of providing ultraviolet light protection for the stored product and having the characteristic of being able to withstand frozen storage. In this configuration the collapsible container would likely have the broadest range of use and would be efficiently manufactured. | A collapsible container is disclosed having a top portion and base portion joined by a midsection of undulating walls of accordion style which allows for the axial compression and expansion of the container. A U-shaped handle is also disclosed which provides for grasping of the container, provides axial stability when the container is in its fully expanded form, secures the container in its fully collapsed form, and protects the container's closure mechanism. | 8 |
This application is a 371 of PCT/FR92/00936, filed Oct. 8, 1992.
FIELD OF THE INVENTION
The present invention relates to fluoro-3quinolinecarboxylic acid derivatives of general formula: ##STR2## in which R is a hydrogen atom or an alkyl radical and Hal is a halogen atom, as well as its salts where they exist.
BACKGROUND OF THE INVENTION
6-Fluoroquinolinecarboxylic acids of structure: ##STR3## in which Hal is a fluorine or chlorine atom, which are useful as intermediates for the preparation of benzo[1,8]naphthyridines having antimicrobial activity, have been described in U.S. Pat. No. 4,970,213.
DESCRIPTION OF THE INVENTION
The preparation of fused pyrimidines, via 2-amino-3-quinolinecarboxamide (or via the corresponding ester or acid) or else, according to another alternative, via alkyl 2-chloro-3-quinolinecarboxylate, has been described in French Patent Application 2,225,166.
Carbostyril derivatives substituted with an azido group or a nitrogen-containing group and with alkyl, alkyloxy, hydroxyl, halogen, etc., radicals have been described in European Application 236,140.
The new quinoline derivatives according to the present invention are also useful for the preparation of antimicrobial benzo[1,8 ]naphthyridine derivatives, but enable improved yields to be obtained and thereby avoid the use of the process involving unstable intermediate products.
In the general formula (I), when R represents an alkyl radical, the latter is unbranched or branched and contains 1 to 4 carbon atoms; moreover, the symbol Hal is advantageously chosen from chlorine and fluorine.
According to the present invention, the new quinoline derivatives of general formula (I) may be prepared by cyclization in an acidic reducing medium of a nitro derivative of general formula: ##STR4## in which Hal is defined as before, R 1 is defined like R with the exception of representing a hydrogen atom and R 2 is defined as COOR 1 or represents a carbamoyl or cyano radical, optionally followed by liberation of the acid function if it is desired to obtain a quinoline derivative for which R is a hydrogen atom.
The treatment in an acid medium is performed in the presence of iron, at a temperature of between 0° and 130° C., by means of any organic or inorganic acid which has no adverse effect on the remainder of the molecule. As an example, the reaction is performed using acetic acid or formic acid; it is also possible to perform it using dilute hydrochloric acid or dilute sulphuric acid in an aqueous-alcoholic medium. It is, of course, understood that the choice of acid is dependent on the product expected. In the case where it is desired to obtain the acid of general formula (I), it is advantageous to work in a stronger acid, under conditions in which hydrolysis of the ester takes place simultaneously; it can also be advantageous to perform the reaction using the product of general formula (II) for which R 2 is cyano. It is, of course, understood that, in cases where the ester has been obtained and where it is desired to obtain the acid of general formula (I) for which R is a hydrogen atom, the hydrolysis of the ester may also be carried out after the cyclization reaction, by any known method for obtaining an acid from an ester without affecting the remainder of the molecule.
Where appropriate, the hydrolysis of the ester is performed in an acid medium, e.g. in the presence of hydrochloric acid, sulphuric acid or methanesulphonic acid. It may also be performed in a basic aqueousalcoholic medium (e.g. sodium hydroxide, potassium hydroxide).
The nitro derivative of general formula (II) may be prepared by the action of a malonic acid derivative of general formula:
R.sub.2 --CH.sub.2 --COOR.sub.1 (III)
in which R 1 and R 2 are defined as before, on a nitrobenzaldehyde derivative of general formula: ##STR5## in which Hal is defined as before.
The reaction is generally performed in a basic medium [e.g. in the presence of an alkali metal bicarbonate (sodium bicarbonate), a hydride (sodium hydride) or an alcoholate [lacuna] at a temperature of between 0° and 150° C., in an organic solvent such as an anhydride (e.g. acetic anhydride) or such as an amide (e.g. dimethylformamide, N-methylpyrrolidone), working in the presence of molecular sieves or any other dehydrating agent, or alternatively in a mixture of solvents such as a polar aprotic solvent/acetic anhydride (e.g. dimethylformamide/acetic anhydride, N-methylpyrrolidone/acetic anhydride) mixture. It is also possible to work in a two-phase medium. It is not essential to isolate the product of general formula (II) in order to use it in the following reaction.
The fluoronitrobenzaldehyde of general formula (IV) is obtained by nitration of the fluorobenzaldehyde of general formula: ##STR6## in which Hal is defined as before.
The reaction is advantageously performed with concentrated nitric acid in the form of a nitric acid/sulphuric acid mixture or of a nitric acid/acetic acid mixture at a temperature of between 0° and 90° C.
4-Chloro-3-fluorobenzaldehyde may he prepared according to the method described in European Application EP 289,942.
According to the invention, the new fluoroquinoline derivatives of general formula (I) are useful as synthesis intermediates for the preparation of benzo[h][1,8]naphthyridine derivatives of general formula: ##STR7## in which either R 3 (which represents an alkyl or fluoroalkyl radical, a cycloalkyl radical containing 3 to 6 carbon atoms or an alkyloxy or an alkylamino radical) and Het (which is a nitrogenous heterocyclic radical) are as defined for the substituents at positions 1 and 8 in European Application EP 431,991 and U.S. Pat. No. 5,004,745, or R 3 is a hydrogen atom or an alkyl, fluoroalkyl or carboxyalkyl radical, a cycloalkyl radical containing 3 to 6 carbon atoms or a fluorophenyl, difluorophenyl, alkyloxy or alkylamino radical and Het is a substituted 1-azetidinyl radical (substituted at position 3 with a radical R 4 which can be a hydrogen atom or a hydroxyl or amino radical or an alkylamino radical in which the alkyl portion is optionally substituted with an amino or hydroxyl radical, or can represent a dialkylamino radical in which the alkyl portions, with the nitrogen atom to which they are attached, can optionally form a 5- or 6 membered heterocycle optionally containing another hetero atom chosen from nitrogen, oxygen and sulphur, or can represent a (3- to 6-membered cycloalkyl)amino radical or an alkanoylamino, N-alkyl-N-alkanoylamino or aminoalkylphenylamino radical, and substituted at positions 2 and 3 with identical or different radicals R 5 and R 6 which represent hydrogen atoms, alkyl radicals, alkenyl radicals containing 2 to 4 carbon atoms, phenyl radicals or phenyl radicals substituted with a halogen atom or with an alkyl, alkyloxy, hydroxyl, nitro, amino, alkylamino, dialkylamino or haloalkyl radical, or alternatively substituted at position 2 with radicals R 5 and R 6 which represent alkyl radicals), on the understanding that the alkyl and alkanoyl radicals mentioned above are unbranched or branched and contain 1 to 4 carbon atoms.
These benzonaphthyridine derivatives are useful as antimicrobials.
The quinoline derivatives according to the present invention are also useful for the preparation of the intermediates of general formula (XI) defined below, which are precursors of benzonapthyridine derivatives of general formula (VI).
According to the invention, the benzo[b][1,8]naphthyridines of general formula (VI) may be obtained from the products according to the invention by working in the following manner:
A chlorofluoro ester of general formula: ##STR8## in which Hal and R are defined as before, is prepared by chlorination of the fluoroquinolinecarboxylic acid derivative of general formula (I) in which, where appropriate, the acid function is protected beforehand (when R is a hydrogen atom).
The chlorination is performed by means of known chlorinating agents which have no adverse effect on the remainder of the molecule. In particular, the chlorination is performed by the action of phosphoryl chloride, sulfuryl chloride or phosphorus pentachloride at a temperature of between 0° and 150° C.
When it is desired to obtain the acid of general formula (VII) in which R is a hydrogen atom, hydrolysis of the ester obtained is performed by any known method which has no adverse effect on the remainder of the molecule. Protection and removal of the protective radical may be carried out with any compatible group whose use and removal have no adverse effect on the remainder of the molecule. In particular, the methods employed are those described by T. W. GREENE, Protective Groups in Organic Synthesis, A. Wiley Interscience Publication (1981), or by McOMIE, Protective Groups in Organic Chemistry, Plenum Press (1973).
The benzonaphthyridine derivative of general formula (VI) may be obtained from the chlorofluoroquinolinecarboxylic acid of general formula (VII) in which R is a hydrogen atom, according to the method described in European Application EP 431,991 and U.S. Pat. No. 5,004,745 or U.S. Pat. No. 4,970,213 or by a method analogous thereto.
The benzonaphthyridine derivative of general formula (VI) may also be obtained from the ester of general formula (VII) by working as follows:
An amine of general formula:
R.sub.3 --NH--CH.sub.2 --CH.sub.2 R.sub.7 (VIII)
in which R 3 is defined as before and R 7 is an alkyloxycarbonyl, cyano, carbamoyl, alkylcarbamoyl, benzylcarbamoyl or hydroxyethylcarbamoyl radical or a dialkylaminoethylcarbamoyl or dialkylcarbamoyl radical in which the alkyl portions, with the nitrogen atom to which they are attached, can optionally form a 5- or 6-membered heterocycle optionally containing another hetero atom chosen from oxygen, sulphur and nitrogen and optionally substituted on the nitrogen with an alkyl radical (the alkyl radicals being unbranched or branched and containing 1 to 4 carbon atoms), is condensed with a chlorofluoroquinoline of general formula (VII) in which R is an alkyl radical, so as to obtain a fluoro ester of general formula: ##STR9## in which Hal, R 3 and R 7 are defined as before.
The reaction is performed at a temperature of between -70° and 120° C. in the presence of a base such as an alcoholate (e.g. sodium ethylate, sodium methylate, potassium t-butylate), an alkali metal hydride (e.g. sodium hydride) or alternatively an alkali metal hydroxide, working under phase transfer conditions. It is advantageous to work in a polar aprotic solvent (e.g. dimethylformamide, tetrahydrofuran) or in an alcohol (e.g. ethanol, methanol), in a glyme or in a glycol (e.g. ethylene glycol). When the reaction is performed under phase transfer conditions, it is advantageous to work in a chlorinated solvent such as methylene chloride, the base being dissolved in the aqueous phase.
The 1,2,3,4-tetrahydrobenzo[b][1,8]naphthyridine of general formula (X) is oxidized to prepare the benzo[b][1,8]naphthyridine of general formula: ##STR10## in which Hal, R 3 and R 7 are defined as before.
The oxidation is performed with hydrogen peroxide, optionally in the presence of potassium iodide, in an organic solvent such as an alcohol (e.g. ethanol), at a temperature of between 0° and 120° C. It is also possible to work in a two-phase medium in a water/chlorinated solvent (dichloromethane, dichloroethane, etc.) mixture.
The heterocycle get is condensed with the benzo[b][1,8]naphthyridine of general formula (XI) or the corresponding acid to prepare a benzonaphthyridine derivative of general formula (VI), working according to the methods described in European Application EP 431,991 and U.S. Pat. No. 5,004,745 or by methods analogous thereto, and then, where appropriate, by converting the ester, amide or nitrile obtained to an acid of general formula (VI). The benzonaphthyridine derivatives of general formula (VI) are antimicrobials whose activities have been described in the European application and the US patent cited above. The benzonaphthyridine derivatives of general formula (VI) for which get is an azetidinyl radical also possess antibacterial properties. They manifest exceptional activity in vitro and in vivo against Gram-positive microorganisms and also against Gram-negative microorganisms. In vitro, they are active at a concentration of between 0.06 and 4 μg/cc against Staphylococcus aureus IP 8203, and at a concentration of between 0.25 and 20 μg/cc against Escherichia coli strain NIHJ JC2. In vivo, they are active against experimental Staphylococcus aureus IP 8203 infections of mice at oral doses of between 10 and 200 mg/kg.
The new products according to the present invention, as well as the products to which they lead, can be optionally purified by physical methods such as crystallization or chromatography.
The new intermediates of general formula (I) for which R is a hydrogen atom may be converted to metal salts or to addition salts with nitrogenous bases according to methods known per se. These salts may be obtained by the action of a metal-containing base (containing, e.g., an alkaline or alkaline earth metal), ammonia or an amine on a product according to the invention in a suitable solvent such as an alcohol, an ether or water, or by an exchange reaction with a salt of an organic acid. The salt formed precipitates after concentration, where appropriate, of its solution; it is separated by filtration, decantation or lyophilization.
As examples of salts, there may be mentioned the salts with alkali metals (sodium, potassium, lithium) or with alkaline earth metals (magnesium, calcium), the ammonium salt, salts of nitrogenous bases (ethanolamine, diethanolamine, trimethyls/nine, triethylamine, methylamine, propylamine, diisopropylamine, N,N-dimethylethanolamine, benzylamine, dicyclohexylamine, N-benzylphenethylamine, N,N'-dibenzylethylenediamine, diphenylenediamine, benzhydrylamine, quinine, choline, arginine, lysine, leucine, dibenzylamine) as well as the addition salts with inorganic acids (hydrochlorides, hydrobromides, sulphates, nitrates, phosphates) or organic acids (succinates, fumarates, maleates, methanesulphonates, p-toluenesulphonates, isethionates).
EXAMPLES
The examples which follow, given without implied limitation, illustrate the present invention.
EXAMPLE
62.8 g of ethyl malonate and 51 g of sodium bicarbonate are added with stirring in the course of ten minutes to a solution of 56.5 g of 3,4-difluoro-6-nitrobenzaldehyde in 92 cm 3 of acetic anhydride. The suspension is maintained for 1 hour at approximately 20° C. and then heated to a temperature of approximately 75° C. for 3 hours. 400 cm 3 of glacial acetic acid and then 65 cm 3 of water are introduced in the course of 30 minutes at this temperature. The temperature is allowed to stabilize at approximately 50° C. and the mixture is stirred for a further 30 minutes at this temperature. 39 g of powdered iron are added portionwise in the course of 2 hours to the reaction mixture. The temperature rises to approximately 85° C. and the suspension is maintained for a further 1 hour at this temperature. The iron salts formed are drained at approximately 80° C. and then washed with twice 150 cm 3 of glacial acetic acid. The filtrate and the acid washing phases are combined and treated with 700 cm 3 of water. The precipitate obtained is drained at approximately 20° C. and washed with 3 times 500 cm 3 of water. The wet product obtained is dried under reduced pressure (20 kPa) at approximately 50° C. 53.5 g of 3-ethoxycarbonyl-6,7-difluorocarbostyril are obtained in the form of a cream-colored solid, melting point 242° C.
3,4,-Difluoro-6-nitrobenzaldehyde is prepared in the following manner:
To 520 cm 3 of sulphuric acid, stirred and cooled to 0° C., 60 cm 3 of fuming nitric acid are added in the course of 30 minutes. 100 g of 3,4-difluorobenzaldehyde are added in the course of 30 minutes at approximately 0° C. to the solution obtained. The temperature is allowed to rise to approximately 20° C. and the mixture is stirred for a further 3 hours at this temperature. After cooling to approximately 5° C., the reaction mixture is introduced in the course of 30 minutes with vigorous stirring into 1,200 g of crushed ice. The temperature is allowed to rise to approximately 20° C. and the mixture is extracted with twice 600 cm 3 of toluene. The combined organic extracts are washed with 3 times 1,000 cm 3 of water and concentrated under reduced pressure (20 kPa) to 50° C. 113 g of 3,4 -difluoro-6-nitrobenzaldehyde are obtained in the form of a brown oil, which is used in the subsequent syntheses without further treatment. A purified sample of 3,4-difluoro-6-nitrobenzaldehyde gives the following characteristics:
B.p. (6.66 kPa)=46° C. NMR spectrum (400 MHz, DMSO, T=298° CK.) 10.20 ppm (1H, 1s); 8.5 ppm (1H, 1q); 8.05 ppm (1H, 1q) The products according to the invention may be used in the following manner:
Application Example 1
50 g of 3-ethoxycarbonyl-6,7-difluorocarbostyril are added in the course of 10 minutes with stirring at 20° C. to 200 cm 3 of phosphoryl chloride. The suspension is heated to a temperature in the region of 70° C. and maintained at this temperature for 3 hours After cooling to approximately 10° C., the solution obtained is poured with stirring into a mixture of 1,000 cm 3 of water and 1,000 g of crushed ice. The temperature is allowed to rise to approximately 20° C. and the mixture is extracted with twice 500 cm 3 of dichloromethane. The combined organic extracts are washed with 1,000 cm 3 of water, and 1,000 cm 3 of water to which sodium bicarbonate has been added to pH 7, dried over sodium sulphate, filtered and concentrated to dryness under reduced pressure (20 kPa) at approximately 40° C. 45.6 g of 2-chloro-3-ethoxycarbonyl-6,7-difluoroquinoline are obtained in the form of a beige solid, melting point 108° C., which is used without further purification for the subsequent steps. 2-Chloro-3-ethoxycarbonyl-6,7-difluoroquinoline is converted to 2-chloro-6,7-difluoro-3-quinolinecarboxylic acid according to the customary methods, and can thus lead to the benzo[b][1,8]naphthyridine derivatives described in U.S. Pat. No. 4,970,213.
Application Example 2
Preparation of 3-ethoxycarbonyl-6,7-difluoro-2-[N-methyl-N-(b-ethoxycarbonylethyl)amino]quinoline:
56.2 g of sodium carbonate are added to a solution of 72 g of 2-chloro-3-ethoxycarbonyl-6,7-difluoroquinoline, prepared as described in Application Example 1, and 45.1 g of N-methyl-N-(b-ethoxycarbonylethyl)amine in 750 cm 3 of toluene. The suspension obtained is heated to approximately 90° C. and then stirred for 4 hours at this temperature. The reaction mixture is then cooled to approximately 20° C. and thereafter washed with 3 times 400 cm 3 of water. The organic phase is concentrated to dryness under reduced pressure (20 kPa) at approximately 50° C. 94 g of 3-ethoxy-carbonyl-6,7-difluoro-2-[N-methyl-N-(b-ethoxycarbonylethyl)amino]quinoline are obtained in the form of an oil, which is used without further purification for the subsequent steps.
Preparation of 3-ethoxycarbonyl-7,8-difluoro-1-methyl-4-oxo-1,2,3,4-tetrahydrobenzo[b][1,8]naphthyridine:
A solution of 94 g of 3-ethoxycarbonyl-6,7-difluoro-2-[N-methyl-N-(b-ethoxycarbonylethyl)amino]quinoline in 300 cm 3 of absolute ethanol is added in the course of 80 minutes to a solution of 26.6 g of sodium ethylate brought to reflux in 900 cm 3 of absolute ethanol. The suspension obtained, still refluxing, is stirred for a further 15 minutes. 38 cm 3 of glacial acetic acid are then introduced in the course of 30 minutes. The reaction mixture is stirred for a further 15 minutes and, with the mixture still refluxing, 500 cm 3 of water are then introduced in the course of 45 minutes. The suspension obtained is cooled to approximately 20° C. The precipitate is drained at approximately 20° C. and washed with twice 300 cm 3 of water. The wet product is dried under reduced pressure (20 kPa) at approximately 60° C. 71.5 g of 3-ethoxycarbonyl-7,8-difluoro-1-methyl- 4-oxo-1,2,3,4-tetrahydro-benzo[b][1,8]naphthyridine are isolated in the form of a yellow solid, melting point 188° C.
Preparation of 3-ethoxycarbonyl-7,8-difluoro-1-methyl-4-oxo-1,4-dihydrobenzo[b][1,8]naphthyridine:
A solution of 3.78 g of potassium iodide in 20 cm 3 of water is added with stirring at approximately 20° C. to a suspension of 71 g of 3-ethoxycarbonyl-7,8-difluoro-1-methyl-4-oxo-1,2,3,4-tetrahydrobenzo[b][1,8]naphthyridine in 1,000 cm 3 of ethanol. The suspension is heated to 77° C., and 30 cm 3 of 33% by weight hydrogen peroxide is added in the course of 60 minutes at this temperature. The reaction mixture is kept refluxing for a further 30 minutes and is then cooled to approximately 20° C. A solution of 11.4 g of sodium thiosulphate in 50 cm 3 of water is introduced in the course of 5 minutes at this temperature. The precipitate obtained is drained at approximately 20° C. and washed with twice 300 cm 3 of water. The wet product obtained is dried under reduced pressure (20 kPa) at approximately 60° C. 73 g of 3-ethoxy-7,8-difluoro-1-methyl-4-oxo-1,4-dihydro-benzo[b][1,8]naphthyridine are isolated in the form of a white solid, melting point above 270° C.
Application Example 3
Preparation of 3-ethoxycarbonyl-6,7-difluoro-2-[N-ethyl-N-(b-ethoxycarbonylethyl)amino]quinoline:
7.8 g of sodium carbonate are added to a solution of 10 g of 2-chloro-3-ethoxycarbonyl-6,7-difluoroquinoline, prepared as described in Application Example 1, and 9.7 g of N-ethyl-N-(b-ethoxycarbonylethyl)amine in 120 cm 3 of toluene. The suspension obtained is heated to approximately 90° C. and then stirred for 4 hours at this temperature. The reaction mixture is then cooled to approximately 20° C. and thereafter washed with 3 times 100 cm 3 of water. The organic phase is concentrated to dryness under reduced pressure (20 kPa) at approximately 50° C. 13 g of 3-ethoxycarbonyl-6,7-difluoro-2-[N-ethyl-N-(b-ethoxycarbonylethyl)amino]quinoline are obtained in the form of an oil, which is used without further purification for the subsequent steps.
Preparation of 3-ethoxycarbonyl-7,8-difluoro-1-ethyl-4-oxo-1,2,3,4-tetrahydrobenzo[b][1,8]naphthyridine:
A solution of 68 g of 3-ethoxycarbonyl-6,7-difluoro-2-[N-ethyl N-(b-ethoxycarbonylethyl)amino]quinoline in 200 cm 3 of absolute ethanol is introduced in the course of 60 minutes into a solution of 16.1 g of sodium ethylate brought to reflux in 600 cm 3 of absolute ethanol. The suspension obtained, still refluxing, is stirred for a further 60 minutes. 20 cm 3 of glacial acetic acid are then introduced in the course of 30 minutes. The reaction mixture is stirred for a further 15 minutes and, with the mixture still refluxing, 400 cm 3 of water are then introduced in the course of 45 minutes. The suspension obtained is cooled to approximately 20° C. The precipitate obtained is drained at approximately 20° C. and washed with twice 200 cm 3 of water. The wet product is dried under reduced pressure (20 kPa) at approximately 50° C. 52.4 g of 3-ethoxycarbonyl -7,8-difluoro-1-ethyl-4-oxo-1,2,3,4-tetrahydro-benzo[b][1,8]naphthyridine are isolated in the form of a golden-yellow solid, melting point 152° C.
Preparation of 3-ethoxycarbonyl-7,8-difluoro-1-ethyl-4-oxo-1,4-dihydrobenzo[b][1,8]naphthyridine:
A solution of 1.7 g of potassium iodide in 10 cm 3 of water is added with stirring at approximately 0° C. to a suspension of 33 g of 3-ethoxycarbonyl-7,8-difluoro -1-ethyl-4-oxo-1,2,3,4-tetrahydrobenzo[b][1,8]naphthyridine in 1,000 cm 3 of ethanol. The suspension is heated to 77° C., and 12.7 cm 3 of 33% by weight hydrogen peroxide are introduced in the course of 30 minutes at this temperature. The reaction mixture is kept refluxing for a further 30 minutes and is then cooled to approximately 20° C. A solution of 6 g of sodium thiosulphate in 20 cm 3 of water is introduced in the course of 5 minutes at this temperature. The precipitate obtained is drained at approximately 20° C. and washed with twice 150 cm 3 of water. The wet product obtained is dried under reduced pressure (20 kPa) at approximately 50° C. 28.7 g of 3-ethoxycarbonyl-7,8-difluoro-1-ethyl-4-oxo-1,4-dihydrobenzo[b][1,8]naphthyridine are isolated in the form of a light yellow solid, melting point 270° C.
Application Example 4
Preparation of 3-ethoxycarbonyl-6,7-difluoro-2-[N-cyclopropyl-N-(b-ethoxycarbonylethyl)amino]quinoline:
3 g of sodium carbonate are added to a solution of 3.48 g of 2-chloro-3-ethoxycarbonyl-6,7-difluoroquinoline, prepared as described in Application Example 1, and 3 g of N-cyclopropyl-N-(b-ethoxycarbonylethyl)amine in 10 cm 3 of toluene. The suspension obtained is heated to reflux and then stirred for 15 hours at this temperature. The reaction mixture is then cooled to approximately 20° C. and 30 cm 3 of water and 4.5 cm 3 of acetic acid are thereafter added. After settling has taken place, the reaction mixture is separated and washed with twice 10 cm 3 of water. The organic phase is concentrated to dryness under reduced pressure (20 kPa) at approximately 50° C. 3.3 g of crude 3-ethoxycarbonyl-6,7-difluoro-2-[N-cyclopropyl-N-(b-ethoxycarbonylethyl)amino]quinoline are obtained in the form of an oil, which is used without further purification for the subsequent step.
Preparation of 3-ethoxycarbonyl-7,8-difluoro-1-cyclopropyl -4-oxo-1,2,3,4-tetrahydro-benzo[b][1,8]naphthyridine:
A solution of 20 cm 3 of 3-ethoxycarbonyl-6,7-difluoro-2-[N-cyclopropyl-N-(b-ethoxycarbonylethyl)amino]quinoline in 20 cm 3 of absolute ethanol is added in the course of 60 minutes to a solution of 1.6 g of sodium ethylate brought to reflux in 40 cm 3 of absolute ethanol. The solution obtained is stirred under reflux for a further 60 minutes. 2.6 cm 3 of glacial acetic acid are then introduced in the course of 10 minutes. The reaction mixture is stirred for a further 15 minutes and, with the mixture still refluxing, 26 cm 3 of water are then introduced in the course of 5 minutes. The suspension obtained is cooled to approximately 20° C. The precipitate is drained at approximately 20° C. and washed with twice 10 cm 3 of water. The wet product is dried under reduced pressure (20 kPa) at approximately 60° C. 1.25 g of crude 3-ethoxycarbonyl-7,8-difluoro-1-cyclopropyl-4-oxo-1,2,3,4-tetrahydrobenzo[b][1,8]naphthyridine are isolated in the form of a yellow solid, melting point 172° C.
Preparation of 3-ethoxycarbonyl-7,8-difluoro-1-cyclopropyl -4-oxo-1,4-dihydrobenzo-[b][1,8]naphthyridine:
A solution of 0.053 g of potassium iodide in 0.5 cm 3 of water is added with stirring at approximately 20° C. to a suspension of 1 g of 3-ethoxycarbonyl-7,8-difluoro-1-cyclopropyl-4-oxo-1,2,3,4-tetrahydrobenzo[b]-[1,8]naphthyridine in 14 cm 3 of ethanol. The suspension is heated to 77° C., and 0.5 cm 3 of 33% by weight hydrogen peroxide is introduced in the course of 5 minutes at this temperature. The reaction mixture is kept refluxing for a further 60 minutes and then cooled to approximately 20° C. 1.06 cm 3 of 1N sodium thiosulphate solution are introduced in the course of 5 minutes at this temperature. The precipitate obtained is drained at approximately 20° C. and washed with twice 10 cm 3 of water. The wet product obtained is dried under reduced pressure (20 kPa) at approximately 60° C. 0.7 g of crude 3-ethoxy-7,8-difluoro-1-cyclopropyl-4-oxo-1-dihydrobenzo[b][1,8]naphthyridine is isolated in the form of an ochre-white solid, melting point 210° C.
Application Example 5
3-Ethoxycarbonyl-6,7-difluoro-2-[N-methyl-N-(b-cyanoethyl)amino]quinoline is prepared in the following manner:
19.08 g of sodium carbonate are added to a solution of 16.3 g of 2-chloro-3-ethoxycarbonyl-6,7-difluoroquinoline, prepared as described in Application Example 1, and 10 g of N-methyl-N-(b-cyanoethyl)amine in 160 cm 3 of toluene. The suspension obtained is heated to reflux and then stirred for 4 hours at this temperature. The reaction mixture is then cooled to approximately 20° C. and thereafter washed with 3 times 50 cm 3 of water. The organic phase is concentrated to dryness under reduced pressure (20 kPa) at approximately 50° C. 19.17 g of 3-ethoxycarbonyl-6,7-difluoro-2-[N-methyl-N-(b-cyanoethyl)amino]quinoline are obtained in the form of an oil, which is used without further purification for the subsequent steps.
3-Cyano-7,8-difluoro-1-methyl-4-oxo-1,2,3,4-tetrahydro-benzo[b][1,8]naphthyridine is prepared in the following manner:
A solution of 19.17 g of 3-ethoxycarbonyl-6,7-difluoro-2-[N-methyl-N-(b-cyanoethyl)amino]quinoline in 50 cm 3 of tetrahydrofuran is introduced in the course of 60 minutes into a solution, cooled to -10° C. of 8.74 g of potassium tert-butylate in 200 cm 3 of tetrahydrofuran. The suspension obtained is stirred, still at -10° C., for a further 30 minutes 4 cm 3 of glacial acetic acid are then introduced. The tetrahydrofuran is evaporated off under reduced pressure (20 pKa). The crude reaction mixture is taken up with 200 cm 3 of an aqueous-alcoholic ethanol/water (70/30 vol/vol) mixture. The precipitate obtained is filtered off, washed twice with 50 cm 3 of water and then dried under reduced pressure (20 kPa). 16.1 g of 3--cyano-7,8-difluoro-1-methyl-4-oxo-1,2,3,4-tetrahydrobenzo[b][1,8]naphthyridine are isolated in the form of a golden-yellow solid, melting point 144° C.
3-Cyano-7,8-difluoro-1-methyl-4-oxo-1,4-dihydrobenzo-[b][1,8]naphthyridine is prepared in the following manner:
A solution of 0.47 g of potassium iodide in 5 cm 3 of water is added with stirring at approximately 20° C. to a suspension of 8.6 g of 3-cyano-7,8-difluoro-1-methyl-4-oxo-1,2,3,4-tetrahydrobenzo[b][1,8]naphthyridine in 350 cm 3 of ethanol. The suspension is heated to 77° C., and 4 cm 3 of 33% by weight hydrogen peroxide are added in the course of 10 minutes at this temperature. The reaction mixture is kept refluxing for a further 30 minutes and is then cooled to approximately 20° C. 10 cm 3 of 1N sodium thiosulphate solution are added in the course of 5 minutes at this temperature. The precipitate obtained is drained at approximately 20° C. and washed with twice 20 cm 3 of water. The wet product obtained is dried under reduced pressure (20 kPa) at approximately 50° C. 8 g of 3-cyano-7,8-difluoro-1-methyl-4-oxo-1,4-dihydrobenzo[b]-[1,8]naphthyridine are obtained in the form of a light yellow solid, melting point 380° C.
3-Cyano-7-fluoro-1-methyl-8-(4-methyl-1-piperazinyl)-4-oxo-1,4-dihydrobenzo[b]-[1,8]-naphthyridine is prepared in the following manner:
A suspension of 2.1 g of 3-cyano-7,8-difluoro-1-methyl-4-oxo-1,4-dihydrobenzo[b][1,8]naphthyridine in 100 cm 3 of dimethyl sulphoxide is heated to 80° C. in the presence of 2 cm 3 of N-methylpiperazine. The reaction mixture is maintained at this temperature for 8 hours. The solution obtained is cooled to room temperature and stirred at this temperature for 15 hours. The precipitate formed is filtered off, washed with 3 times 20 cm 3 of water and dried under vacuum (20 kPa) at 50° C. 2.6 g of 3-cyano-7-fluoro-1-methyl-8-(4-methyl-1-piperazinyl)-4-oxobenzo[b][1,8]naphthyridine are obtained in the form of a yellow precipitate, melting point 335° C.
7-Fluoro-1-methyl-8-(4-methyl-1-piperazinyl)-4-oxo-1,4-dihydrobenzo[b][1,8]naphthyridine-3-carboxylic acid is prepared in the following manner:
A suspension of 2 g of 3-cyano-7-fluoro-1-methyl-8-(4-methyl-1-piperazinyl)-4-oxo-1,4-dihydrobenzo[b][1,8]naphthyridine is heated to reflux in 40 cm 3 of 12N hydrochloric acid. The reaction mixture is maintained at this temperature for 15 hours. The solution obtained is cooled to room temperature. The product which crystallizes is filtered off, washed with water to neutrality and dried under reduced pressure (20 kPa) at 50° C. 1.5 g of 7-fluoro-1-methyl-8-(4-methyl-1-piperazinyl)-4-oxo-1,4-dihydrobenzo[b][1,8]naphthyridine-3-carboxylic acid monohydrochloride are obtained in the form of yellow crystals, melting point 290° C. (decomposition).
Application Example 6
3-Ethoxycarbonyl-6,7-difluoro-2-{N-methyl-N-(b-(N',N'-dimethylaminocarbonyl)ethyl]amino}quinoline is prepared in the following manner:
31 g of sodium carbonate are added to a solution of 26 g of 2-chloro-3-ethoxycarbonyl-6,7-difluoroquinoline, prepared as described in Application Example 1, and 25 g of N-methyl-N-[b-(N',N'-dimethylaminocarbonyl)ethyl]amine in 300 cm 3 of toluene. The suspension obtained is heated to reflux and then stirred for 2 hours 30 minutes at this temperature. The reaction mixture is then cooled to approximately 20° C. and thereafter washed with 3 times 100 cm 3 of water. The organic phase is concentrated to dryness under reduced pressure (20 kPa) at approximately 50° C. 35 g of 3-ethoxycarbonyl-6,7-difluoro-2-{N-methyl-N(b-(N',N'-dimethylaminocarbonyl)ethyl]amino}-quinoline are obtained in the form of an oil, which is used without further purification for the subsequent steps.
N,N-Dimethyl-7,8-difluoro-1-methyl-4-oxo-1,2,3,4-tetrahydrobenzo[b][1,8]naphthyridine-3-carboxamide is prepared in the following manner:
A solution of 35 g of 3-ethoxycarbonyl-6,7-difluoro-2-{N-methyl-N-[b-(N',N'-dimethylaminocarbonyl)ethyl]amino}quinoline in 150 cm 3 of tetrahydrofuran is added in the course of 75 minutes to a solution of 15.7 g of potassium tert-butylate in 150 cm 3 of tetrahydrofuran cooled to 0° C. The suspension obtained is then stirred at 0° C. for a further 30 minutes and 8 cm 3 of glacial acetic acid are thereafter added. The tetrahydrofuran is evaporated off under reduced pressure (20 kPa). The crude reaction mixture is taken up with 200 cm 3 of an aqueous-alcoholic ethanol/water (70:30 vol/vol) mixture. The precipitate obtained is filtered off, washed 3 times with 100 cm 3 of water and then dried under vacuum (20 kPa). 25 g of N,N-dimethyl-7,8-difluoro-1-methyl-4-oxo-1,2,3,4-tetrahydrobenzo[b][1,8]naphthyridine-3-carboxamide are isolated in the form of a lemon-yellow solid, melting point 206° C.
N,N-Dimethyl-7,8-difluoro-1-methyl-4-oxo-1,4-dihydrobenzo[b][1,8]naphthyridine-3-carboxamide is prepared in the following manner:
A solution of 1.35 g of potassium iodide in 10 cm 3 of water is added with stirring at approximately 20° C. to a suspension of 25 g of 7,8-difluoro-1,N,N-trimethyl-4-oxo-1,2,3,4-tetrahydrobenzo[b][1,8]naphthyridine-3-carboxamide in 1,000 cm 3 of ethanol. The suspension is heated to 77° C., and 25 cm 3 of 33% by weight hydrogen peroxide are introduced in the course of 20 minutes at this temperature. The reaction mixture is kept refluxing for a further 1 hour 30 minutes and is then cooled to approximately 20° C. 30 cm 3 of 1N sodium thiosulphate solution are introduced in the course of 5 minutes at this temperature. The precipitate obtained is drained at approximately 20° C. and washed with twice 60 cm 3 of water. The wet product obtained is dried under reduced pressure (20 kPa) at approximately 50° C. 19.5 g of N-N-dimethyl-7,8-difluoro-1-methyl-4-oxo-1,4-dihydrobenzo[b][1,8]naphthyridine-3-carboxamide are isolated in the form of a light yellow solid, melting point 324° C.
A suspension of 2.96 g of 7,8-difluoro-N,N-dimethyl-4-oxo-1-methyl-1,4-dihydrobenzo[b][1,8]naphthyridine-3-carboxamide, 1.12 g of 1-methylpiperazine and 1.55 g of potassium carbonate in 100 cm 3 of dimethyl sulphoxide is heated with stirring for 5 hours at approximately 80° C. After cooling to approximately 20° C., the reaction mixture is treated with 100 cm 3 of water; the insoluble matter is drained and washed with twice 30 cm 3 of water and twice 30 cm 3 of ethanol.
2.3 g of N,N-dimethyl-7-fluoro-1-methyl-8-(4-methyl-1-piperazinyl)-4-oxo-1,4-dihydrobenzo-[b][1,8]naphthyridine-3-carboxamide are obtained in the form of a yellow solid, which decomposes at 275° C.
A solution of 0.5 g of N,N-dimethyl-7-fluoro-1-methyl-8-(4-methyl-1-piperazinyl)-4-oxo-1,4-dihydrobenzo-[b][1,8]-naphthyridine-3-carboxamide in 10 cm 3 of 6N aqueous hydrochloric acid is heated with stirring to approximately 95° C. for 5 hours. After cooling to approximately 20° C., the insoluble matter is drained and washed with 3 times 20 cm 3 of water and twice 10 cm 3 of ethanol.
The product obtained is suspended in 30 cm 3 of water; 0.6 cm 3 of N aqueous potassium hydroxide is added and the mixture is stirred for 1 hour at approximately 20° C. The insoluble matter is drained and washed with twice 20 cm 3 of water and twice 10 cm 3 of ethanol. After recrystallization in 15 cm 3 of dimethylformamide, 0.15 g of 7-fluoro-1-methyl-8-(4-methyl-1-piperazinyl)-4-oxo-1,4-dihydrobenzo[b][1,8]naphthyridine-3-carboxylic acid is obtained in the form of a yellow solid, which decomposes at 354° C.
Application Example 7
3-Ethoxycarbonyl-6,7-difluoro-2-[N-methyl-N-(b-aminocarbonylethyl)amino]quinoline are prepared in the following manner:
4.4 g of sodium carbonate are added to a solution of 4 g of 2-chloro-3-ethoxycarbonyl-6,7-difluoro-quinoline, prepared as described in Application Example 1, and 3 g of N-methyl-N-(b-aminocarbonylethyl)amine in 40 cm 3 of toluene. The suspension obtained is heated to reflux and then stirred for 2 hours 30 minutes at this temperature. The reaction mixture is then cooled to approximately 20° C. and thereafter washed with 3 times 25 cm 3 of water. The organic phase is concentrated to dryness under reduced pressure (20 kPa) at approximately 50° C. 4.7 g of 3-ethoxycarbonyl-6,7-difluoro-2-[N-methyl-N-(b-aminocarbonylethyl)amino]quinoline are obtained in the form of an oil, which is used without further purification for the subsequent steps.
3-carboxamide-7,8-difluoro-1-methyl-4-oxo-1,2,3,4-tetrahydrobenzo[b]-[1,8]naphthyridine is prepared in the following manner:
A solution of 4.23 g of 6,7-difluoro-2-[N-methyl-N-(b-aminocarbonylethyl)amino]quinoline in 20 cm 3 of tetrahydrofuran is added in the course of 30 minutes to a solution of 1.8 g of potassium tert-butylate in 50 cm 3 of tetrahydrofuran cooled to 0° C. The suspension obtained is then stirred at 0° C. for a further 30 minutes and thereafter 2 cm 3 of glacial acetic acid are introduced. The tetrahydrofuran is evaporated off under reduced pressure (20 kPa). The crude reaction mixture is taken up with 10 cm 3 of an aqueous-alcoholic ethanol/water (70:30 vol/vol) mixture. The precipitate obtained is filtered off, washed 3 times with 10 cm 3 of water and then dried under reduced pressure (20 kPa). 1.6 g of 3-carboxamide-7,8-difluoro-1-methyl-4-oxo-1,2,3,4-tetrahydrobenzo[b]-[1,8]naphthyridine are obtained in the form of a yellow solid, melting point 182° C.
3-Carboxamide-7,8-difluoro-1-methyl-4-oxo-1,4-dihydrobenzo[b]-[1,8]naphthyridine is prepared in the following manner:
A solution of 0.1 g of potassium iodide in 1 cm 3 of water is added with stirring at approximately 20° C. to a suspension of 1.3 g of 3-carboxamide-7,8-difluoro-1-methyl-4-oxo-1,2,3,4-tetrahydrobenzo[b][1,8]naphthyridine in 25 cm 3 of ethanol. The suspension is heated to 77° C., and 15 cm 3 of 33% by weight hydrogen peroxide are added in the course of 5 minutes at this temperature. The reaction mixture is kept refluxing for a further 1 hour 30 minutes and is then cooled to approximately 20° C. 1 cm 3 of 1N sodium thiosulphate solution is added at this temperature. The precipitate obtained is drained at approximately 20° C. and washed with twice 5 cm 3 of water. The wet product obtained is dried under reduced pressure (20 kPa) at approximately 50° C. 1.1 g of 3-carboxamide-7,8-difluoro-1-methyl-4-oxo-1,4-dihydrobenzo[b][1,8]naphthyridine are isolated in the form of an orange-colored solid, melting point 318° C.
A suspension of 1.3 g of 7,8-difluoro-1-methyl-4-oxo-1,4-dihydrobenzo[b][18]naphthyridine-3-carboxamide, 0.54 g of 1-methylpiperazine and 0.75 g of potassium carbonate in 25 cm 3 of dimethyl sulphoxide is heated to approximately 80° C. for 6 hours. After cooling to a temperature in the region of 20° C., the reaction mixture is treated with 100 cm 3 of water. The insoluble matter is drained and washed with twice 20 cm 3 of water and twice 20 cm 3 of ethanol.
The product obtained is chromatographed on 20 g of silica gel (0.063-0.200 mm) suspended in a dichloromethane mixture containing 10% of methanol. Reaction impurities are removed by elution with 500 cm 3 of this solvent mixture. The expected product is then eluted with 500 cm 3 of the same solvent mixture. After concentration to dryness under reduced pressure (20 kPa) at approximately 40° C., the solid residue is recrystallized in 25 cm 3 of dimethylformamide, drained and washed with twice 30 cm 3 of ethanol at approximately 70° C.
0.6 g of 7-fluoro-1-methyl-8-(4-methyl-1-piperazine)-4-oxo-1,4-dihydrobenzo-[b][18]-naphthyridine-3-carboxamide is obtained in the form of a yellow solid, which decomposes at 265° C.
7-Fluoro-8-(4-methyl-1-piperazinyl)-1-methyl-4-oxo-1,4-dihydrobenzo[b][1,8]naphthyridine-3-carboxylic acid is prepared under the conditions of Application Example 2, but starting with 0.3 g of 7-fluoro-1-methyl-8-(4-methyl-1-piperazinyl)-4-oxo-1,4-dihydrobenzo[b][1,8]naphthyridine-3-carboxamide. After cooling to approximately 20° C., the reaction mixture is treated with 50 cm 3 of water; the insoluble matter is drained and washed with twice 10 cm 3 of water.
The product obtained is suspended in 20 cm 3 of water, treated with 0.4 cm 3 of N aqueous potassium hydroxide solution and stirred for 1 hour at approximately 20° C. The insoluble matter is drained, washed with 3 times 10 cm 3 of water and twice 10 cm 3 of ethanol and recrystallized in 20 cm 3 of dimethylformamide.
0.17 g of 7-fluoro-1-methyl-8-(4-methyl-piperazinyl)-1,4-dihydrobenzo[b][1,8]naphthyridine-3-carboxylic acid is obtained in the form of a yellow solid, which decomposes at 354° C.
Although the invention has been described in conjunction with specific embodiments, it is evident that many alternatives and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, the invention is intended to embrace all of the alternatives and variations that fall within the spirit and scope of the appended claims. the above references are hereby incorporated by reference. | This invention relates to new derivatives of fluoro quinoline carboxylic-3 acid having general formula (I), ##STR1## wherein R is a hydrogen atom or an alkyl radical and Hal is a halogen atom, as well as salts thereof, when they exist, preparation thereof and utilization as synthesis intermediary. | 2 |
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a process for preparing alkyl- and arylmalonic acids of the formula I ##STR2## where R 1 =H, C 1 -C 12 -alkyl, phenyl, C 1 -C 4 -alkylphenyl, C 2 -C 4 -dialkylphenyl,
R 2 C 1 -C 12 -alkyl, phenyl, C 1 -C 4 -alkylphenyl, C 2 -C 4 -dialkylphenyl or
R 1 +R 2 =--CH 2 --CH 2 -- by alkaline saponification of the corresponding C 1 -C 4 -alkyl esters.
Alkyl- and arylmalonic acids are important intermediates for the synthesis of agrochemicals and pharmaceutical active ingredients. They are used, for example, for the preparation of Meldrum's acids, barbiturates, fragrances and vitamins.
The preparation of substituted malonic acids is generally described in Kirk-Othmer, Encyclopedia of Chemical Technology, 3rd Edition (1981), Vol. 14, 794-810. Procedures may employ acid or alkaline saponification of esters, nitriles or amides of carboxylic acids. One problem often encountered in such processes is that the products are obtained as mixtures with sodium chloride.
Complicating factors in the preparation of the substituted malonic acids are their excellent solubility in water and their ready decarboxylation which, in the case of malonic acid, begins to occur at temperatures as low as 70° C.
The best-known preparation of methylmalonic acid starts from α-chloropropionic acid which is reacted with sodium cyanide to give the corresponding nitrile. This product is then saponified with sodium hydroxide solution, NH 3 being eliminated by the hydrolysis reaction. After hydrolysis, according to organic Syntheses, Vol. 11 (1943), 376, methylmalonic acid is only obtained by a laborious procedure which, at one point, requires the formation of Ca salts.
If, after the alkaline saponification of a malonic ester, the malonic acid is present as the alkali metal salt, dissolved in water, the alkali metal cations can be removed, as taught by DE-A-41 20 704, via acid ion exchangers, followed by isolation of the free acid. Since alkaline saponifications always require the use of at least stoichiometric amounts of alkali, which are neutralized again with strong acids in the course of malonic acid work-up, this process produces at least stoichiometric amounts of salt, which often have to be disposed of at considerable expense. This is a major drawback of this process of alkaline saponification.
Cyclopropane-1,1-dicarboxylic acid can be prepared in a yield of about 70%, as described in org. Syntheses, Vol. 60 (1981), 66, by the reaction of diethyl malonate 1,2-dibromoethane, sodium hydroxide solution and stoichiometric amounts of a phase transfer catalyst. Simultaneous saponification of the intermediate diethyl cyclopropane-1,1-dicarboxylate also occurs in the process. In addition to the large quantity of phase transfer catalyst required, which is 2.5 times the amount of catalyst, based on the cyclopropane-1,1-dicarboxylic acid obtained, considerable quantities of sodium chloride are also produced which, dissolved in water, require disposal.
Dimethylmalonic acid has likewise been known for a long time and can be prepared by alkaline saponification of the corresponding diethyl ester. The saponification of the dimethyl ester with potassium hydroxide solution to give the acid is mentioned by W. Schauzer, K. Clusius, Z. Physik. Chemie A 190 (1941), 243, without the yield and purity being stated. According to other processes, the acid is obtained by oxidation, employing KMnO 4 or HNO 3 , of methyl precursors.
All these known processes for preparing the substituted malonic acids by alkaline saponification of the corresponding esters give rise to twice the molar amount, based on the product, of salt dissolved in water. A problem which, therefore, is inherent to all of these processes is the disposal of considerable amounts of salt solutions, which is made more difficult by official regulations. In order to reduce the degree of the disposal problem, water can be evaporated from the salt solutions. However, evaporation of water requires large amounts of energy. A need continues to exist for an improved method of isolating malonic acids simply and without requiring major use of energy.
SUMMARY OF THE INVENTION
Accordingly, one object of the present invention to provide a process by which the salts, inevitably produced in the course of alkaline hydrolysis, of malonate diester can be removed and isolated simply without major energy expenditure.
Briefly, this object and other objects of the present invention as hereinafter will become more readily apparent can be attained by process for preparing alkyl- and arylmalonic acids of the formula I: ##STR3## wherein R 1 =H, C 1 -C 12 -alkyl, phenyl, C 1 -C 4 -alkylphenyl, C 2 -C 4 -dialkylphenyl,
R 2 =C 1 -C 12 -alkyl, phenyl, C 1 -C 4 -alkylphenyl, C 2 -C 4 -dialkylphenyl or
R 1 +R 2 =--CH 2 --CH 2 --, by alkaline saponification, comprising:
hydrolyzing the corresponding C 1 -C 4 -alkyl esters of the malonic acid of formula I, with alkali metal hydroxide dissolved in an aqueous alkali metal salt solution containing salt at 90-100% of saturation;
acidifying the hydrolysis product with a mineral acid;
removing the precipitated alkali metal salt which forms upon acidification; and
extracting the alkyl- and arylmalonic acid formed from the aqueous solution with the aid of an organic solvent.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Suitable substituents R 1 and R 2 in formula I include, for example, methyl, ethyl, isopropyl, n-butyl, n-octyl, and methyl-, ethyl- or dimethylphenyl.
Examples of potentially suitable C 1 -C 4 -esters include the methyl, ethyl, isopropyl and n-butyl esters, preference being given to the methyl ester.
Examples of suitable alkali metal hydroxides are sodium hydroxide, potassium hydroxide, lithium hydroxide or cesium hydroxide, preference being given to sodium hydroxide or potassium hydroxide. The alkali metal hydroxide is usually employed in amounts of from 2-4 mol per mol of substituted malonic acid diester, preference being given to the use of an alkali metal hydroxide excess of from 1-50 mol %.
KOH is especially preferred, since the potassium salts are often less soluble than the sodium salts.
The alkali metal hydroxide is preferably dissolved in an aqueous saturated alkali metal salt solution. However, the concentration of salt in the salt solution normally ranges from 90% of saturation to 100% saturation.
Examples of mineral acids which can be used for this purpose include sulfuric acid, hydrochloric acid, phosphoric acid, hydriodic acid, hydrochloric acid and perchloric acid. Acidification is preferably effected with sulfuric acid or hydrochloric acid.
The aqueous solution, present after the hydrolysis, of the alkali metal salt of the substituted malonic acid is generally acidified with the mineral acid to a pH of from 1-2, the alkyl- or arylmalonic acid then being present entirely as the free acid. Based on the diester originally used, from 2-4 mols of mineral acids are most commonly used, acid preferably being employed in an excess of from 1-50 mol %.
Preference is given to an alkali metal hydroxide and an alkali metal salt solution of the same alkali metal, the acidification employing the mineral acid which corresponds to the anion of the alkali metal salt. Particular preference is given to the use of KOH as the alkali metal hydroxide, K 2 SO 4 as the alkali metal salt and H 2 SO 4 as the mineral acid.
The removal of the alkali metal salt which has precipitated or crystallized can be effected by filtration or centrifuging, filtration being preferred. Depending on the substituent, the alkyl- and arylmalonic acids in this situation are more or less water-soluble. The salting-out effect by itself may be sufficient to cause a fraction of the malonic acid to cocrystallize. However, crystallized malonic acid can be rapidly dissolved again if the separated solid is washed with an alcohol.
Suitable extractants generally include organic solvents which are sparingly miscible with water and sufficiently polar to take up the substituted malonic acids such as, for example, ketones, long-chain alcohols or ethers, dialkyl ethers having from 3-8 C atoms being preferred. Examples of these ether solvents include methyl ethyl ether, diethyl ether, methyl t-butyl ether, diisopropyl ether and dibutyl ether, particular preference being given to the last two mentioned.
The high salt concentrations in the aqueous phase facilitate the extraction considerably. The extraction can be effected continuously e.g. by means of a mixer-settler apparatus or batchwise by a shaking or stirring operation being carried out 2 or 3 times.
After the extraction, the solvent, optionally after it is dried, is evaporated, the alkyl- or arylmalonic acid then being produced in crystalline form. Drying can also be dispensed with, since the evaporation operation usually also goes hand in hand with azeotropic drying.
It may also be advantageous to add, towards the end of the evaporation operation, an organic nonsolvent for the alkyl- or arylmalonic acid, thereby causing the product to be precipitated and allowing it to be filtered. By means of washing and drying it is thus often possible to obtain a particularly pure product.
According to the present process, the alkali metal salts which have crystallized can be isolated by simple filtration, being produced in a sufficiently pure form to be suitable for other purposes. Having been washed with an alcohol, preferably with the alcohol formed during the hydrolysis, and having been dried, e.g. K 2 SO 4 can be used as a fertilizer or can be employed for the preparation of alum, persulfate, potash and other products.
After the extraction of the alkyl- and arylmalonic acids the aqueous solutions can also be reused any number of times for new batches.
The process can advantageously be applied to the preparation of mono- and dialkylmalonic acids and particularly to the synthesis of phenylmalonic acid, since the equivalent of alkali, in the form of the alkali metal alcoholate, required for the synthesis of phenylmalonic acid dialkyl ester can also be utilized for the hydrolysis of the ester.
The process can also make use of the hemiesters of the alkyl- and arylmalonic acids.
Having generally described this invention, a further understanding can be obtained by reference to certain specific examples which are provided herein for purposes of illustration only and are not intended to be limiting unless otherwise specified.
EXAMPLES
Example 1
Preparation of diethylmalonic acid (DEMA)
The following are weighed into a 2 liter multinecked flask equipped with a stirrer, thermometer, dropping funnel and distilling section: 530 ml of aqueous saturated K 2 SO 4 solution (10% strength, from previous batches), 206 g of KOH flakes (85%, 3.12 mol) and 500 ml of ethanol 95% strength (recovery from previous batches). The mixture is then heated to boiling until a clear solution is obtained. Over a period of 1 h, 270.5 g of diethyl diethylmalonate (1.25 mol) are added dropwise, and over a period of 5-6 hours from 160-180 ml of ethanol are removed by distillation. The batch is cooled. Then, with cooling (to about 25° C.), a 177 g amount of conc. H 2 SO 4 (96% strength, 1.73 mol), which amount beforehand is diluted with about the same amount of H 2 O, is added gradually until the pH has dropped to a level of from 1-2.
The K 2 SO 4 which has crystallized is removed by filtration, washed twice with ethanol and is dried: 272 g (yield: 100% of the theoretical yield).
Under a partial vacuum of about 300 mbar all the ethanol is removed by distillation from the filtrate, and the DEMA is extracted from the aqueous solution by being shaken 3 times with methyl t-butyl ether (400 ml, 200 ml, 100 ml).
Methyl t-butyl ether is largely removed by distillation and replaced by toluene (400 ml). All the remaining water and methyl t-butyl ether is removed by distillation. The DEMA which has crystallized is removed by filtration, washed with toluene and dried in vacuo.
Final weight: 190 g (95% of the theoretical yield)
Purity: 99.4% (titration, GC)
Melting point: 120° C.
All the solvent distillates and the aqueous saturated K 2 SO 4 solution (after neutralization with KOH) are reused in the subsequent batches.
Example 2
Preparation of ethylmalonic acid (EMA)
A 2 liter multinecked flask, equipped with stirrer, thermometer, dropping funnel and distillation head is charged with 600 g of aqueous saturated with K 2 SO 4 solution-obtained from a previous batch, 203 g of KOH flakes (87%, 3.15 mol) and 350 ml of ethanol (recovered from previous batches).
The mixture is heated, with stirring, until everything has dissolved, whereupon a 282.1 g amount of diethyl ethylmalonate (1.5 mol) is added gradually over a period of 90 minutes at a temperature of 70°-80° C. During the postreaction time of from 2-3 hours, some of the alcohol (about 200 g) is removed by distillation, and the aqueous reaction solution is then, with cooling, acidified with a 168.8 g amount of H 2 SO 4 (96% strength, 1.65 mol) which has previously been diluted with 100 ml of water. The K 2 SO 4 which has crystallized is filtered, washed with ethanol and dried: 274 g (yield: 99.8% of the theoretical yield). All of the alcohol is distilled from the collected filtrates, in a partial vacuum of from 150-300 mbar, and the remaining aqueous solution is then extracted 4 times with methyl t-butyl ether (400 ml, 200 ml, 200 ml, 100 ml).
The organic extracts are combined and all of the methyl t-butyl ether is distilled, EMA crystallizing out in dry form.
Final weight: 191 g (96.4% of the theoretical yield)
Purity: 99.4% (titration, GC)
Melting point: 111° C.
The aqueous K 2 SO 4 -containing filtrate is neutralized with KOH and is employed for the hydrolysis in subsequent batches.
Example 3
Preparation of cyclopropane-1,1-dicarboxylic acid (CDA)
In a 4 liter multinecked flask, 800 ml of aqueous saturated K 2 SO 4 solution (from previous batches, neutralized), 500 ml of methanol and 330 g of KOH (85%, 5.0 mol) are heated and then, at 68° C., over a period of 90 minutes, a 316.2 g amount of dimethyl cyclopropane-1,1-dicarboxylate (2.0 mol) is added gradually. During the postreaction time of 4 hours, some of the methanol distills. After the reaction solution has cooled it is acidified, with cooling, with a 281 g amount of sulfuric acid (96% strength, 2.75 mol) which has previously been diluted with 100 ml of water. The K 2 SO 4 which crystallizes is filtered via a sintered disk, washed with methanol and dried: 380 g (87.2% of the theoretical yield).
All the methanol of the collected filtrates is removed by distillation in a partial vacuum and the aqueous solution is then extracted twice with diisopropyl ether (400 ml, 200 ml portions). The combined ether phases are briefly washed with 30 ml of water, to remove residual K 2 SO 4 , and then boiled down in vacuo until dry, the CDA precipitating in crystalline form.
Final weight: 216.9 g (83.4% of the theoretical yield)
Purity: 98.8% (titration, GC)
Melting point: 136°-137.5° C.
The distillates of the organic solvents and the aqueous K 2 SO 4 filtrate (after neutralization with KOH) are reused in the subsequent batches.
Example 4
Preparation of phenylmalonic acid (PMA)
In a 2 liter multinecked flask equipped a distilling section, 300 g of a 32% strength potassium methylate solution (1.37 mol) are boiled down until largely dry. On top of the potassium methylate crystals, 205.5 g of ethylphenyl acetate (1.25 mol) and 826 g of diethyl carbonate (7.0 mol, fresh and recovery) are introduced, whereupon all of the methanol and ethanol is distilled at reduced pressure of about 500 mbar and a bottom temperature of about 90° C. After the end of the reaction the excess diethyl carbonate is likewise distilled in a partial vacuum until only a K salt of diethyl phenylmalonate remains.
This salt is dissolved in about 500 ml of an aqueous saturated K 2 SO 4 solution (filtrate from previous batches), and a conc. KOH solution (130.5 g of KOH, 85%, 2.33 mol) is added. This is followed by saponification over a period of from 4-5 hours at about 90° C.
After cooling, acidification is effected carefully to a pH of about 1.5, using 201 g of conc. H 2 SO 4 (96% strength, 1.97 mol) which have previously been diluted with H 2 O. In the process, K 2 SO 4 and some of the PMA is precipitated. Work-up:
The PMA is redissolved by the addition of alcohol, K 2 SO 4 is filtered, washed and dried, and 322 g (100% of the theoretical yield) of product is obtained. From the filtrate, after the alcohol has been removed by distillation, the PMA is obtained by extracting the filtrate 3 times with methyl t-butyl ether (800 ml). (Alternatively, PMA can be obtained directly from the salt suspension by extraction with methyl t-butyl ether, the K 2 SO 4 crystals being filtered subsequently.)
The collected methyl t-butyl ether extracts are boiled down to dryness, and PMA crystals precipitate. The crystals are purified by being taken up in toluene, and then filtered.
Final weight: 189 g (84% of the theoretical yield)
Melting point: 152°-153° C. (decomp.)
Purity: 99.7% (titration, ion chrom.)
The preparation of PMA can equally effectively be carried out with potassium ethylate. In that case, only ethanol is produced as the distillate; the PMA crystals may assume a yellowish tinge.
The extracted phases saturated with K 2 SO 4 , and the methyl t-butyl ether distillates can be reused for subsequent batches.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | Alkyl- and arylmalonic acids of the formula I ##STR1## where R 1 =H, C 1 -C 12 -alkyl, phenyl, C 1 -C 4 -alkylphenyl, C 2 -C 4 -dialkylphenyl,
R 2 =C 1 -C 12 -alkyl, phenyl, C 1 -C 4 -alkylphenyl, C 2 -C 4 -dialkylphenyl or
R 1 +R 2 =--CH 2 --CH 2 --, are prepared by alkaline saponification by hydrolyzing the corresponding C 1 -C 4 -alkyl esters of the malonic acid of formula I, with alkali metal hydroxide dissolved in an aqueous alkali metal salt solution containing salt at 90-100% of saturation, acidifying the hydrolysis product with a mineral acid, removing the precipitated alkali metal salt which forms upon acidification, and extracting the alkyl- and arylmalonic acid formed from the aqueous solution with the aid of an organic solvent. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to cryogenic assemblies for magnetic resonant imaging systems and the like. In particular, but not necessarily restricted thereto, the present invention relates to a cryogenic hose of the type which is employed to connect a cryogenic compression apparatus to a superconducting system such as a magnetic resonant imaging system.
BACKGROUND TO THE INVENTION
[0002] In many cryogenic applications components, e.g. superconducting coils for magnetic resonance imaging (MRI), superconducting transformers, generators, electronics, are cooled by keeping them in contact with a volume of liquefied gas (e.g. Helium, Neon, Nitrogen, Argon, Methane), the whole cryogenic assembly being known as a cryostat. In order to operate a superconducting magnet, it must be kept at a temperature below its superconducting transition temperature. For conventional low temperature superconductors, the transition temperature is in the region of 10K, and typically the magnet is cooled in a container or vessel comprising a bath of liquid helium, commonly called a helium vessel, at 4.2K. For simplicity, reference shall now be made to helium, but this does not preclude the use of other gases. Services need to be run from the external environment at room temperature into the helium vessel, for monitoring purposes and to energize the magnet.
[0003] The cooling, liquefaction and/or further cooling of gasses such as helium require the generation of very low temperature refrigeration. Helium liquefies at 4.21K. The generation of such a low temperature is very expensive and any improvements in cost and efficiency are very desirable. Pulse tube refrigerators are being increasingly used wherein pulse energy is converted to refrigeration using an oscillating gas. Such systems can generate refrigeration to very low levels, sufficient to liquefy helium. Gifford McMahon (GM) coolers are also used in such applications.
[0004] It will be appreciated that cryostats are not closed systems and have access necks to enable gas replenishment, service of the pulse tube refrigerator sleeve etc. Furthermore the pulse tube system relies upon a supply of oscillating gas driven by a compressor system. As will be appreciated, the pulse tube system has input and output tubes between the compressor and the cryostat. Equally GM coolers have such input and output tubes. These pairs of gas transfer hoses conduct refrigerant gases from a compressor source to a cooling device within a cryostat. These hoses are constructed from convoluted hose to withstand the pressures. As the gas passes over the internal convolutions a whistling sound is created. This is typically most dominant in the low pressure hose, where the gas is more voluminous having expanded, as its energy and temperature have been increased during the energy transfer process of cooling in the cryostat.
[0005] This whistling noise is, at the minimum annoying for operatives of a cryostat, but can have untoward effects for patients in a magnetic resonant imaging system. It should be remembered that many magnetic resonant systems closely surround patients and this may make a patient fearful—if a patient is uncomfortable or disturbed during an imaging scan, then they may physically move the part of their body being scanned resulting in a failure of the scanning operation. Furthermore, the acoustic disturbance can set up vibrational disturbances in the associated equipment. The cooling device's performance may be limited due to flow disturbance. The scanning device and other equipment operable to scan a patient/subject may also work less well with tolerances being larger than preferred.
OBJECT OF THE INVENTION
[0006] The present invention seeks to provide an improved cryogenic assembly. The present invention also seeks to reduce the sound levels produced by a cryogenic apparatus and the level of noise transferred through a gas transfer hose.
STATEMENT OF THE INVENTION
[0007] The present invention accordingly provides apparatus and a method as defined in the appended claims.
[0008] In accordance with an aspect of the invention, there is provided a gas transfer hose for supplying a compressed gas to an equipment, and conducting a return flow of gas from the equipment. The hose comprises a inner and outer coaxial hoses defining a first inner conduit and a second circumferential conduit which surrounds the first conduit. One conduit is operable to transfer the compressed gas from a compressor to the equipment and the other conduit is operable to transfer the return flow of gas from the equipment to the compressor.
[0009] The inner hose may be supported within the outer hose by supports. At least one of the inner and outer hoses may be convoluted. An inner or an outer surface of at least one of the inner and outer hoses is covered in braiding. The hoses may be formed from stainless steel.
[0010] The present invention also provides a cryogenic assembly comprising a compressor and a refrigerator each having respective gas inlet and outlet ports joined by a gas transfer hose of the present invention. The first, inner conduit may be arranged to conduct the return flow of gas from the refrigerator.
[0011] The present invention also provides MRI equipment comprising a cryogenic assembly according to the present invention.
[0012] The present invention also provides a method of operating a cryogenic assembly comprising a cryostat, a compressor and a gas transfer hose, wherein the hose comprises a first axial conduit and a second circumferential conduit which surrounds the first conduit, the method steps comprising passing high pressure gases from a compressor to a cryostat through one conduit and passing low pressure, high velocity from the cryostat to the compressor.
BRIEF DESCRIPTION OF THE FIGURES
[0013] The invention may be understood more readily, and various other aspects and features of the invention may become apparent from consideration of the following description and the figures as shown in the accompanying drawings, wherein:
[0014] FIG. 1 shows a prior art cryostat-compressor arrangement;
[0015] FIG. 2 shows cross-sectional view of an embodiment of the invention;
[0016] FIG. 3 shows a cryostat-compressor arrangement in accordance with the invention; and
[0017] FIG. 4 shows a hose according to the present invention in more detail.
DETAILED DESCRIPTION OF THE INVENTION
[0018] There will now be described, by way of example, the best mode contemplated by the inventors for carrying out the invention. In the following description, numerous specific details are set out in order to provide a complete understanding of the present invention. It will be apparent, however, to those skilled in the art, that the present invention may be put into practice with variations of this specific.
[0019] FIG. 1 shows a basic representation of a magnetic resonant imaging machine system 10 with a cryostat and imaging equipment 12 enclosing a patient 20 . Gas transfer hoses 16 and 18 connect the compressor 14 with the equipment 12 . An pulsed supply of gas flows from the compressor 14 to a refrigerator, cryostat, or other equipment 12 , and back again from the refrigerator, cryostat, or other equipment 12 to the compressor. The present invention is particularly applicable to supply and return hoses used to supply a refrigerator 12 with pulsed or oscillating gas flow from a remote compressor 14 .
[0020] The hoses 16 , 18 are preferably convoluted, so as to better withstand the required operating pressures. The hoses 16 , 18 may be formed from thin walled stainless steel. As the gas passes over the internal convolutions of each hose, a whistling sound is created. This is typically most dominant in the low pressure hose, where the gas is more voluminous having expanded, as its energy and temperature have been increased during the energy transfer process of cooling in the cryostat. The volume flow rate in the low pressure hose is accordingly significantly greater than the volume flow rate in the high pressure hose. Such acoustic disturbances may set up vibrational disturbances in the equipment 12 . This may limit the ability for the equipment 12 to be usefully employed in industrial and medical applications which may be intolerant of physical vibrations. The noise itself can limit the use of equipment 12 using such gas hoses due to the unpleasant working environment for the operator caused by the noise. In medical applications, the noise may cause an unpleasant environment for the patient, which may be stressful and may cause the patient to move, preventing clear imaging.
[0021] FIG. 2 shows a cross-sectional view through a gas transfer hose 22 made in accordance with an embodiment of the invention. An inner hose 30 defines an inner conduit 24 within a second conduit 26 defined by outer hose 32 . Braiding 34 preferably surrounds the hose 32 for strength and abrasion resistance. Inner hose 30 is supported within the outer hose 32 by supports 28 which may be continuous supports—for example as made in an extrusion process—or may be individual supports placed at regular intervals. It is important, in the event that individual supports are employed, that the supports are spaced such that they do not allow the inner hose to lie against the outer hose.
[0022] As with the prior art arrangement of FIG. 1 , the hoses 30 , 32 are preferably convoluted, so as to better withstand the required operating pressures. The hoses 30 , 32 may be formed from thin walled stainless steel. As the gas passes over the internal convolutions of each hose, a whistling sound is created. This is typically most dominant in the low pressure hose, where the gas is more voluminous having expanded, as its energy and temperature have been increased during the energy transfer process of cooling in the cryostat. The volume flow rate in the low pressure hose is accordingly significantly greater than the volume flow rate in the high pressure hose.
[0023] The inventors have found that the coaxial arrangement of hoses as shown in FIG. 2 contributes to an overall reduction in the level of noise produced in the hoses. It is believed that noise generated by gas flowing through one conduit is cancelled, to some extent, by noise due to gas which is flowing in the opposite direction in the other conduit.
[0024] Once a piece of equipment 12 is installed and the minimum distance between compressor 14 and equipment 12 such as a cryostat is determined, the length of the hose 22 can be tuned to achieve a minimum noise level. Conveniently, in use, the supply of compressed gas is provided from the compressor 14 through the outer conduit 26 . The return flow of low pressure gas from the supplied equipment 12 flows through the inner conduit 24 . In such an arrangement, the second conduit 26 can further reduce noise transmission to a certain extent by a muffling effect. The functions of the outer and inner conduits may be reversed.
[0025] While braiding 34 is shown in the embodiment if FIG. 2 for strength and abrasion resistance, similar braiding may be applied to the outer surface of the inner hose 30 . As well as increasing the overall strength of the structure, such a placement of braiding may also reduce noise still further, by damping the vibrations of the wall of inner hose 30 . Such braiding may also advantageously streamline the flow of gas through the outer conduit 26 .
[0026] In certain embodiments, the inner surfaces of hoses 30 , 32 may also or alternatively be braided. Such braiding will not provide abrasion resistance, but may reduce the overall level of noise, either by mechanically damping vibration of the hoses, or by streamlining the gas flows through the conduits.
[0027] FIG. 3 shows a schematic, part sectional representation of a hose in accordance with the invention in operating position, linking a compressor 14 to a refrigerator, cryostat, or other supplied equipment 12 . At the compressor 14 , there is an outlet 42 and an inlet 44 , providing connection to hose conduits 32 a and 32 b to supply compressed gases to the equipment 12 ; and to receive high velocity, low pressure exhaust gases from the equipment 12 , respectively, via hose 30 . At the equipment 12 , there is an inlet 46 and an outlet 48 providing connection to hose conduits 50 a and 50 b , to receive compressed gases from the compressor 12 ; and to supply high velocity, low pressure exhaust gases to the compressor 12 , respectively. Hose conduits 32 a and 50 a connect to flanges 36 , 38 which are associated with the outer conduit 26 and compress outer tube 32 against a terminal/junction piece (not shown). Such junction piece preferably has rounded contours to enable a smooth gas flow between outer conduit 26 and respective hose conduits 32 b and 50 b . At the equipment 12 the tubes 50 b and 50 a connect with outlet 48 and inlet 46 ports. The ports 46 , 48 maybe associated with a service neck 40 of a cryostat 12 .
[0028] Inside tube 30 may carry low pressure gas, as this will generate most noise and can then be more effectively soundproofed by enclosure within the outer tube 32 . Alternatively, the inner hose 30 may provide a conduit 24 for the compressed gas, where it is likely to suffer less energy increase from the exhausted gas at low pressure. The outer conduit 26 may have a larger cross-sectional area than inner conduit 24 , making it more suitable for carrying the low pressure gas. By carrying the low pressure gas through the outer conduit and the high pressure gas through the inner conduit, the respective gas speeds may be made more equal, which may have a beneficial effect on noise cancellation.
[0029] FIG. 4 shows an embodiment of the present invention in more detail. As shown, outer hose 32 is convoluted, and covered in braiding 34 on its outer surface. Similarly, inner hose 30 is convoluted and covered in braiding 31 on its outer surface. The remaining features carry labels corresponding to the labels of FIG. 3 .
[0030] Comparative tests have been conducted using Siemens OR64 magnetic resonance system, connected to a Sumitomo model reference CSW 71 gas compressor. A microphone was mounted on a tripod 1.15 m above floor level, 0.46 m away from a magnet to detect noise emitted by the hoses. At various pulse tube refrigerator operating frequencies (1.56, 1.75, 1.8 Hz), the noise levels at five positions were tested.
[0031] In the reference arrangement, conventional twin hoses were used. A separate 35 mm diameter, 20 m long convoluted hose was used to connect each of the inlet 44 and outlet 42 ports of the compressor 14 to the corresponding port 46 , 48 of the magnet. The results of this conventional arrangement were compared with an arrangement using a hose 22 according to the present invention with a bidirectional coaxial hose 22 , again of 20 m length, having coaxial convoluted outer 32 and inner 30 hoses. The hose 22 had a first conduit 24 having an inside diameter of 25 mm and a second conduit 26 having an inside diameter of 50 mm. The coaxial inner hose 30 had an outside diameter of 35.1 mm.
[0032] The results showed that the arrangement according to the present invention produced a reduction in hose noise of up to 3 dB. Differences in heat exchange properties were also noticeable.
[0033] The present invention provides a neat solution to the issue of gas induced noise in gas conduit pipes supplied with pulse dor oscillating gas flow. In the setting up of a system it will be necessary to tune the length of a conduit to enable appropriate connection of services to a cryostat. A minimum length of hose can be used as a guide to the actual length of tube required. Once a reduced noise level has been attained with the cryostat in operation, it may be worthwhile employing sound insulating foam about the hose to still further reduce noise transmitted by the hose. While the invention has been described with particular reference to convoluted hoses, at least some of the advantages of the present invention may be achieved with non-convoluted hoses.
[0034] While the invention has been discussed with particular reference to gas supply to and from refrigerators for MRI systems, at least some of the advantages of the present invention may be achieved in any application where return supply of gas is required, particularly pulsed or oscillating supplies of gas. | A gas transfer hose for connecting a cryogenic apparatus to a superconducting system such as a magnetic resonant imaging system. The improved gas transfer hose, in operation, is quieter than hitherto. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improved low-calorie powdered ice tea mix.
More particularly, the present invention relates to a low-calorie powdered ice tea mix having improved dispersibility and solubility when mixed with liquid in the preparation of an ice tea beverage.
2. Description of the Related Art
Typical conventional powdered ice tea mixes normally comprise tea components, an artificial or natural sweetener (one or more) and a citric acid. Depending on the particular type of mix, normally the product is put into a container, followed by water addition and then stirred prior to drinking.
With the low-calorie powdered ice tea mixes of the prior art, the failure of the person preparing the beverage to follow the stated recipe of the product results in poor dispersibility and solubility of the powdered mix which in turn results in the reconstituted beverage being unattractive. Thus, if water is added to the container followed by the powdered ice tea mix being added to the water, even with agitation (such as stirring), one obtains a high level of undissolved tea or insolubles due to dispersability problems. This is particularly accentuated when using artificial or high intensity sweeteners and does not appear to be prevalent in powdered ice tea compositions using natural sweeteners.
Applicant has now discovered that the solubility problems of the prior art low-calorie powdered ice tea mixes occur when the acid and tea components are being dissolved simultaneously. Thus, it is believed that the poor dispersibility and solubility in low-calorie ice tea mixes when compared to regular powdered ice tea mixes is related to the presence of the high intensity sweeteners and thus the lack of physical bulk of such sweeteners in the mixes. In this respect, conventional powdered ice tea mixes employ citric acid which has a particle size where about 90% of the particles have a 180-425 micron size.
SUMMARY OF THE INVENTION
A feature of one embodiment of the present invention is to provide an improved low-calorie powdered ice tea mix with good dispersibility and solubility when mixed with liquid. Another feature of the present invention is to provide a powdered ice tea mix or composition which, when diluted with water, despite the user not following the proper recipe directions, results in a lower amount of insolubles or undissolved tea components in a prepared drink.
In accordance with an embodiment of the present invention there is provided a powdered ice tea composition comprising finely ground particles of ice tea solids, finely ground particles of at least one artificial sweetener and a granulated citric acid. The granules of the granulated citric acid have an average particle size where greater than about 90% of the particles are in the range of about 425 to about 1180 microns, whereby the ice tea solids and the citric acid dissolve in a liquid at different rates.
By virtue of the present invention, it is now possible to produce commercially acceptable, low-calorie powdered ice tea mixes which, when mixed with water, have good dispersibility and solubility thereby producing a consumer acceptable low-calorie ice tea beverage.
DETAILED DESCRIPTION OF THE INVENTION
A typical low-calorie powdered ice tea mix comprises tea solids, artificial sweetener and a citric acid. The powdered ice tea mix may also include other additives such as natural or synthetic tea aromas or flavours, colouring agents, additional sweeteners, preservatives, additional flavouring agents and the like.
Conventional tea solids may be employed in the present invention; such tea solids may typically include concentrates or the-like.
The tea solids may be those obtained by e.g. drying (e.g. spray-dried) tea extract although any other form of tea solids suitable for a powdered mix can be utilized. The tea extracts used to obtain the dried tea solids can be obtained from fermented or unfermented teas or mixtures thereof. The tea leaves can be enzyme treated as such treated tea leaves are believed to provide a higher yield of tea extract. The tea leaves, whether enzyme treated or not, can be processed in any conventional manner to provide the required tea extract. Pintaura, Tea and Soluble Tea Products Manufacture, (1977), pp.39-81 discloses various methods of obtaining tea extract from tea leaves.
Typically, after preparation of the tea extract, the tea extract is clarified by cooling to separate solids which form in a decreaming step. Removal of tea creams can be achieved by centrifugation, filtration, or any other suitable means. Depending on the desired tea solids concentration in the powdered ice tea mix, the extract can be further concentrated by suitable methods. The above noted Pintaura reference also discloses typical methods for decreaming, filtering and concentrating tea extracts. For spray-drying, the extract is usually concentrated to a solids level of about 20 to 35% by weight.
The amount of dried tea solids present in the compositions of the present invention may be present in an amount of from about 5 to 95% by weight of the total composition. Preferably, the amount of tea solids present is about 40 to about 50% by weight of the total composition. Of course, the higher the desired dilution ratio of water to composition, the higher the level of tea solids which should be present in the composition.
Preferably, the artificial sweetening agent is present in an amount of from about 1 about 10% by weight of the total composition. A particularly preferred amount of artificial sweetener is in the range of about 5 to about 8% by weight of the total composition. The artificial sweetener may be any suitable artificial sweetener or a mixture of several artificial sweeteners. Typical examples of such artificial sweeteners are aspartame compounds, cyclamates, sucraloses and the like. Sometimes, it may be desirable to combine one or more artificial sweeteners together or even naturally occurring sweeteners with synthetic sweeteners. It will be understood, having regard to the present invention, that the particle size of the artificial sweetener is not a critical factor relative to the particle size of the tea solids and the citric acid. Preferably, however, as is conventional, the artificial sweetener will have a relatively fine particle size in order to dissolve relatively quickly and typically this is approximately less than 150 microns.
In accordance with the present invention, it has been found that by employing coarsely granulated citric acid, there appears to be differential dissolution times for the tea solids and the acid so that improved solubility of the total composition is obtained. To this end, the coarser particles of citric acid would appear to dissolve more slowly and thus the improved solubility of the total composition is obtained.
The coarsely granulated citric acid is preferably present in the composition in an amount of about 5 to about 95% by weight of the total composition. Preferably, the coarsely granulated citric acid is present in an amount of about 30 to about 45% by weight of the composition. The coarsely granulated citric acid preferably has a particle size where greater than about 90% or more of the particles have a size ranging from about 425 to about 1180 microns. Particularly preferred is the above type of coarsely granulated citric acid where 93% or more of the particles have the above particle size range; the balance of the particles can be particles below the above range. In addition to citric acid, other conventional food grade acids may also be employed such as fumaric acid, adipic acid and the like.
As noted above, the mix may include other additives such as flavouring agents, preservatives, additional sweeteners, colouring agents, and the like. Typical examples of such other additives may include lemon oil flavouring agent, trisodium citrate, etc.
Having thus generally described the invention, reference will now be made to the following examples, describing preferred embodiments of the present invention.
EXAMPLE I
In this example, comparison of compositions according to the present invention with conventional compositions were carried out in order to demonstrate the improved attributes of this invention.
A first composition of a conventional low calorie powdered ice tea formulation containing the following ingredients was utilized (Composition A).
______________________________________ Amounts - % By WeightIngredients (Rounded off to nearest %)______________________________________Conventional Ice Tea Solids 45%Sweetening Agent (*Aspartame) 6%Food Grade Acid (Citric Acid) 34%(Having an average particle sizewhere about 90% of the particlesare in the range of about 180 toabout 425 microns)Flavouring Agents 9%Trisodium Citrate 6%TOTAL 100%______________________________________
A second composition of a low calorie powdered ice tea formulation according to the present invention containing the following ingredients was utilized (Composition B).
______________________________________ Amounts - % By WeightIngredients (Rounded off to nearest %)______________________________________Conventional Ice Tea Solids 45%Sweetening Agent (*Aspartame) 6%Citric Acid 34%(Having an average particle sizewhere greater than about 90% ofthe particles are in the rangeof about 425 to 1180 microns)Flavouring Agents 9%Trisodium Citrate 6%TOTAL 100%______________________________________
Compositions A and B were subjected to three procedures for formulating an ice tea drink.
In Test (1) 0.8 g of the product was placed into a container, water .was added and the mixture was stirred for one minute; the resulting beverage was then observed and filtered for insolubles.
In Test (2) water was put into a container first, 0.8 g of the product was added and the mixture was stirred for one minute; the resulting beverage was then observed and filtered for insolubles.
In Test (3) 0.8 g of the product was put into the container first, water was forcefully added (directly from the cold water tap) and the product was left to sit for one minute; the resulting beverage was then observed and filtered for insolubles.
The following results were obtained when measuring the amount of insolubles for the different tests using the different compositions:
______________________________________Compositions Test Method Insolubles (g/1500 mL)______________________________________A 1 0.1870B 1 0.0281A 2 0.7830B 2 0.2317A 3 0.3302B 3 0.0391______________________________________
From the above, it will be seen that compositions of the present invention (Composition B) using an average particle size for the citric acid where greater than about 90% of the particles have a size in the range of about 425 to about 1180 microns resulted in significantly reduced insolubles in the consumable liquid. | There is disclosed a low-calorie powdered ice tea composition and a method for making the same. The ice tea composition comprises finely ground particles of ice tea solids; finely ground particles of at least one artificial sweetener; and a granulated citric acid where the granules have an average particle size where greater than about 90% of the particles have a size in the range of about 425 to about 1180 microns. With such a composition, the ice tea solids and the citric acid dissolve in a liquid at different rates. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to sewing machines which are supported in a work table for tilting between a sewing position and an elevated position wherein the sewing machine may be serviced or the like.
It is common in the sewing industry to support a sewing machine in a work table with the work table also supporting a clutch motor beneath the surface thereof for driving the sewing machine upon actuation by the operator through a foot controller or the like. The clutch motor is connected to the sewing machine by means of a drive belt or belts which belts are usually under tension during operation thereof. As such sewing machines are usually heavy it is often difficult to elevate the sewing machine from the sewing position for inspecting or servicing the machine. Also, the difficulty of elevating the sewing machine is often increased due to the fact that the drive belts connecting the clutch motor and the machine are under tension and when it is desired to tilt the machine one must work against the tension of the belts to elevate the same. It is known in the art that the belts may be completely removed to elevate the sewing machine in order to overcome working against the tension of the belts. However, this is not entirely satisfactory since it is often difficult to get at the belts to remove them from the pulleys and also once the machine is returned to its operating position the belts must be reinstalled which is time consuming and may require the services of a skilled mechanic.
SUMMARY OF THE INVENTION
According to the present invention, a belt tensioning mechanism is provided which maintains the drive belts under tension during operation of the sewing machine but relieves the tension on the belts during elevation of the machine for servicing or the like. The operation of the invention is such that when the machine is tilted to an elevated position the belts need not be removed while at the same time the tension in the belts is released so as not to provide a force from the belts opposing the effort of the person lifting the machine.
The present invention is carried out by providing an idler pulley disposed intermediate of the clutch motor and the driving mechanism of the sewing machine for supporting the drive belts and which idler pulley is also supported for movement along a fixed path with the sewing machine during elevation thereof to the tilted position. The fixed path of movement of the idler pulley is selected such that during elevation of the sewing machine to the tilted position the distances between the axis of the clutch motor and the idler pulley and the axis of the idler pulley and the driven mechanism of the sewing machine will decrease so that the tension in the belts will be relieved during said elevation. During return movement of the sewing machine to a working or sewing position, the path of the idler pulley is such that the aforementioned distances will increase whereby tension in the belts will be automatically restored.
Accordingly, it is one object of the invention to provide a novel and improved belt tensioning mechanism for a tiltable sewing machine.
It is another object of the invention to provide a novel and improved mechanism to permit easy tilting of a sewing machine from a work table surface without requiring any removal of the drive belts or handling or adjustment of parts therefore.
It is a further object of the invention to provide a novel and improved belt tensioning mechanism for a tiltable sewing machine wherein, during tilting of the sewing machine, tension on the drive belts is relieved and upon return of the sewing machine to a sewing position tension in the drive belts is automatically restored.
It is still another object of the invention to provide a novel and improved mechanism for permitting quick and easy disconnecting of the sewing machine from the work table and associated drive mechanism.
Other objects and advantages of the invention will be best understood when reading the following detailed description of the preferred embodiment of the invention with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents a front plan view of a sewing machine supported in a work table;
FIG. 2 is an enlarged partial sectional view of the invention showing a portion of the drive mechanism of the sewing machine of FIG. 1;
FIG. 3 is an enlarged end view partially in section of the combination shown in FIG. 1 including a portion of the sewing machine thereof illustrated in the sewing position; and
FIG. 4 is a view similar to that shown in FIG. 3 but illustrating the sewing machine in the elevated or tilted position.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings in particular FIG. 1, there is shown therein a sewing machine 10 supported in a work table 12 which also supports a clutch motor 14 for driving the sewing machine in a manner which is known in the art and which will be more fully referred to hereinafter. The sewing machine 10 includes a standard 16 supporting an arm 18 which supports and contains the standard sewing mechanism of the sewing machine. The sewing machine 10 also includes a base member 20 which supports the standard 16 and arm 18 and in turn is supported in the table top 22 of the table 12. The top 22 is provided with a sewing machine opening 24 (FIGS. 3 and 4) and also includes indentations or sockets 26 for receiving ball members 28 affixed to the base 20. Preferrably there are three ball members 28 provided on the base 20, there being two spaced ball members 28 adjacent each end of the rear portion of the sewing machine base member 20, or the right hand side as viewed in FIGS. 3 and 4, and one such ball member 28 positioned substantially at the center portion of the base 20 so as to provide a tripod-like support for the sewing machine in the work table top 22.
The clutch motor 14 is supported in a frame structure 30 which in turn is suitably fixed to the work table 12. The frame structure 30 which is provided between the clutch motor 14 and table 12 may comprise a block 31 on table 12 bolted to an arm 33 extending from the clutch motor housing. The arm 33 is adjustable relative to the block 31 for permitting adjustment of the tension in the drive belt 48 by adjusting the clutch motor upwardly or downwardly. The clutch motor 14 is of the standard type found in the industry which provides on-off type operation for the sewing machine 10 in accordance with manual actuation by an operator as by a knee actuator 32 or suitable treadle device (not shown). The clutch motor 14 includes a main shaft 34 on which is fixed for rotation therewith a pulley 36. The pulley 36 carries a motor drive belt 38 and connects the pulley 36 with one side of a double idler pulley 40 which is supported for rotation about a shaft 42 as by bearings 43. The shaft 42 is supported in a pair of spaced walls 44 and 46 of the belt housing 47 for movement relative thereto as will be more fully explained below. As also seen in FIGS. 3 and 4 the belt housing 47 is connected by screws 49 in slots 51 to the clutch motor section of the housing 47 for permitting adjustment therebetween to adjust the tension in belt 38. The machine drive belt 48 is carried by the other side of the double pulley 40 and extends around a pulley 50 which is fixed to the drive shaft 52 for the sewing machine 10. As illustrated in FIG. 2, the machine drive shaft 52 is supported for rotation in the base 20 of the machine frame as by ball bearings 53 or the like. As will be apparent, when the operator actuates the knee actuator 32 the clutch motor will drive the pulley 36 fixed to the shaft 34 to drive the belt 38 and pulley 40 which in turn drives the belt 48 to drive the machine pulley 50 and the drive shaft 52 for transmitting power from the clutch motor 14 to the various elements of the sewing machine such as the sewing mechanism and feed mechanism.
It is often necessary to tilt the sewing machine from the sewing position illustrated in FIG. 3 to an elevated or tilted position illustrated in FIG. 4 as for inspection or servicing or the like. Because the drive belts between the clutch motor and the sewing machine must be under tension in order to properly transmit power, it is very difficult to raise or tilt the sewing machine without somehow releasing the tension as, for example, by disconnecting or removing a belt or the belts connected to the sewing machine drive mechanism. Removing the belts is often very time consuming and can be dangerous, and usually requires the services of a skilled serviceman. As will be apparent from the description found hereinafter, the present invention provides a means for relatively quickly raising or tilting the sewing machine without disconnecting any of the belts and with a minimum of difficulty.
Referring now particularly to FIGS. 2 - 4, it will be seen that the shaft 42 and its double idler pulley 40 are supported in a slot 54 in walls 44 and 46. As best seen in FIG. 2, the shaft 42 is supported by a pair of bushings 56 and 58 in the said slot 54 and "C" - rings 60 are disposed at each axial end of the shaft 42 for maintaining the bushings 56 and 58 in place relative to the shaft 42 and the slot 54. The bushing 58 includes an annular groove 62 in which is positioned the slotted end of a lock rod 64. The opposite end of the lock rod 64 is provided with a hook portion 66 for detachably engaging an annular grooved elastomeric shock absorbing member 67 mounted on a protruding stud 68 suitably fixed to the base member 20 and extending therefrom for receiving the hook portion 66. The hook portion of the lock rod 64 is adjustable relative to the main body of the rod 64 and is provided with screws and slotted portions for providing a lengthwise adjustment of the hook end relative lock rod main body in order to accommodate variations in the positions of the stud portion 68 for different machines or the like. Thus it will be apparent that there is provided a rigid connection between the sewing machine base 20 and the double idler pulley 40 so that any initiation of movement of the lock rod 64 in a substantially vertical path will cause initiation of a similar movement to the pulley 40.
With reference to FIGS. 3 and 4 it will be seen that when the machine is tilted from a sewing position to an elevated position in FIG. 4 the lock rod 64 will be raised as it is hooked to the machine base 20 and in turn will cause the double idler pulley 40 to follow. As the double idler pulley 40 is positioned within the slot 54 its movement will be restrained to the shape of the slot. The slotted end of the lock rod 64 which contains the double idler pulley 40 permits for some relative movement between the lock rod 64 and said pulley 40 in order to accommodate differences in the path of movement. As further seen in FIGS. 3 and 4 the slot 54 has a substantially curved path. The curved or arcuate shape of the slot 54 is generated about an axis which is offset from the axis of the clutch motor 14 and the axis of the machine drive shaft 52. The site of the axis of the curved slot 54 is chosen such that the path of travel of the pulley 40 will be such that as the machine is elevated the distance between the axis of the clutch motor 14 and the axis of the pulley 40 and the distance between the axis of machine drive shaft 52 and the axis of the pulley 40 will decrease.
It will be apparent therefore that as the machine is raised and the pulley 40 travels upwardly in the slot 54 the tension in the belt 38 between the clutch motor 14 and the pulley 40 and the tension in the belt 48 between the pulley 50 and the pulley 40 will be relieved or decreased. Therefore, as the operator or the serviceman lifts the machine the tension in the belts will not add any restraint to said lifting thereby removing this factor from the difficulty in raising the sewing machine to the elevated position. Thus, the machine may be elevated relatively easily and without requiring removal of either of the belts 38 or 48. When any inspection or servicing is completed, the operator or serviceman need only lower the machine to the sewing position wherein the lock rod 64 will cause the pulley 40 to travel downwardly or in a return path along slot 54 and which during such return the tension in the belts 38 and 40 will be restored to their former condition. If it is desired to completely remove the machine from the table 12, it is only necessary to swing the machine upwardly as seen in FIG. 4 and pull the lock rod 64 to the left or towards the front of the machine as viewed in FIGS. 3 and 4 wherein the hook end portion of the lock arm 64 will be removed from the annular shock absorber 67 on stud 68. At that time the lock rod 64 is raised along with pulley 40 to relieve tension in the belt 48 and the belt 48 can be removed from pulley 50 and the machine completely removed from the opening 24 in the table top 22.
It will be apparent from the above description that a novel and improved belt tensioning means for a tiltable sewing machine is provided wherein the machine can be relatively easily elevated within a work table without requiring removal of any belts and wherein the tension in the belts is relieved so as not to provide an opposing force to the lifting thereof. When the sewing machine is returned to its original sewing position the tension in the belts is automatically restored so that no time need be wasted in replacing belts on pulleys or in adjusting the tension. While the invention has been described in its preferred embodiment it will be apparent to those skilled in the art that various modifications and changes may be made without departing from the spirit and scope as defined in the appended claims. | This disclosure relates to the combination of a sewing machine and a work table wherein the sewing machine is supported in the work table for movement between a sewing position and a tilted position, a drive motor supported remote from the driven mechanism of the machine and an idler pulley supported intermediate the drive motor and the machine with the idler pulley drivingly connecting the machine with the drive motor by means of drive belts, and the idler pulley being supported for movement with the sewing machine during tilting thereof in a manner whereby the tension in the drive belts is relieved during tilting of the sewing machine and tension is restored during return movement of the sewing machine to the sewing position. | 3 |
The invention relates to a piston pump, particularly a radial piston pump for producing high-pressure fuel in a common rail, high-pressure fuel injection system.
BACKGROUND OF THE INVENTION
In diesel engines, the fuel is injected, atomized as finely as possible, into the combustion chamber of the engine. Piston pumps, in particular radial piston pumps of compact construction, are used for producing the high fuel injection pressure necessary for this purpose. Particularly for common-rail injection systems, use of a radial piston pump having a plurality of pump pistons permits the generation of constant high-pressure fuel supply.
In known radial piston pumps, three pump pistons are generally arranged in a pump housing in the radial direction around a camshaft. An eccentric cam having a central shaft, which is connected to the camshaft of an engine rotates with the camshaft. The rotation of the camshaft causes a polygon ring, which is arranged concentrically with respect to the eccentric cam, to execute a movement in the direction of the longitudinal axis of the pump piston and a transverse movement. The pump piston is pressed toward the polygon ring by a spring. The stroke movement is transmitted from the polygon ring to the pump piston via a piston-end disc. The transverse movement leads to a movement of the polygon ring relative to the piston-end disc. With the large forces, which occur on the basis of the high pressures, this transverse movement leads to increased wear between the piston-end disc and polygon ring. In addition, the high frictional forces decrease the efficiency of known piston pumps.
It is the object of the present invention to provide a high-pressure piston pump for pumping fuel, which is subjected only to low wear during operation.
SUMMARY OF THE INVENTION
In a piston pump for providing high-pressure fuel in a common-rail fuel injection system including a camshaft ( 2 ), which is mounted rotatably in a pump housing ( 1 ) and which has at least one eccentric cam 93 ) for operating a pump piston ( 4 , 14 ) in an approximately radial direction with respect to the camshaft ( 2 ), in order to reduce the wear of the piston pump, a piston-rod element ( 6 , 16 , 26 , 36 , 46 ) is arranged between each pump piston ( 4 , 14 ) and the eccentric cam ( 3 ) so as to transmit the stroke movement ( 5 ) and the force from the eccentric cam of the camshaft ( 2 ) to the pump piston ( 4 , 14 ) by a rolling movement thereby reducing friction and wear.
The bearing surface, which faces the eccentric cam, advantageously engages the eccentric cam over an angle of less than 180°. Expediently, a plurality of pump pistons is provided, and the piston-rod elements can be rotated at least in one angular range about the eccentric-cam central axis independently of other piston-rod elements.
The piston-rod element is expediently in contact on one contact surface with the contact surface of the pump piston, with at least one of the contact surfaces being of convex design. This enables a rolling movement to be obtained between the pump piston and piston rod element, with the result that no sliding friction and therefore virtually no wear occurs between the pump piston and piston rod element. By means of the use of the crank-mechanism principle in conjunction with the rolling coupling and transmission of force from the piston-rod element to the pump piston, the sliding friction, which occurs in the prior art, between the polygon ring and piston-end disc is thus avoided, in which case the surface pressure which occurs in the contact surface area between the piston-rod element and the pump piston clearly remains below the permissible limit value because of the large diameters which can be realized for the radii of curvature of the contact partners.
It may be advantageous for one of the contact surfaces to be concave, with the radius of the concave contact surface being greater than the radius of the convex contact surface. The concave and convex contact surfaces roll on each other. The difference between the radii of curvature is as small as possible so as to minimize the surface pressure. However, it may also be advantageous for both contact surfaces to be convex. One contact surface, in particular the contact surface of the pump piston, is expediently planar. The planar contact surface is expediently arranged perpendicularly with respect to the longitudinal axis of the pump piston. However, it may be advantageous, particularly in order to compensate for tangentially acting dynamic forces, for the planar contact surface of the pump piston to be inclined relative to the longitudinal axis of the pump piston.
The contact surface of the piston-rod element is expediently curved concentrically with respect to the central axis of the eccentric cam. The concentric design of the contact surface has the effect that the forces which are introduced act directly on the central point of the eccentric cam, and a torque about the axis of the eccentric cam acting upon the piston-rod element is not produced. Provision is made for at least one contact surface to be curved spherically. At least one contact surface is advantageously curved cylindrically, in particular the contact surface having the smaller radius is curved spherically and the contact surface having the larger radius is curved cylindrically. In order to compensate for the dynamic inertia forces which occur and, in particular in the downstroke, to prevent a relative movement between the pump piston and piston-rod element, the contact surface of the piston-rod element may be convex, with that region of the contact surface which is in contact with the pump piston in the downstroke having a smaller radius of curvature. The smaller radius of curvature, which, in particular, is smaller than the spacing of the contact surface from the central axis of the eccentric cam, results in a torque which acts on the piston-rod element counter to the dynamic inertia forces.
In order to reduce the surface pressure and/or for adaptation to the size of the eccentricity of the eccentric cam, the end of the pump piston which is in contact with the surface of the piston-rod element may be provided with a larger diameter so as to enlarge the contact surface.
In order to provide for a compact design a plurality of piston-rod elements may be distributed around the circumference of the eccentric cam. In order to avoid the possibility of the piston-rod elements becoming detached in the radial direction from the eccentric cam during the down-stroke, fingers may protrude from each piston-rod element in the circumferential direction, which fingers engage adjacent piston-rod element with a small radial spacing. The fingers expediently extend from each piston-rod element in the circumferential direction towards both sides. Since there is always only one piston-rod element in a down-stroke mode, the adjacent piston-rod elements, which are pressed in the upstroke against the eccentric cam by the pump piston, can hold the piston-rod element, which is in the upstroke, in place. However, it may also be advantageous for the pump piston to be pressed against the piston-rod element by means of a spring. In this case, the fingers serve as a safety device in the event of a spring breakage. In order to avoid that the pump piston does not follow the piston-rod element in the down-stroke particularly if the spring breaks, provision is made for the pump piston to be held on the piston-rod element in a form-fitting manner, in particular by means of a clip. If the pump piston and piston rod elements are connected in a form-fitting manner, a spring does not have to be provided.
Substantially greater forces act between the piston-rod element and the pump piston in the upstroke than in the downstroke. In order to reduce the surface pressures in the upstroke, the longitudinal axis of the pump piston may be arranged in spaced relationship with respect to the camshaft axis. This offset enables the surface where the piston-rod element and pin are in contact in the upstroke to be shifted into the region of the pump-piston center.
At least one guide member is provided in order to limit the relative movement between the piston-rod element and pump piston in the circumferential direction of the eccentric cam. The guide member is expediently arranged approximately level with the contact surfaces and, in the circumferential direction, approximately in the center of the rolling region, since in this region the relative movement in the radial direction between the piston-rod element and pump piston is minimal. Guide members may also be arranged on both sides of the contact surfaces in the circumferential direction. The guide members extend approximately parallel to the piston longitudinal axis, in particular in the positions in which the pump piston has covered half the upstroke or half the downstroke. However, it may also be expedient for a guide structure to be arranged on the pump housing.
In order to reduce the surface pressure, the piston-rod element may be of multi-part design, the individual segments being arranged in the direction of the piston longitudinal axis and being moveable relative to one another on contact surfaces, and, in particular, the radii of curvature of the contact surfaces increasing outwards in the radial direction. As a result, a convexly curved contact surface rolls in each case on a concavely curved contact surface. The effective radius decisive for the Hertzian stress increases herein as the difference between the radii decreases. The arrangement of a plurality of parts of a piston-rod element thus enables the Hertzian stress to be reduced.
In order to reduce wear, the piston-rod element may have an insert made of wear-resistant material, in particular of anti-friction bearing steel or of ceramic, in the region of the contact surface. In order to reduce the friction and to improve the emergency running properties, a bearing-shell segment may be arranged on the piston-rod element between the piston-rod element and the eccentric cam, the said bearing-shell segment being, in particular, PTFE-coated. The bearing-shell segment is expediently soldered onto the piston-rod element, in particular with soft solder or with low-melting, silver-containing solder. In particular, the bearing-shell segment is fastened in a form-fitting manner, advantageously by bending it over and/or clipping it on. However, it may also be expedient for a bearing sleeve particularly one, which is coated with PTFE, to be arranged on the circumference of the eccentric cam.
Exemplary embodiments of the invention will be described below with reference to the drawing:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic illustration of a piston pump with a piston-rod element, which is arranged between the pump piston and an eccentric cam, in the downstroke,
FIG. 2 is a diagrammatic illustration of the piston pump of FIG. 1 in the upstroke,
FIG. 3 shows a section through a piston pump with three radially arranged pump pistons,
FIG. 4 is, in a sectional illustration, showing a detail of a piston pump in the upstroke,
FIG. 5 shows the detail from FIG. 4 with the pump piston in the downstroke,
FIG. 6 is a diagrammatic illustration of the pump piston, piston-rod element and eccentric cam with an axial offset between the pump piston and camshaft axis in the downstroke,
FIG. 7 is a diagrammatic illustration of the arrangement from FIG. 6 in the upstroke,
FIG. 8 is a diagrammatic illustration of a design variant of the pump piston spring plate with a guide for the piston-rod element and piston-rod element,
FIG. 9 is a diagrammatic illustration of a further design variant of the piston-rod element,
FIG. 10 is a sectional illustration of a further design variant of a piston-rod element, and
FIG. 11 is a sectional illustration of a further design variant of the piston-rod elements and of the guides.
FIG. 12 shows an arrangement with curved engagement surfaces of the piston and the piston rod element, and
FIG. 13 shows an arrangement with curved contact surface of the piston rod element and a flat piston end face which however is slightly inclined.
DESCRIPTION OF PREFERRED EMBODIMENTS
The coupling of a pump piston 4 to an eccentric cam 3 is illustrated diagrammatically in FIGS. 1 and 2 . The pump piston 4 is mounted approximately radially with respect to the axis 7 of the camshaft 2 in a pump housing 1 . The pump piston 4 is biased in the direction of the camshaft axis 7 by a compression spring 11 . The compression spring 11 is supported at one end on the housing 1 and at the other end on a spring plate 17 , which is fixed to the pump piston 4 . An eccentric cam 3 , the central axis 10 of which is spaced apart radially from the camshaft axis 7 , is arranged on the camshaft 2 .
A piston-rod element 6 is arranged between the eccentric cam 3 and pump piston 4 . The piston-rod element 6 rests on a bearing sleeve 50 , which is arranged on the circumference of the eccentric cam 3 , and can rotate about the central axis 10 of the eccentric cam 3 . In this case, the support surface 54 of the piston-rod element 6 surrounds the eccentric cam by less than 180°. With a contact surface 8 , the piston-rod element 6 is in contact with the contact surface 9 of the pump piston 4 . Rotation of the camshaft 2 causes the piston-rod element to execute a sinusoidal movement in the radial direction and a sinusoidal movement transversely thereto. The movement in the radial direction is transmitted to the pump piston 4 , which executes a stroke movement 5 including a downstroke 5 ′ and an upstroke 5 ″.
In the case of the downstroke illustrated in FIG. 1 , the contact surfaces 8 and 9 touch one another at the contact point 20 , which may also be linear, depending on the design of the contact surfaces 8 , 9 . The pump piston 4 is pressed against the piston-rod element 6 by the spring 11 and therefore follows the eccentric cam 3 during the down-stroke 5 ′. During the upstroke 5 ″ illustrated in FIG. 2 , the pump piston 4 is forced by the eccentric cam 3 via the piston-rod element 6 radially outwards from the cam center point against the force of the spring 11 . During the stroke movement 5 , the contact surfaces 8 , 9 roll on each other. During rolling the stroke movement and the force are transmitted by the piston-rod element 6 to the pump piston 4 .
FIG. 3 shows a piston pump having three pump pistons 4 arranged radially about the camshaft axis 7 . The eccentric cam 3 is arranged on the camshaft 2 . Three piston-rod elements 6 are distributed around the circumference of the eccentric cam 3 and in each case have a bearing-shell segment 25 with which they can slide on the eccentric cam 3 . The piston-rod elements 6 can be moved relative to one another. On the side facing the pump piston 4 , the piston-rod elements 6 have a contact surface 8 , which can be formed, for example, from anti-friction bearing steel or ceramic. The contact surface 9 of the pump piston 4 is of planar design and is arranged perpendicularly with respect to the longitudinal axis 12 of the pump piston 4 . The contact surface 8 of the piston-rod element 6 is curved concentrically with respect to the eccentric cam 3 . The contact surface 8 is bounded in the circumferential direction by guide walls 13 . The guide walls 13 extend approximately parallel to the longitudinal axis 12 of the pump piston 4 in the positions in which the pump piston 4 has covered half of the upstroke 5 ″ or half of the downstroke 5 ′. The contact surface 8 is in contact with a contact surface 9 of the pump piston 4 .
Formed above the piston-rod element 6 , on the pump piston 4 , is a bead 45 at which the spring plate 17 is held axially in the direction of the camshaft 2 . However, it may be advantageous for the spring plate 17 to be held by a locking ring arranged in a groove of the pump piston 4 . The spring 11 is supported radially to the inside against the spring plate 11 and radially to the outside against an insert 47 , which is fixed on the housing and which has a bore 52 in which the pump piston 4 is guided. The pump chamber 44 , into which fuel can flow via a valve 24 , which is designed, in particular, as a nonreturn valve, is formed at the end of the pump piston 4 . A nonreturn valve (not illustrated) in the outlet prevents the fuel fed into the high-pressure tank during the upstroke 5 ″ from flowing back into the pump chamber 44 .
During rotation of the camshaft 2 , the eccentric cam 3 actuates the pump pistons 4 successively via the piston-rod elements 6 . In the downstroke 5 ′, fuel is sucked into the pump chamber 44 via the inlet 22 and the valve 24 . The valve in the outlet is closed. The pump piston 4 is pressed against the piston-rod element 6 by the spring 11 . During the upstroke 5 ″, the piston-rod element presses the piston 4 radially to the outside against the force of the spring 11 and the hydraulic pressure, as a result of which the fuel in the pump chamber 44 is pressed through the nonreturn valve in the outlet, which valve automatically opens during the upstroke 5 ″, into a high-pressure tank. During the stroke movement, the piston-rod elements 6 and the pump pistons 4 roll on one another on the contact surfaces 8 and 9 . Since the forces always act perpendicularly on the surfaces, the pump piston is always acted upon only by a force parallel to the longitudinal axis 12 while the piston-rod element 6 is acted upon by a force in the direction of the center point of the eccentric cam. As a result, a torque about the central axis 10 of the eccentric cam is not transmitted to the piston-rod element 6 . The rolling movement means that there is no sliding movement between the pump piston 4 and piston-rod element 6 .
The forces, which are in effect, are illustrated diagrammatically in FIGS. 4 and 5 . FIG. 4 shows a piston 4 during the upstroke 5 ″. Owing to the sinusoidal movement in the horizontal direction, dynamic inertia forces θ·ω act on the piston-rod element 6 . The frictional force R, which acts between the piston-rod element 6 and pump piston 4 , counteracts the inertia forces. In the upstroke 5 ″, the force F and hence also the frictional force R are very large, with the result that, in spite of the inertia forces θ·ω, sliding between the piston-rod element 6 and pump piston 4 cannot occur. Since the contact surface 8 of the piston-rod element 6 is formed concentrically with respect to the central axis 10 of the eccentric cam at the contact point 20 in that instance, the force F acts directly on the central axis 10 . The force F corresponds approximately to the pressure of the fuel in the pump chamber 44 (illustrated in FIG. 3 ) multiplied by the surface area of the pump piston 4 .
In the down-stroke 5 ′, which is illustrated in FIG. 5 , the lower pressure in the pump chamber 44 means that the force F is likewise lower. The frictional force R also counteracts the dynamic inertia force θ*ω here. However, the lower force F means that the frictional force R is also substantially lower. The contact surface 8 of the piston-rod element 6 has, at the contact point 20 at that instance, a radius which is smaller than the spacing between the contact surface 8 and central axis 10 of the eccentric cam 3 . As a result, the force F does not act on the central axis 10 , but at a distance 1 therefrom. This produces a torque about the central axis 10 which counteracts the dynamic inertia force θ*ω and therefore prevents sliding.
FIGS. 6 and 7 diagrammatically illustrate a pump piston 4 in the downstroke 5 ′ and in the upstroke 5 ″. The rolling regions in the contact surface 9 are illustrated on the pump piston 4 . The longitudinal axis 12 of the piston 4 is spaced from the camshaft axis 7 . FIG. 6 shows the piston 4 in the position in which the pump piston 4 has covered half of the downstroke 5 ′. The distance a between the camshaft axis 7 and piston longitudinal axis 12 leads to a reduction in the contact surface in the downstroke 5 ′. Since the surface pressures also depend on the contact surface, they are increased as a result. Since, however, only low forces act on the pump piston 4 in the downstroke 5 ′, this does not result in impermissibly high surface pressures.
In the case of the upstroke 5 ″ illustrated in FIG. 7 , the rolling region between the pump piston and piston rod element 6 is displaced toward the center of the pump piston 4 . Because of the circular cross section of the pump piston 4 , this results in an increase in the amount of contact surface 9 which is loaded in the upstroke 5 ″ and therefore to a reduction in the surface pressures. The surface pressures which occur in a cylindrical pump piston 4 can therefore be reduced by an offset between the camshaft and piston longitudinal axis by the distance a.
FIG. 8 diagrammatically illustrates a design variant. The pump piston 14 , the contact surface 19 of which faces the piston-rod element 16 , and interacts with the contact surface 18 of the piston-rod element 16 , is guided in the pump cylinder 15 . The piston-rod element 16 is arranged via a bearing-shell segment 25 on an eccentric cam 3 and is actuated by the latter, as already described. The spring 11 is fixed in place in the axial direction by the spring plate 27 , which is fixed on the pump piston 14 . Arranged on that side of the spring plate 27 which faces the piston-rod element 16 are guides 23 which extend both in the direction of the pump piston 14 and in the direction of the piston-rod element 16 from the region of the contact surfaces 18 and 19 .
The contact surface 19 of the pump piston 14 is planar and extends perpendicularly to the longitudinal axis 12 of the pump piston 14 . The contact surface 18 of the piston-rod element 16 is curved concentrically with respect to the central axis 10 of the eccentric cam 3 . The guide pin 49 arranged on the piston-rod element 16 reaches between the guide walls 23 arranged on the spring plate 27 . The side walls of the guide pin 49 extend parallel to the guide walls 23 in the positions in which the pump piston 4 has covered half of the downstroke 5 ′ or half of the upstroke 5 ″. The guide walls 23 prevent a relative movement between the piston-rod element 16 and the pump piston 14 in the circumferential direction. Since the relative movement in the radial direction level with the contact surfaces 18 , 19 is minimal, there will be only minimal radial relative movement and therefore virtually no wear in the contact points of the guides 23 and guide pin 49 when the contact points between the guides 23 and guide pin 49 are arranged in this radial region. In order to achieve small surface pressures during the transfer of the compressive forces from the piston-rod element 16 to the pump piston 14 , the longitudinal axis 12 of the pump piston 14 is also offset relative to the camshaft axis 7 .
FIG. 9 illustrates an exemplary embodiment for a piston-rod element 26 , which is of multi-part design. The piston-rod element 26 has three cup-shaped segments, which are arranged one above another in the radial direction with respect to the eccentric cam 3 . The inner segment 35 has a contact surface 25 with which it is supported on the eccentric cam. On the radially outer side, the segment 35 has a contact surface 42 which is curved convexly and which has guides 56 in the circumferential direction. The segment 34 , the outside diameter of which corresponds approximately to the inside diameter on the contact surface 42 , is arranged radially outwards on the segment 35 . That contact surface 41 of the segment 34 which faces the segment 35 is curved concavely, with the radius of the contact surface 41 being greater than the radius of the contact surface 42 .
On the radially outwardly facing side, the segment 34 has a contact surface 40 which is curved convexly, with this radius of curvature having the same center point as the radius of curvature of the contact surface 41 . The segment 34 also has guides 57 in the circumferential direction. Arranged radially outside the segment 34 is the segment 32 , whose contact surface 39 , which faces the segment 34 , is curved convexly and rolls on the contact surface 40 while the radially outwardly facing contact surface 28 is in contact with the pump piston 4 via the contact surface 9 . The segment 32 has guides 33 in the circumferential direction. During movement of the eccentric cam 3 , the segments 32 , 34 and 35 of the piston-rod element 26 roll on one another. Small surface pressures are produced because of the relatively small differences between the radii of the surfaces rolling on one another. Piston-rod elements, which are formed only from two or from more than three segments, may also be advantageous.
The piston pump illustrated in FIG. 10 corresponds largely in its function and its construction to the piston pump shown in FIG. 3 . Arranged on the circumference of the eccentric cam 3 are three piston-rod elements 36 , which are supported on the eccentric cam 3 via bearing-shell segments 25 . The piston-rod elements 36 act on the pump piston 4 via contact surfaces 38 . The movement in the circumferential direction between the piston-rod element 36 and pump piston 4 is limited by guides 43 , which are arranged on both sides of the contact surfaces 38 in the circumferential direction. The piston-rod elements 36 have lugs 37 pointing towards the adjacently arranged piston-rod elements 36 on both sides in the circumferential direction, the lugs 37 engaging at a small radial spacing over the respective adjacent piston-rod element 36 . Since at least one pump piston always executes an upstroke 5 ″ and a large force F acts on the corresponding piston-rod element 36 in the direction of the central axis 10 of the eccentric cam 3 , the piston-rod elements 36 secure one another in the radial direction via the lugs 37 . Even if a spring 11 breaks, this avoids a piston-rod element 36 from lifting off the eccentric cam 3 to too great an extent, thereby preventing, for example, blocking the pump.
FIG. 11 illustrates a further embodiment in a sectional view. Arranged in the radial direction of the eccentric cam 3 are three piston-rod elements 46 , which are supported on the eccentric cam via bearing-shell segments 25 . The radially outwardly pointing contact surfaces 48 of the piston-rod elements 46 are curved concentrically with respect to the central axis 10 of the eccentric cam 3 and roll on the contact surfaces 9 of the pump pistons 4 . In order to prevent a relative movement between the pump piston 4 and piston-rod element 46 , a stop 51 , which has two lateral guide walls 53 , is arranged on the housing. The adjacent piston-rod elements 46 can butt in the circumferential direction against these guide walls 53 and the central piston-rod element 46 can in turn butt against the adjacent piston-rod elements 46 in their extreme positions, with the result that sliding of the contact surfaces 9 and 48 on each other is avoided. At the same time, it is avoided that a piston-rod element 46 can be removed to such an extent from the associated pump piston 4 in the circumferential direction that the pump piston 4 is no longer in contact with the contact surface 48 . However, it may also be advantageous to provide for each piston-rod element 46 a guide wall 53 fixed on the housing.
The piston-rod elements are advantageously produced from cost-effective materials by machining, shaping or casting. In the region of the contact surfaces, the piston-rod elements advantageously have an insert made of hard and wear-resistant material. This may advantageously be anti-friction bearing steel or ceramic. The bearing-shell segments, which are arranged between the piston-rod element and the eccentric cam 3 , are expediently coated with a layer having good emergency running properties, for example PTFE. The bearing-shell segments can be soldered onto the piston-rod elements, in particular with a low-melting solder, for example soft solder or silver-containing solder having a melting point of approximately 220° C. However, it may also be expedient for the bearing-shell segments to be riveted on the piston-rod elements or to be bent over and/or clipped on at the bearing-shell edges. Instead of the bearing-shell segments, it may also be expedient for a bearing sleeve to be fitted on the circumference of the eccentric cam, which bearing sleeve can, in particular, be shrunk on and can be coated, for example, with PTFE.
The piston-rod elements are expediently mounted through the walls of the pump housing 1 in the direction of the central axis 10 of the eccentric cam 3 . However, it may also be expedient to mount the piston-rod elements via the pump piston 4 by means of a corresponding connection. The contact surfaces may be of planar design in the direction of the central axis 10 , so that planar or cylindrical contact surfaces are produced. However, it may also be advantageous for the contact surfaces to be curved in the direction of the central axis 10 , as a result of which, in particular, spherically curved contact surfaces are produced. In an advantageous manner, the contact surface having the smaller radius value is curved spherically and the contact surface having the larger radius is curved cylindrically.
FIG. 12 shows the pump piston 4 with a curved surface rolling on the curved surface 48 of the piston rod element 46 . The curved surface 48 may include a region R with a somewhat reduced radius of curvature.
FIG. 13 shows the surface 48 of the piston rod element curved convexly and in contact with the flat surface 9 of the piston, which flat surface 9 however is slightly inclined with respect to the longitudinal axis of the piston 4 or rather to a plane extending normal to the longitudinal axis of the piston 4 . | In a piston pump for providing high-pressure fuel in a common-rail fuel injection system including a camshaft ( 2 ), which is mounted rotatably in a pump housing ( 1 ) and which has at least one eccentric cam 93 ) for operating a pump piston ( 4, 14 ) in an approximately radial direction with respect to the camshaft ( 2 ), in order to reduce the wear of the piston pump, a piston-rod element ( 6, 16, 26, 36, 46 ) is arranged between each pump piston ( 4, 14 ) and the eccentric cam ( 3 ) so as to transmit the stroke movement ( 5 ) and the force from the eccentric cam of the camshaft ( 2 ) to the pump piston ( 4, 14 ) by a rolling movement. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates in general to an evaporative control in an internal combustion engine adapted to trap fuel vapor in a fuel tank, etc. of a fuel supply system of the engine and supply the vapor together with air to an intake passage, etc. of the intake system and more particularly to a purge gas quantity control in such an internal combustion engine.
2. Description of the Prior Art
A fuel vapor control system has heretofore been proposed in which fuel vapor in a fuel tank, etc. in a fuel supply system of an internal combustion engine is once trapped by a canister and then the trapped vapor is purged from the canister so that the purged air-fuel mixture (purge gas) is supplied by way of a purge line to an intake system of the engine, whereby to prevent the fuel vapor in the fuel tank, etc. from being emitted into the open air, as disclosed in JP-A-62-7962 (Laying-open publication of Japanese patent application).
In the above described fuel vapor control system for supplying the purge gas from the canister to the intake system of the engine, extra purge gas is added to usual air-fuel mixture, so there is a possibility of a large variation in air-fuel ratio due to the supply of the purge gas. The purge gas supply quantity is thus controlled so that its influence over the injection quantity Ti of fuel supplied to the engine is constant, e.g., the percentage of the purge gas quantity relative to the fuel injection quantity Ti is equal to or less than 10% or so. Specifically, a purge gas quantity is determined so as to have a predetermined ratio relative to a basic fuel injection quantity T P or the like engine operating condition, and the width of pulse for drive of a purge control valve serving as a purge gas quantity altering means is controlled so that the purge gas quantity determined as above is attained.
However, with the structure adapted to control the purge gas quantity in accordance with the basic fuel injection quantity T P , the purge gas quantity is caused to decrease as the vehicle goes to a higher altitude, and it becomes impossible to attain a required purge gas quantity, resulting in that fuel vapor is escaped from the canister and hydrocarbons HC are emitted into the open air. Due to this, there exists a problem that the emission control standards having become more stringent recently cannot be met.
In this instance, the reason why the purge gas quantity reduces as the vehicle goes to higher altitudes is as follows. That is, consider a case in which a vehicle whose engine is conditioned so as to meet the requirement for the purge gas quantity at flatlands or low altitudes, goes to highlands or higher altitudes. The purge gas quantity is firstly determined by the difference of the pressures across the purge control valve (P P -P E ) and the opening area of the purge control valve (i.e., drive pulse width).
When going to higher altitudes, the atmospheric pressure PA becomes lower. Due to this, when the same basic fuel injection quantity T P as that at flatlands is given, the pressure P E downstream of the purge control valve becomes higher. Thus, assuming that the pressure P P upstream of the purge control valve is constant, controlling the purge control valve by the same drive pulse width causes the purge gas quantity to be reduced.
On the other hand, the pressure within the fuel tank is determined by the check valve for the fuel tank and the atmospheric pressure, so the pressure within the fuel tank becomes lower at higher altitudes, and also the pressure P P upstream of the purge control valve becomes lower.
As a result, the differential pressure (P P -P E ) across the purge control valve becomes smaller, and thus the purge gas quantity is reduced.
SUMMARY OF THE PRESENT INVENTION
In accordance with the present invention, there is provided a fuel vapor control system for an internal combustion engine, which comprises fuel vapor adsorbing means for adsorbing fuel vapor produced in a fuel supply system of the engine, purge means for purging fuel vapor from the fuel vapor adsorbing means and supplying it together with air to the intake system of the engine, purge gas quantity altering means for altering a quantity of purge gas purged from the fuel vapor adsorbing means and supplied to the intake system of the engine by way of the purge means, engine operating, condition detecting means for detecting an operating condition of the engine, basic purge gas quantity determining means for determining a basic purge gas quantity based on an engine operation condition detected by the engine operating condition detecting means, altitude detecting means for detecting an altitude at which the engine is located and producing a signal representative thereof, purge gas quantity correcting and determining means for correcting the basic purge gas quantity determined by the basic purge gas quantity determining means, in response to the signal from the altitude detecting means and determining a conclusive purge gas quantity, and purge gas quantity control means for controlling the purge gas quantity altering means based on the conclusive purge gas quantity corrected and determined by the purge gas quantity correcting and determining means.
The above structure is effective for solving the above noted problems inherent in the prior art system.
It is accordingly an object of the present invention to provide a novel and improved fuel vapor control system for an internal combustion engine which can prevent the escape of fuel vapor from the engine with efficiency and assuredness, irrespective variations of the altitude at which the engine is located.
It is a further object of the present invention to provide a novel and improved fuel vapor control system of the above described character which can assuredly attain a required purge gas quantity both at low altitudes and high altitudes and thus can meet with the emission control standards which have become more stringent recently.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram for general illustration of a fuel vapor control system according to an embodiment of the present invention;
FIG. 2 is a schematic view for more specific illustration of the fuel vapor control system of FIG. 1;
FIG. 3 is a flow chart for illustration of a control effected by the fuel vapor control system of FIG. 1;
FIG. 4 is a graph for illustration of a map table, previously stored, of a relation of correction coefficient K P and atmospheric pressure;
FIG. 5 is a graph for illustration of a map table, previously stored, of a relation of a basic fuel injection quantity T P and a basic purge gas quantity Pa;
FIG. 6 is a flow chart for illustration of a control effected by a vapor fuel control system according to another embodiment of the present invention;
FIG. 7 is a graph for illustration of a map table, previously stored, of throttle opening α in relation to a parameter of throttle valve opening TVO;
FIG. 8 is a graph for illustration of a map table, previously stored, of basic fuel injection quantity T P α-N in relation to a parameter of engine speed N and throttle opening area α;
FIG. 9 is a graph for illustration of a map table, previously stored, of a relation between correction coefficient K P and (T P -T P α-N);
FIG. 10 is a flow chart for illustration of a control effected by a fuel vapor control system according to a further embodiment of the present invention;
FIG. 11 is a graph for illustration of a map table, previously stored, of throttle-passed intake air quantity Q.sub.α-N in relation to a parameter of throttle opening area α; and
FIG. 12 is a graph for illustration of a map table, previously stored, of a relation of correction coefficient K P and (Q-Q.sub.α-N).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIGS. 1 and 2, a fuel vapor control system according to an embodiment of the present invention will be described.
As shown in a block diagram of FIG. 1, a fuel vapor control system consists of a fuel vapor adsorbing means 1, a purge means 2, a purge gas quantity altering means 3, an engine operating condition detecting means 4, an altitude detecting means 5, a basic purge gas quantity determining means 6, a purge gas quantity correcting and determining means 7, and a purge gas quantity control means 8.
More specifically, with additional reference to FIG. 2, an engine 11 has an induction passage 12 which is provided with an airflow meter 13 for detecting a flow rate Q of intake air supplied by way of an air cleaner (not shown) and a throttle valve 14 movable in timed relation to an accelerator pedal (not shown) for controlling the flow rate Q of intake air. The intake passage 12 includes branch portions of an intake manifold downstream of the throttle valve 14 and is provided at each branch portion with a fuel injection valve 15 for each cylinder, constituting a fuel supply means.
The fuel injection valve 15 is driven by an injection pulse signal from a control unit (C/U) 16 comprised of a microcomputer, to open intermittently for injection of fuel to be supplied.
A coolant temperature sensor 17 is provided for detecting a temperature T w of coolant within a water jacket of the engine 11.
An exhaust passage 18 is provided at a collective portion of an exhaust manifold (i.e., a portion where manifold branches are collected) with an air-fuel ratio sensor (hereinafter referred to as oxygen sensor) 19 constituting a means for detecting an air-fuel ratio of an intake mixture by detecting the oxygen content in the exhaust gases and at an exhaust pipe downstream of the collective portion with a three-way catalytic converter 20 for oxidation of CO and HC and reduction of NOx for thereby purifying the exhaust gases.
A crank angle sensor 21 is incorporated in a distributor (not shown) to detect engine speed N by counting, for a fixed time, unit crank angle signals generated by the crank angle sensor 21 in timed relation to engine speed or by measuring the cycle in which a reference crank angle signal is generated by the crank angle sensor 21.
An atmospheric pressure sensor 32 is provided for constituting the altitude detecting means 5 for detecting an altitude by detecting an atmospheric pressure.
The fuel supply system of the engine 11 will now be described. Within a fuel tank 22, there is disposed a fuel pump 23, so that the fuel discharged from the fuel pump 23 is conducted through a fuel supply passage 25 and a pressure regulator 24 where it is regulated to a predetermined pressure and is supplied to the aforementioned fuel injection valve 15. The excess fuel from the pressure regulator 24 is returned through a return fuel passage 26 to the fuel tank 22.
Fuel vapor staying at an upper part of the space within the fuel tank 22 is drawn through a fuel vapor passage 28 provided with a check valve 27 into a canister 29 and is trapped by the canister 29. The fuel vapor temporarily trapped by the canister 29 is purged therefrom and drawn through a purge passage 31 equipped with a purge control valve 30 into the intake passage 12 downstream of the throttle valve 14.
In this instance, the structure for drawing the fuel vapor staying at the upper part of the space within the fuel tank 22, by way of the fuel vapor passage 28 and into the canister 29, and trapping the fuel vapor by the adsorbent within the canister 29, constitutes the fuel vapor adsorbing means 1 of the fuel vapor control system of this invention.
The structure for fluidly connecting the canister 29 to the intake passage 12 at a portion thereof downstream of the throttle valve 14 by way of the purge passage 31, constitutes the purge means 2 of the fuel vapor control system of this invention.
The purge control valve 30 constitutes the purge gas quantity altering means 3.
The control unit 16 determines the quantity of purge gas to be drawn into the engine 11 by way of the purge passage 31 based on detection signals from various sensors and controls the duty (i.e., turning on and off) of the purge control valve 30.
The purge gas control by the control unit 16 of the fuel vapor control system according to an embodiment of the present invention will be described with reference to the flow chart of FIG. 3.
In the meantime, as will be seen from the flow chart of FIG. 3, the basic purge gas quantity determining means 6, the purge gas quantity correcting and determining means 7 and the purge gas quantity control means 8 are constituted by the software or programs of the control unit 16.
In this embodiment, the engine operating condition detecting means 4 is constituted by the airflow meter 13 and the crank angle sensor 21.
Further, in this embodiment, the basic purge gas quantity determining means 6 is constructed so as to determine a basic purge gas quantity corresponding to a present engine operating condition by retrieval from a memory means in which basic purge gas quantity in relation to a parameter of engine operation condition is stored.
The basic purge gas quantity determining means 6 may be constructed so as to determine a basic purge gas quantity based on a basic fuel supply quantity representing an engine operating condition.
The purge gas quantity correcting and determining means 7 is constructed so as to correct the purge gas quantity in such a manner that the purge gas quantity increases as the altitude becomes higher.
In this embodiment, the altitude detecting means 5 is constituted by the atmospheric pressure sensor 32 which serves as an atmospheric pressure detecting means for detecting the atmospheric pressure.
In the flow chart of FIG. 3, in step S1 the atmospheric pressure is detected by the atmospheric pressure sensor 32 and stored in the memory. In step S2, the correction coefficient K P for correcting a purge gas quantity which is determined in such a manner as will be described later, is set. The correction coefficient K P is set to such a value as to cause the purge gas quantity to increase as the atmospheric pressure becomes lower, i.e., as the altitude becomes higher, and is actually determined through retrieval from a map table as shown in FIG. 4 and previously stored in a read-only memory (ROM).
In step S3, a basic purge gas quantity Pa corresponding to a present fuel injection quantity T P is retrieved from the map table as shown in FIG. 5 and previously stored in a read-only memory (ROM) for determining a basic purge gas quantity Pa in relation to a parameter of a basic fuel injection quantity T P of the fuel injection valve which is calculated based on flow rate Q of intake air and engine speed N. In this instance, the percentage of the basic purge gas quantity Pa relative to the basic injection fuel quantity T P is set to a predetermined value (e.g., about 10%).
In step S4, the basic purge gas quantity Pa obtained in the step S3 is multiplied by the correction coefficient K P also obtained in the step S3, and lastly the duty for controlling the on/off operation of the purge control valve 30 is determined. In step S5, an energization control signal representing the duty is supplied to the purge control valve 30, whereby the quantity of purge gas supplied to the engine by way of the purge control valve 30 is altered under control.
As described above, in this embodiment, the atmospheric pressure is detected by the atmospheric pressure sensor 32, and as the atmospheric pressure becomes lower, i.e., as the altitude becomes higher the purge gas quantity is increased, whereby it becomes possible to attain a required purge gas quantity both in lowlands and highlands, thus making it possible to prevent the escape of fuel vapor and therefore hydrocarbons (HC) from being emitted into the atmosphere, and therefore making it possible to meet with the emission control standards which have become more stringent recently.
Another embodiment will be described hereinlater.
In this embodiment, the above described altitude detecting means 5 is constructed so as to estimate the altitude based on the result of comparison between a basic fuel injection quantity T P α-N determined depending upon engine speed N and opening area α represented by throttle valve opening (hereinafter referred to simply as throttle opening area) and a basic supply fuel quantity T P calculated depending upon engine speed N and flow rate Q of intake air.
That is, in this embodiment, the altitude detecting means 5 is constituted by the crank angle sensor 21 serving as an engine speed detecting means for detecting engine speed N, an opening area detecting means for detecting a throttle opening area α which is controlled by the throttle valve 14 serving as an intake air flow rate control means, the airflow meter 13 for detecting a flow rate Q of intake air, a basic fuel supply quantity determining means for determining the basic fuel injection quantity T P α-N as a basic fuel supply quantity depending upon detected engine speed N and detected opening area α, a basic fuel supply quantity calculating means for calculating a basic fuel injection quantity TP depending upon detected engine speed N and detected flow rate Q of intake air, and a means for estimating an altitude based on the result of comparison between the determined basic fuel injection quantity T P α-N and the calculated basic fuel injection quantity T P .
The control routine effected by this embodiment will be described with reference to the flow chart of FIG. 6.
In this flow chart, in step S11 engine speed N is read and stored. In step S12, the throttle opening area α corresponding to the present throttle valve opening degree TVO is retrieved from the map table, sotred in a read-only memory(ROM), of throttle opening area α in relation to a parameter of throttle valve opening degree TVO, as shown in FIG. 7. In step S13, the basic fuel injection quantity T P α-N corresponding to the present engine speed N and the present throttle opening area α (i.e., the engine speed N and the throttle opening area α occurring at the present time), is retrieved from the map table, stored in a read-only memory, of basic fuel injection quantity T P α-N in relation to a parameter of throttle opening area α, as shown in FIG. 8.
In step S14, the basic fuel injection quantity TP is calculated by the following expression.
T.sub.P =(Q/N)×K
where Q is flow rate of intake air, N is engine speed and K is constant for determining basic air-fuel ratio.
In step S15, the difference (T P -T P α-N) between the basic fuel injection quantity TP obtained in the step S14 and the basic fuel injection quantity T P α-N obtained in the step S13 is calculated.
In this instance, the above described difference (T P -T P α-N) is related to the altitude and becomes larger as the altitude becomes higher. Accordingly, the altitude can be estimated based on (T P -T P α-N).
In step S16, the correction coefficient K P for correcting the purge gas quantity, which is determined in such a manner as will be described hereinlater, is determined in accordance with (T P -T P α-N). The correction coefficient K P is set to such a value as to allow the purge gas quantity to increase as (T P -T P α-N) becomes larger, i.e., the altitude becomes higher and specifically retrieved from the map table shown in FIG. 9 and stored in a read-only memory (ROM).
Step S17 and onward are the same as the step S4 and onward in FIG. 3.
In this embodiment, as described above, the purge gas quantity is increased as the difference between the basic fuel injection quantity T P which is calculated depending upon engine speed N and flow rate Q of intake air and the basic fuel injection quantity T P α-N which is determined depending upon engine speed N and throttle opening area α, becomes larger, i.e., the altitude becomes higher.
Then, a further embodiment will be described.
This embodiment is constructed so as to estimate the altitude based on the result of comparison between the flow rate Q.sub.α-N of intake air (i.e., flow rate of intake air passing throttle valve) determined depending upon detected throttle opening area α and the flow rate Q of intake air detected by the air flow meter 13.
That is, in this embodiment, the altitude detecting means 5 is constituted by an opening area α detecting means for detecting a throttle opening area α, an intake air flow rate determining means for determining a flow rate Q.sub.α-N of throttle-passed intake air depending up a detected opening area, an air flow meter 13 for detecting the flow rate Q of intake air, and a means for estimating an altitude from the result of comparison between the flow rate Q.sub.α-N of throttle-passed intake air determined as above and the detected flow rate Q of intake air.
The control routine of this embodiment will be described with reference to the flow chart of FIG. 10.
In step S21, a flow rate Q of intake air detected by the air flow meter 13 is read and stored. In step S22, the throttle opening area α corresponding to the present throttle valve opening degree TVO is retrieved from the map table, stored in a read-only memory (ROM), of throttle opening area α in relation to a parameter of throttle valve opening TVO, as shown in FIG. 7. In step 23, the flow rate Q.sub.α-N of throttle-passed intake air corresponding to the present throttle opening area α is retrieved from the map table of FIG. 11 previously stored in a read-only memory (ROM) for determining a flow rate Q.sub.α-N of throttle-passed intake air in relation to a parameter of a throttle opening area α.
In step S24, the difference (Q-Q.sub.α-N) between the flow rate Q of intake air obtained in the step S21 and the flow rate Q.sub.α-N of intake air obtained in the step S22, is calculated.
In this instance, the above described difference (Q-Q.sub.α-N) is mutually related to the altitude and becomes larger as the altitude increases. Accordingly, the altitude can be estimated from (Q-Q.sub.α-N).
In step S25, the correction coefficient K P for correcting the purge gas quantity which is determined in such a manner as will be described hereinlater, is determined based on (Q-Q.sub.α-N). This correction coefficient K P is set to such a value as to allow the purge gas quantity to increase as (Q-Q.sub.α-N) becomes larger, i.e., as the altitude becomes higher, and is actually retrieved from the map table of FIG. 12 previously stored in a read-only memory (ROM).
Step S26 and onward are the,same as the step S17 and onward in FIG. 6.
In this embodiment, as described above, the purge gas quantity increases as the difference between the flow rate Q of intake air detected by the air flow meter 13 and the flow rate Q.sub.α-N of throttle-passed intake air determined depending upon the detected throttle opening area α, becomes larger, i.e., as the altitude becomes higher. | A fuel vapor control system for an internal combustion engine is constructed so as to first determine a basic purge gas quantity based on an operating condition of the engine, then corrects the basic purge gas quantity in accordance with an altitude at which the engine is located and determines a conclusive purge gas quantity. The conclusive purge gas quantity is determined so as to increase as the altitude becomes higher, whereby the escape of fuel vapor from the intake system of the engine can be prevented with efficiency and assuredness. | 5 |
TECHNICAL FIELD
[0001] The present invention relates to methods and arrangements in a Wideband Code Division Multiple Access (WCDMA) communication system, in particular to an enhanced uplink for WCDMA.
BACKGROUND OF THE INVENTION
[0002] Enhanced uplink for WCDMA is currently being standardized within the Third Generation Partnership Project (3GPP). Among the features introduced is fast scheduling and fast hybrid Automatic Retransmission Request (ARQ) with soft combining, both located in the Node B.
[0003] Hybrid ARQ with soft combining allows the Node B to rapidly request retransmissions of erroneously received data entities, leading to significantly reduced delays compared to earlier releases of the WCDMA specification where the Radio Network Controller (RNC) is responsible for all retransmissions within the radio access network. Soft combining with hybrid ARQ can also be used to enhance the capacity of the system by deliberately target multiple transmission attempts for each data entity and use the soft combining mechanism in the receiver to accumulate the received energy until the data is successfully decoded. This can be viewed as implicit link adaptation and is not possible in earlier releases of the WCDMA specification due to lack of a soft combining mechanism in these releases. Typically, a small number of transmission attempts, i.e. a low Block Error Rate (BLER) for the initial transmission, reduce the transmission delays at the cost of a decreased system capacity. Similarly, by targeting a larger number of transmission attempts, i.e. a high BLER for the initial transmission attempt, the system capacity is increased at the cost of increased delays. The choice of hybrid ARQ operating points (in terms of the targeted number of transmission attempts) thus depends on the system load and the delay requirements for a particular service. The possibility for retransmission by the Radio Link Control (RLC) layer in the RNC remains with the introduction of hybrid ARQ in the Node B. This is useful in situations when the hybrid ARQ mechanism in the Node B cannot deliver error-free data entities to the RNC.
[0004] Fast scheduling denotes the possibility for the Node B to control when a user equipment is transmitting and at what data rate. Data rate and transmission power is closely related and scheduling can thus also be seen as a mechanism to vary the transmission power used by the user equipment for the enhanced uplink traffic on the E-DPDCH. As the power availability in the user equipment at the time of transmission is not known to the Node B, the final selection of data rate has to be performed by the user equipment itself. The Node B only sets an upper limit on the transmission power the UE may use on the E-DPDCH.
[0005] Similarly to the uplink in earlier releases of the WCDMA standard, the enhanced uplink uses inner and outer loop power control. The power control mechanism ensures that a user equipment does not transmit with higher power than required for successful delivery of the transmitted data. This ensures stable system operation and efficient radio resource utilization.
[0006] The power control mechanism consists of two parts: an inner loop, located in the Node B, and an outer loop, located in the RNC. The inner loop is fast and updates the user equipment transmission power 1500 times per second in order to combat fast fading. This is done by measuring the received Signal to Interference Ratio (SIR), comparing it with a SIR target, and sending a power control command to the user equipment. If the received SIR is below the SIR target, the user equipment is instructed to increase the transmission power and vice versa if the received SIR is above the target the user equipment is instructed to decrease. The inner loop power control operates on the DPCCH. The transmission power of the E-DPDCH is set relative to the DPCCH and depends on the instantaneous data rate on the E-DPDCH.
[0007] The outer loop sets the SIR target in the inner loop and uses statistics available to the RNC, e.g. information whether each data entity for a particular UE delivered to the RNC from the Node B is error-free or not. The outer loop is significantly slower than the inner loop and adapts to slow changes in the radio conditions to match the SIR target to the required quality of service in terms of, e.g., BLER or packet delay.
[0008] The introduction of a Hybrid ARQ protocol in the Node B requires modifications to the outer loop mechanism compared to previous releases as the hybrid ARQ protocol ideally hides all the error events from the RNC. Solutions to this problem are described in the patent application PCT/SE2004/000541, where different types of statistics on the Hybrid ARQ operation is proposed to be forwarded to the RNC. One possibility is to inform the RNC about the number of transmission attempts required until a packet is successfully received. If the number of attempts indicated to the outer loop mechanism is larger (smaller) than a target value, the SIR target is increased (decreased), resulting in the inner loop requesting a higher (lower) transmission power from the UE.
SUMMARY OF THE INVENTION
[0009] It is the object of the present invention to provide an improved method for obtaining efficient radio resource utilization in a communication network comprising a first communication network entity ( 10 ), a second communication network entity ( 15 ) connected to said first communication network over a communication interface and one or more user equipments ( 18 ) transmitting data to said second communication network entity ( 15 ) over a radio interface.
[0010] This object is achieved by a method according to the characterising portion of claim 1 .
[0011] Accordingly it is an object of the present invention to provide an improved arrangement for obtaining efficient radio resource utilization in a communication network comprising a first communication network entity ( 10 ), a second communication network entity ( 15 ) connected to said first communication network over a communication interface and one or more user equipments ( 18 ) transmitting data to said second communication network entity ( 15 ) over a radio interface.
[0012] This other objective is achieved through providing an arrangement according to the characterising portion of claim 9 .
[0013] Due to the provision of a system where the user equipments autonomously select a hybrid automatic retransmission request operation point, an improved link efficiency is obtained where the user equipment selects operating point depending of the existing circumstances, such as power availability, granted upper limit of power offset and/or on which logical channel the user equipment has received data.
[0014] Still other objects and features of the present invention will become apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed solely for purposes of illustration and not as a definition of the limits of the invention, for which reference should be made to the appended claims. It should be further understood that the drawings are not necessarily drawn to scale and that, unless otherwise indicated, they are merely intended to conceptually illustrate the structures and procedures described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] In the drawings:
[0016] FIG. 1 shows the communication network architecture according: to the present invention.
[0017] FIG. 2 illustrates the uplink channels after the introduction of the enhanced uplink according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0018] A network according to a standard like 3GPP comprises a Core Network (CN), Radio Access Networks (RAN) and User Equipments (UE) attached to a RAN, such as the UMTS Terrestrial Radio Access Network (UTRAN) architecture. FIG. 1 shows an exemplary network like this, wherein the UTRAN comprises one or more Radio Network Controllers (RNCs) 10 and one or more radio base stations 15 , in the following denoted as Node B, which are connected to the RNC 10 through the lub-interface. The UTRAN connects to the core network 12 through the lu-interface. The UTRAN and the CN 12 provide communication and control for a plurality of user equipments 18 .
[0019] Node B 15 is the function within the UTRAN that provides the physical radio link between the user equipments 18 and the network. Along with the transmission and reception of data across the radio interface the Node B 15 also applies the codes that are necessary to describe channels in a CDMA system. In Node B 15 , there is provided a scheduler which controls when a user equipment is transmitting and at what data rate. There is also provided the Hybrid Automatic Retransmission Request (HARQ), which allows Node B 15 to rapidly request retransmissions of erroneously received data entities.
[0020] The RNC 10 comprises an Outer Loop Power Controller (OLPC) which sends a SIR target level to an inner loop power controller provided in Node B 15 as described above.
[0021] In the uplink direction, several channels from each UE 18 will be transmitted with the introduction of the enhanced uplink as illustrated in FIG. 2 . The Dedicated Physical Control Channel (DPCCH) carries pilot symbols and parts of the outband control signalling. Remaining outband control signalling for the enhanced uplink is carried on the Enhanced Dedicated Physical Control Channel (E-DPCCH) which is a new control channel, while the Enhanced Dedicated Physical Data Channel (E-DPDCH) carries the data transmitted using the enhanced uplink features. As the High Speed Dedicated Physical Control Channel (HS-DPCCH) is not related to the enhanced uplink it is not discussed further.
[0022] As stated above, the scheduler in the Node B cannot set exactly which power the user equipment may use on the E-DPDCH, but can only set an upper limit on the E-DPDCH/DPCCH power ratio. Consequently, the probability of successful decoding of the transmitted data will vary, depending on the power ratio used by the user equipment. The power ratio used is not known to the RNC, which thus cannot differentiate between variations in the number of transmission attempts due to channel variations and due to the user equipment varying the E-DPDCH/DPCCH power ratio.
[0023] There are several reasons why the user equipment may vary the E-DPDCH/DPCCH transmission power for a given size of a packet:
High priority delay sensitive data. In this case, the user equipment may want to use a higher E-DPDCH/DPCCH power ratio to target a smaller number of transmission attempts than typically used in the outer loop power control. The scheduler may have granted the user equipment to use a higher upper limit on the power ratio (data rate) than can be used with respect to the amount of data in the user equipment buffer. One reason could be that the network is lightly loaded and the excess capacity can be used to lower the data transmission delays by trying to obtain a successful transmission with a smaller number of transmission attempts than typically used. Therefore, it is typically desirable if the user equipment uses as much of the granted power as possible. At the time of retransmission, the amount of power available may be larger than for the initial transmission. Provided that the user equipment is allowed to exploit this additional power for the retransmission, the data transmission delays can be reduced.
[0027] It is proposed to solve the problem outlined above by informing the outer loop power control of a momentarily change in the power offset, or targeted number of transmissions. With this information, the outer loop can determine whether a change in the number of transmission attempts compared to the configured value for a particular packet depends on variations in the channel quality or on temporary changes in the E-DPDCH power decided upon by the user equipment. For example, if the power offset is larger than configured, the outer loop power control can treat the packet as if the targeted number is achieved, although a smaller number of transmissions are needed.
[0028] The user equipment is allowed to select autonomously between a number of power offset values for each transport block size (TB size) according to a transport format (TF) table. The table below shows an example of a transport format table containing two possible offsets per transport block size. In said table two levels are available, a “normal” mode and a “boost” mode. The offset Δ corresponds to a block error rate, BLER, after N transmission attempts while the offset Δ′ corresponds to a block error rate BLER′ after N′ transmission attempts.
Power Power offset N tgt offset N tgt TF TB size normal normal boost boost 1 320 Δ N Δ′ N′ 2 2 × 320 2 × Δ N 2 × Δ′ N′ 3 3 × 320 3 × Δ N 3 × Δ′ N′ 4 4 × 320 4 × Δ N 4 × Δ′ N′ 5 5 × 320 5 × Δ N 5 × Δ′ N′ . . . . . . . . . . . . . . . . . .
[0029] The Node B can either estimate the power ratio for each transmission attempt or be informed by the UE about the ratio used through control signalling on the E-DPCCH. The number of offsets allowed for the UE can be limited in order to limit to signalling requirements or, in case the offset is estimated, simplify the estimation. The power ratio and/or the TF (or a similar quantity) that has been used by the UE is sent to the outer loop. The outer loop uses this information to adjust the SIR target according to the block error rate and number of transmission attempts corresponding to the offset.
[0030] Alternatively, if the same BLER is assumed for the different number of target attempts, the Node B can estimate the number of transmission attempts that the UE targeted, T tgt , based on the power ratio used by the UE. The outer loop can use some relation between the actual number of transmission attempts needed, N tx with the number of transmission attempts targeted by the UE, N tgt , to decide on the SIR target setting.
[0031] If the outer loop power control is situated in the RNC some information is signalled from the HARQ entity to the outer loop power control to inform the RNC about the power offset (or a similar quantity) the UE is using for a particular packet. This signalling occurs between the Node B and the RNC; so this information should be transmitted using the lub frame protocol. The needed information should preferably be included in an existing user plane frame protocol frames as a new information field. Alternatively a new frame protocol control signalling between Node B and RNC could be used.
[0032] The information signalled in the frame protocol could, for example, contain an indication on what power offset is used or weather or not the UE has used a higher offset than the minimum or some other reference level. In another solution the signalling contains a relation between the actual number of transmission attempts needed, N tx , and the number targeted by the UE, N tgt . For example the ratio, N tx /N tgt , or the difference, N tx −N tgt can be signalled.
[0033] The UE may select HARQ operating point based on which logical channel said data is received. Data with different priorities is often mapped on different logical channels, i.e. each logical channel represents different degree of priority. The skilled person realizes that the HARQ operating point may be chosen directly depending on the priority of the data was received. | A method and an arrangement for obtaining efficient radio resource utilization in a communication network comprising a first communication network entity ( 10 ), a second communication network entity ( 15 ) connected to said first communication network over a communication interface and one or more user equipments ( 18 ) transmitting data to said second communication network entity ( 15 ) over a radio interface. The user equipments ( 18 ) perform the step of autonomously selecting a hybrid automatic retransmission request (HARQ) operating point in order to efficiently deliver transmitted data. | 7 |
CLAIM TO PRIORITY
[0001] This application claims the benefit of our co-pending United States provisional patent application entitled “Method and Device to Calculate and Display the Transformation of Optical Polarization States” filed Dec. 21, 2001 and assigned serial No. 60/343,268, which is incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The invention relates to methods of using a representation called the Hybrid Polarization Sphere for calculating and displaying the polarization state of an optical beam as the beam propagates through polarizing elements (waveplates, polarizers, and rotators).
BACKGROUND
[0003] Polarization is one of the fundamental properties of electromagnetic radiation. Numerous investigations over the past two hundred years have sought to understand and control the state of polarization (SOP) of optical beams. This has led to dozens of applications of polarized light such as the measurement of the refractive index of optical materials, saccharimetry, ellipsometry, fluorescence polarization, etc., to name only a few. In recent years, fiber optic communications has led to new discoveries on the behavior of polarized beams propagating in fibers. Bit rates at and above 10 Gbs manifest polarization-related signal degradation caused by the birefringence of the fiber optic transmission medium. In order to mitigate these effects, it is important to measure, model, and display the SOP of the optical beam.
[0004] There are several standard methods for modeling the SOP of a polarized optical beam. One of the most useful is a polarimetric method known as the Poincaré Sphere (PS) method. This method is particularly valuable because it provides a quantitative visualization of the behavior of polarized light propagating through an optical fiber or optical polarizing devices.
[0005] Henri Poincaré, a French mathematician, suggested the Poincaré Sphere in the late 19th century, based on an analogy with the terrestrial (or celestial) sphere. He proposed it as a visualization tool and a calculating aid to describe the SOP of a polarized beam propagating through polarizing elements. One can readily determine the shortest travel distance between two cities, e.g., London and New York either by using the equations of spherical trigonometry (difficult) or by directly measuring the length of a piece of string stretched taut between those two locations on a terrestrial globe (easy). Poincaré conceived that SOP transformations performed by optical devices could be similarly done on the Poincaré Sphere.
[0006] Poincaré was motivated by the near-intractability of direct calculations of SOP transformations using the mathematics of his day. Nevertheless, the hoped-for simplicity using the Poincaré sphere did not occur. It was an excellent visualization tool but most practical calculations using the sphere were still extremely difficult to do. Poincaré did not take into account that no single conventional spherical polar coordinate system could simplify polarization calculations.
[0007] The computation problems for polarized light were first solved in the late 1940s with the introduction of the algebraic methods of the Jones and Mueller/Stokes calculi. These parametric calculi, however, did not directly enable simple visualizations of polarized light interactions. Thus, they did not fulfill Poincaré's goal of a device that would allow both visualization and calculation to be made in the same space without having to resort to complex algebraic and trigonometric calculations. Modern digital computers have automated the Jones/Mueller/Stokes computations, but this still does not provide a simple geometric view of how polarization works.
[0008] Remarkably, a consistent mathematical treatment of the Poincaré sphere did not appear until H. Jerrard's analysis in 1954, which provided some important clues about the Poincaré's formulation. Jerrard wrote down the first formal algorithms for using the Poincaré sphere as a computing device, and constructed a physical model to verify the usability of these algorithms. He mounted a globe in a gimbal with protractor markings, so that it could be rotated with precision around both a north-south and an east-west axis. During computation, a reference point fixed in space just above the surface of the sphere tracked the state of polarization (e.g., a crosshair projected on the surface from a fixed projector), while the sphere was rotated underneath. The computational accuracy thus depended on mechanical stability and eccentricity. To our knowledge, Jerrard's implementation never came into use as a computational aid. Our analysis of its mechanical and operational complexity led back to Poincaré's original polar coordinate system, which is optimally oriented for carrying out calculations involving rotational elements (polarizing rotators such as quartz rotators) but is not oriented for modeling phase shifting elements (waveplates).
[0009] Because of this limitation on phase shifting, we developed a new polarization sphere, which we call the Observable Polarization Sphere (OPS). This sphere also uses a spherical polar coordinate system that, as it turns out, is optimally oriented for solving problems involving phase shifting elements (waveplates). However, it is not particularly well suited for treating rotation problems. Thus, the behavior of the OPS is a mathematical dual of the Poincaré Sphere, and its applicability faces similar complications. Independently, other researchers, most notably Jerrard in 1982, Collett in 1992, and Huard in 1997, investigated similar angular representations of the Stokes parameters, but passed them over as having no apparent improvement over the Poincaré Sphere.
[0010] To combine the rotational strength of the Poincaré Sphere and the phase shifting strength of the Observable Polarization Sphere, we have superimposed the coordinate systems for both spheres, forming another representation, which we call the Hybrid Polarization Sphere (HPS). The HPS is a four-pole sphere having two orthogonal axes. This simplifies the complex system of gimbals, protractors, and fixed points needed with Jerrard's implementation of the Poincaré sphere; all the computing apparatus lies on the surface of the sphere itself. Instead of rotating a physical globe, one simply traverses lines on its surface. This means that the HPS can be realized as a flat map projection, with major advantages in both convenience and accuracy. The most flexible realization, however, uses an electronic display.
[0011] Using the HPS, we have developed algorithms that are simpler than Jerrard's for calculating and displaying the SOP of any electromagnetic beam propagating through waveplates, rotators, and ideal linear polarizers.
SUMMARY OF THE INVENTION
[0012] The present invention provides a method whereby a practitioner can visualize and calculate the polarization behavior of an optical beam as it propagates through an optical fiber system (or bulk optical system). This calculation can be done by visual interpolation using ordinary map-reading skills, and without the aid of a computer or other external calculation aid. The invention is based on a sphere, called the Hybrid Polarization Sphere, which is a superposition of the Poincaré Sphere and the Observable Polarization Sphere in mutually orthogonal orientations, consistent with the Stokes basis vectors. All polarization computations are reduced to sequences of simple angular displacements along small circle latitude lines (phase shifts) and small circle longitude lines (rotations) on the HPS. Since both coordinate systems (the Poincaré Sphere and the Observable Polarization Sphere) are superimposed, elaborate mechanical contrivances previously needed to calculate within the single polar coordinate system of the Poincaré Sphere are unnecessary.
[0013] While a geometric model of a mathematical domain is not patentable in itself, such models give rise to useful analog computing devices and methods, such as the terrestrial globe, the slide rule, and the nomograph. Even in the age of high-speed digital computers, some of these devices (e.g., the terrestrial and celestial globes) and their methods survive in simulated form. This is done not because they are essential for finding numerical solutions, but because their visual presentation remains a natural frame of reference for humans to better understand, validate, and extend those solutions. Such is the case with the methods we have invented for utilizing the HPS.
[0014] We enumerate three embodiments of the invention: using a three-dimensional globe, using two-dimensional spherical plots, and using an electronic display. The electronic embodiment is preferred. Even though computer automation of the Jones and Mueller/Stokes calculi has reduced the need for an analog computation aid, the ability to display the numerical solutions in terms of a simple geometric means will help practitioners to understand the behavior of polarized light as it propagates through a polarizing system.
[0015] The implementation of the HPS is simplified by the fact that both the Poincaré Sphere and the OPS assume a right-handed coordinate system with respect to the three Stokes polarization parameters that serve as the basis vectors of the underlying Euclidean 3-space. This ensures that the physical interpretation of clockwise vs. counter-clockwise rotation is completely consistent among the three constructs. All that is required to create the HPS is to rotate the Poincaré spherical polar coordinate system 90° clockwise relative to an OPS coordinate system.
[0016] Because the HPS superposes two complete spherical polar coordinate systems, it is a four-pole sphere. Based on the concepts of observables in optics, we elect to designate the prime axis of the OPS as the north-south (vertical) axis of the HPS, and the Poincaré prime axis becomes the east-west (horizontal) axis of the HPS. This choice has the advantage that it is directly connected to the optical apparatus used to measure polarized light.
[0017] The following table summarizes the physical interpretation of the four-pole coordinate system of the HPS in terms of fundamental properties of the polarization ellipse (Collett, 1992).
Moving Along Moving Along Coordinate Longitudinal Latitudinal System Great Circles Small Circles Poincaré changing chi (χ): changing psi (ψ): ellipticity angle rotation angle OPS changing alpha (α): changing delta (δ): arctangent of phase angle orthogonal amplitude ratio
[0018] With regard to the methods of the invention itself, calculating the behavior of an optical system begins with determining the location of an input State of Polarization (SOP) on the HPS using either Poincaré or OPS coordinates. The SOP transformations are then modeled as sequences of rotation and phase shift operations starting from the initial input SOP, according to the following rules:
[0019] Field rotations using polarizing rotators are calculated by measuring out angular displacements (θ) along longitudinal small circles (ψ) of the HPS. Counter-clockwise displacements represent positive rotator angles.
[0020] Phase shifts are calculated by measuring out angular displacements (φ) along latitudinal small circles (δ) on the HPS. Counter-clockwise displacements represent phase lead and clockwise displacements represent phase lag.
[0021] Attenuation by a rotated linear polarizer is represented by a discontinuous jump to the north pole of the HPS, followed by performing the action of rotation.
[0022] By concatenating a sequence of angular displacements, the polarization behavior of any sequence of waveplates, rotators, and polarizers upon a beam of polarized light may be calculated. The point on the HPS that is the result after all the displacements have been measured represents the final SOP for the beam emerging from the optical system.
[0023] The properties represented by psi (ψ) and delta (δ) are fundamental to high-speed fiber optic transmission systems. On the other hand, chi (χ) and alpha (α) do not represent distinct physical properties of interest in polarization measurements. When solving polarization problems on the HPS it is never necessary to traverse longitudinal or latitudinal great circles.
Mathematical Development of the Hybrid Polarization Sphere
[0024] In order to understand the Hybrid Polarization Sphere and its operation, it is necessary to understand its mathematical foundations. This is done by first describing the mathematics of the Poincaré Sphere followed by the mathematics of the Observable Polarization Sphere. In both cases the Mueller matrices for the rotation, phase shifting, and attenuation of a polarized beam are required.
[0025] Two formulations of polarized light exist. The first is in terms of the amplitudes and absolute phases of the orthogonal components of the optical field. In the amplitude representation the orthogonal (polarization) components are represented by
E x ( z,t )= E 0x cos(ω t−kz+δ x ) (1a)
E y ( z,t )= E 0y cos(ω t−kz+δ y ) (1b)
[0026] Eq. (1) describes two orthogonal waves propagating in the z-direction at a time t. In particular, in eq. (1), E 0x and E 0y are the peak amplitudes, ωt−kz is the propagator and describes the propagation of the wave in time and space, and δ x and δ y are the absolute phases of the wave components.
[0027] Eq. (1) is an instantaneous representation of the optical field and, in general, cannot be observed nor measured because of the short time duration of a single oscillation, which is of the order of 10 −15 seconds. However, if the propagator is eliminated between eq. (1a) and eq. (1b) then a representation of the optical field can be found that describes the locus of the combined amplitudes E x (z,t) and E y (z,t). Upon doing this one is led to the following equation:
E x ( z , t ) 2 E 0 x 2 + E y ( z , t ) 2 E 0 y 2 - 2 E x ( z , t ) E y ( z , t ) 2 E 0 x E 0 y cos δ = sin 2 δ ( 2 )
[0028] where δ=δ y −δ x . Eq. (2) is the equation of an ellipse in its non-standard form and is known as the polarization ellipse. Thus, the locus of the polarized field describes an ellipse as the field components represented by eq. (1) propagate. For special values of E 0x , E 0y , and δ, eq. (2) degenerates to the equations for a straight line and circles; this behavior leads to the optical polarization terms linearly polarized light and circularly polarized light.
[0029] Eq. (2) like eq. (1) can neither be observed nor measured. However, the observed form of eq. (2) can be found by taking a time average. When this is done, eq. (2) is transformed to the following equation (Collett, 1968, 1992):
S 0 2 =S 1 2 +S 2 2 +S 3 2 (3a)
[0030] where
S 0 =E 0x 2 +E 0y 2 (3b)
S 1 =E 0x 2 −E 0y 2 (3c)
S 2 =2 E 0x E 0y cos δ (3d)
S 3 =2 E 0x E 0y sin δ (3e)
[0031] Eq. (3b) through eq. (3e) are known as the Stokes polarization parameters, which are the observable (measurables) of the polarization of the optical field because they are all intensities. In order to determine the polarization of the optical field all four Stokes polarization parameters must be measured. The first Stokes parameter S 0 , is the total intensity of the optical beam. The remaining three parameters, S 1 , S 2 , and S 3 describe the (intensity) polarization state of the optical beam. The parameter S 1 describes the preponderance of linearly horizontal polarized light over linearly vertical polarized light, the parameter S 2 describes the preponderance of linearly +45° polarized light over linearly −45° polarized light, and finally the parameter S 3 describes the preponderance of right-circularly polarized light over left-circularly polarized light, respectively. The Stokes parameters, eq. (3), can be written as a column matrix known as the Stokes vector,
S = ( S 0 S 1 S 2 S 3 ) = ( E 0 x 2 + E 0 y 2 E 0 x 2 - E 0 y 2 2 E 0 x E 0 y cos δ 2 E 0 x E 0 y sin δ ) ( 4 )
[0032] Eq. (4) describes elliptically polarized light. However, for special conditions on E 0x , E 0y , δ, eq. (4) reduces to the important degenerate forms for 1) linearly horizontal and linear vertical polarized light, 2) linear +45° and linear −45° polarized light, and 3) right- and left-circularly polarized light. The Stokes vectors for these states in their normalized form (S 0 =1) are:
S LHP = ( 1 1 0 0 ) S LVP = ( 1 - 1 0 0 ) S L + 45 P = ( 1 0 1 0 ) S L - 45 P = ( 1 0 - 1 0 ) S RCP = ( 1 0 0 1 ) S LCP = ( 1 0 0 - 1 ) ( 5 )
[0033] Finally, a polarized optical beam can be transformed to a new polarization state S′ by using a waveplate, rotator, and/or linear polarizer. This is described by a matrix equation of the form
S′=M·S (6)
[0034] where M is a 4×4 matrix known as the Mueller matrix.
[0035] The Mueller matrix for a waveplate with its fast axis along the horizontal x-axis and a phase shift of φ is
M WP ( φ ) = ( 1 0 0 0 0 1 0 0 0 0 cos φ - sin φ 0 0 sin φ cos φ ) ( 7 )
[0036] Similarly, the Mueller matrix for a rotator (rotated through a positive (counter-clockwise) angle through an angle θ from the horizontal x-axis) is
M ROT ( θ ) = ( 1 0 0 0 0 cos 2 θ sin 2 θ 0 0 - sin 2 θ cos 2 θ 0 0 0 0 1 ) ( 8 )
[0037] Finally, the Mueller matrix for an ideal linear polarizer with its transmission along the horizontal x-axis is
M POL = 1 2 ( 1 1 0 0 1 1 0 0 0 0 0 0 0 0 0 0 ) ( 9 )
[0038] For rotation of a waveplate or polarizer through an angle, θ, the Mueller matrix is found to transform according to the equation
M (θ)= M ROT (−θ)· M·M ROT (θ) (10)
[0039] Straightforward substitution of the Mueller matrices for a waveplate (phase shifter) or polarizer (attenuator), eq. (7) and eq. (9), yields the rotated form. However, as we shall see, it is much more useful to use the form given by eq. (10) to describe the motion of these polarizing elements on the Hybrid Polarization Sphere.
[0040] The Poincaré Sphere
[0041] The Stokes parameters can also be expressed in terms of the orientation and ellipticity angles, ψ and χ, of the polarization ellipse. In terms of these angles, the Stokes vector is then found to have the form
S = ( S 0 S 1 S 2 S 3 ) = ( 1 cos 2 χcos 2 ψ cos 2 χsin 2 ψ sin 2 χ ) 0 ≤ ψ ≤ π , - π 4 ≤ χ ≤ π 4 ( 11 )
[0042] A sphere can be constructed in which the Cartesian x-, y-, and z-axes are represented in terms of the Stokes parameters S 1 , S 2 , and S 3 , respectively. This spherical representation is known as the Poincaré Sphere and is shown in FIG. 1. The angle ψ is measured from the S 1 axis and the angle χ is measured positively above the equator and negatively below the equator. In particular, the degenerate forms (linear and circularly polarized light) are found as follows. For χ=π/4 and χ=−π/4 eq. (11) becomes
S RCP = ( S 0 S 1 S 2 S 3 ) = ( 1 0 0 1 ) S LCP = ( S 0 S 1 S 2 S 3 ) = ( 1 0 0 - 1 ) ( 12 )
[0043] These two Stokes vectors represent right- and left-circularly polarized light and correspond to the north and south poles of the Poincaré Sphere along the positive and negative S 3 axis, respectively. This is emphasized by retaining the notation for the Stokes vector preceding each of the specific Stokes vector in eq. (12).
[0044] The equator on the Poincaré Sphere corresponds to χ=0 so eq. (11) reduces to
S LP = ( S 0 S 1 S 2 S 3 ) = ( 1 cos 2 ψ sin 2 ψ 0 ) ( 13 )
[0045] Eq. (13) is the Stokes vector for linearly polarized light. Thus, along the equator all polarization states are linearly polarized. The degenerate forms for linearly polarized light are then found by setting ψ=0, π/4, π/2, and 3π/4, respectively. Eq. (13) then reduces to the following corresponding forms:
S LHP = ( S 0 S 1 S 2 S 3 ) = ( 1 1 0 0 ) S L + 45 P = ( S 0 S 1 S 2 S 3 ) = ( 1 0 1 0 ) ( 14 a ) S LVP = ( S 0 S 1 S 2 S 3 ) = ( 1 - 1 0 0 ) S L - 45 P = ( S 0 S 1 S 2 S 3 ) = ( 1 0 - 1 0 ) ( 14 b )
[0046] Eq. (14a) and eq. (14b) clearly show that linearly horizontal polarized light and linear vertical polarized light are associated with the positive and negative Stokes parameter S 1 and linear +45 polarized light and the linear −45 polarized light are associated with the positive and negative S 2 parameter. This is important to note the construction of the coordinates of the Hybrid Polarization Sphere must be consistent with the Poincaré Sphere and the Observable Polarization Sphere. In FIG. 2, the degenerate polarization states are shown on the Poincaré Sphere.
[0047] We now describe an important property of the Poincaré Sphere, namely, its rotational behavior. In order to understand this behavior we consider that an input beam, represented by eq. (11), propagates through a rotator, eq. (8). Then, the Stokes vector of the output beam is
S′=M ROT (θ)· S (15)
[0048] and
S ′ = ( S 0 ′ S 1 ′ S 2 ′ S 3 ′ ) = ( 1 0 0 0 0 cos 2 θ sin 2 θ 0 0 - sin 2 θ cos 2 θ 0 0 0 0 1 ) ( 1 cos 2 χcos 2 ψ cos 2 χsin 2 ψ sin 2 χ ) ( 16 )
[0049] Carrying out the matrix multiplication in eq. (16) leads to
S ROT ′ = ( S 0 ′ S 1 ′ S 2 ′ S 3 ′ ) = · ( 1 cos 2 χcos ( 2 ψ - 2 θ ) cos 2 χsin ( 2 ψ - 2 θ ) sin 2 χ ) ( 17 )
[0050] Thus, the operation of a rotation on the incident beam leads to the Stokes vector of the output beam in which the initial value of ψ is decreased by the rotation angle θ. Furthermore, this means that rotation appears on the small circle latitude lines since χ remains unchanged.
[0051] Next, consider that the incident beam propagates through a waveplate represented by eq. (7). We see immediately using eq. (11) that the Stokes vector of the output beam becomes
S WP ′ = ( S 0 ′ S 1 ′ S 2 ′ S 3 ′ ) = · ( 1 cos 2 χcos 2 ψ cos 2 χsin2 ψcos φ - sin 2 χsin φ cos 2 χsin2 ψsin φ + sin 2 χcos φ ) ( 18 )
[0052] We see that there is no trigonometric simplification in the matrix elements when the input beam propagates through a waveplate, unlike that of propagation through a rotator. Thus, rotation is simplified on the Poincaré Sphere but phase shifting is not.
[0053] Finally, we consider the propagation of an incident beam, eq. (11), through an ideal linear polarizer represented by the Mueller matrix, eq. (9). We have
S′=M POL ·S (19a)
[0054] so
S POL ′ = ( S 0 ′ S 1 ′ S 2 ′ S 3 ′ ) = 1 2 ( 1 1 0 0 1 1 0 0 0 0 0 0 0 0 0 0 ) · ( 1 cos 2 χcos 2 ψ cos 2 χsin 2 ψ sin 2 χ )
and ( 19 b ) S POL ′ = ( S 0 ′ S 1 ′ S 2 ′ S 3 ′ ) = 1 2 ( 1 + cos 2 χcos 2 ψ ) ( 1 1 0 0 ) ( 19 c )
[0055] Eq. (19c) is the Stokes vector of linearly horizontal polarized light (see eq. (14a)). This is a very important result and states that regardless of the polarization state of the input beam, when the beam propagates through a linear polarizer the polarization state of the output beam will always be linearly horizontal polarized.
[0056] The Observable Polarization Sphere
[0057] It is possible to find an alternative representation of the Stokes parameters and show that they can be expressed in terms of a different set of angles, namely, the auxiliary angle α, which is a measure of the intensity ratio of the orthogonal components of the beam, and the phase angle δ (Jerrard, 1982, Collett, 1992, Huard, 1997). The Observable Polarization Sphere derives its name from the fact that the two angles α and δ, are associated with the observables (measurables) of the polarization ellipse. Analysis shows that the Stokes vector then has the form
S = ( S 0 S 1 S 2 S 3 ) = ( 1 cos 2 α sin 2 αcos δ sin 2 αsin δ ) 0 ≤ α ≤ π / 2 , 0 ≤ δ < 2 π ( 20 )
[0058] A sphere can be constructed in which the Cartesian x-, y-, and z-axes are now represented in terms of the Stokes parameters S 2 , S 3 , and S 1 , respectively. The spherical angles of the Observable Polarization Sphere are shown in FIG. 3. The angle α is measured from the vertical S 1 axis and the angle δ is measured along the equator in the S 2 −S 3 as shown in FIG. 3. In particular, the degenerate forms (linear and circularly polarized light) are found as follows. For α=π/4 and δ=π/2 and α=π/4 and δ=3π/2 eq. (20) becomes
S RCP = ( S 0 S 1 S 2 S 3 ) = ( 1 0 0 1 ) S LCP = ( S 0 S 1 S 2 S 3 ) = ( 1 0 0 - 1 ) ( 21 )
[0059] These two Stokes vectors are located at east and west ends of the equator of the Observable Polarization Sphere, that is, along the positive and negative S 3 axis, respectively. This is emphasized by retaining the notation for the Stokes vector preceding each of the specific Stokes vector in eq. (21).
[0060] The prime meridian corresponds to δ=0 and we see that eq. (20) reduces to
S LP = ( S 0 S 1 S 2 S 3 ) = ( 1 cos 2 α sin 2 α 0 ) ( 22 )
[0061] Thus, all polarization states on the prime meridian are linearly polarized. The degenerate states (Stokes vectors) are then found by setting α=0, π/4, π/2, and in eq. (20) α=π/4, δ=π, respectively. Eq. (22) then reduces to the following forms:
S LHP = ( S 0 S 1 S 2 S 3 ) = ( 1 1 0 0 ) S L + 45 P = ( S 0 S 1 S 2 S 3 ) = ( 1 0 1 0 ) ( 23 a ) S LVP = ( S 0 S 1 S 2 S 3 ) = ( 1 - 1 0 0 ) S L - 45 P = ( S 0 S 1 S 2 S 3 ) = ( 1 0 - 1 0 ) ( 23 b )
[0062] Eq. (23a) and eq. (23b) show that linearly horizontal polarized light and linear vertical polarized light are associated with the positive and negative Stokes parameter S 1 and the linear +45 polarized light and the linear −45 polarized light are associated with the positive and negative S 2 parameter.
[0063] In FIG. 4, the degenerate polarization states are shown on the Observable Polarization Sphere.
[0064] On the equator of the Observable Polarization Sphere (2α=π/2) the Stokes vector, eq. (20), reduces to
S = ( S 0 S 1 S 2 S 3 ) = ( 1 0 cos δ sin δ ) 0 ≤ δ < 2 π ( 24 )
[0065] Eq. (24) is the Stokes vector for the polarization ellipse in standard form. This behavior is preserved on the equator of the Hybrid Polarization Sphere where eq. (24) goes from linearly +45° polarized light (δ=0) to right circularly polarized light (δ=π/2), etc.
[0066] We now describe an important property (behavior) of the Stokes vector, eq. (20), on the Observable Polarization Sphere. In order to understand this behavior we again consider an input beam represented by eq. (20) that propagates through a waveplate (phase shifter), eq. (7). Then, the Stokes vector of the output beam is
S′=M WP (φ)· S (25a)
[0067] and
S ′ = ( S 0 ′ S 1 ′ S 2 ′ S 3 ′ ) = ( 1 0 0 0 0 1 0 0 0 0 cos φ - sin φ 0 0 sin φ cos φ ) · ( 1 cos 2 α sin 2 αcos δ sin 2 αsinδ ) ( 25 b )
[0068] Carrying out the matrix multiplication in eq. (25b) yields
S WP ′ = ( S 0 ′ S 1 ′ S 2 ′ S 3 ′ ) = ( 1 cos 2 α sin 2 α cos ( δ + φ ) sin 2 α sin ( δ + φ ) ) ( 26 )
[0069] Thus, the operation of waveplate on the incident beam is to increase the phase of the initial phase of the beam. This means that on the Observable Polarization Sphere, phase shifts appear on the small circle latitude lines. In addition, the phase shift is positive when moving to the right on both the Observable Polarization Sphere; this behavior is also preserved on the Hybrid Polarization Sphere.
[0070] Consider now that the incident beam, eq. (20), propagates through a rotator represented by eq. (8). We see immediately that the output beam is
S ROT ′ = ( S 0 ′ S 1 ′ S 2 ′ S 3 ′ ) = ( 1 cos 2 α cos 2 θ + sin 2 α sin 2 θ cos δ - cos 2 αsin 2 θ + sin 2 α cos 2 θ cos δ sin 2 α sin δ ) ( 27 )
[0071] Eq. (27) shows that there is no trigonometric simplification in the matrix elements when the input beam propagates through a rotator. Thus, phase shifting is simplified on the Observable Polarization Sphere but rotation is not and we see that the Poincare' Sphere and the Observable Polarization Sphere behave in opposite manners for rotation and for phase shifting.
[0072] Finally, we again consider the propagation of an incident beam represented by eq. (20) through an ideal linear polarizer represented by the Mueller matrix, eq. (9). We then see that
S′=M POL ·S (28a) S POL ′ = ( S 0 ′ S 1 ′ S 2 ′ S 3 ′ ) = 1 2 ( 1 + cos 2 α ) ( 1 1 0 0 ) ( 28 b )
[0073] We again obtain a Stokes vector that is linearly horizontal polarized. Thus, in both the Poincare' Sphere and Observable Polarization Sphere formulations the linear polarizer operation is identical.
[0074] We also consider the case where the ideal linear polarizer is rotated through an angle θ. The Mueller matrix for a rotated ideal linear polarizer is
M POL (θ)= M ROT (−θ)· M POL ·M ROT (θ) (29)
[0075] where M ROT (θ) and M POL are given by eq. (8) and eq. (9), respectively. Carrying out the matrix multiplication in eq. (29) yields
M POL ( θ ) = ( 1 cos 2 θ sin 2 θ 0 cos 2 θ cos 2 2 θ cos 2 θ sin 2 θ 0 sin 2 θ cos 2 θ sin 2 θ sin 2 2 θ 0 0 0 0 0 ) ( 30 )
[0076] Finally, multiplying the Stokes vector of the input beam, eq. (20), with eq. (30) yields
S ′ = 1 2 ( S 0 + S 1 cos 2 θ + S 2 sin 2 θ ) ( 1 cos 2 θ sin 2 θ 0 ) ( 31 )
[0077] Eq. (31) shows that regardless of the state of polarization of the incident beam, the Stokes vector of the output beam will always be on the equator for the Poincare' Sphere or on the prime meridian of the Observable Polarization Sphere. Because we choose the Observable Polarization Sphere to be the “primary” polarization sphere and the Poincare' Sphere as the “secondary” polarization sphere, the Stokes vector of the output beam will always be located on the prime meridian of the Observable Polarization Sphere; this behavior is also preserved on the Hybrid Polarization Sphere. Furthermore, if there is no physical rotation the output beam will be linearly horizontal polarized, that is, it will be located at the north pole of the Observable Polarization Sphere and the Hybrid Polarization Sphere.
[0078] The Hybrid Polarization Sphere
[0079] On the Hybrid Polarization Sphere the alpha-delta form of the Stokes vector given by eq. (20) is used to describe the coordinates. The Hybrid Polarization Sphere is constructed in the following way. First, we begin with the Observable Polarization Sphere in the orientation as shown in FIG. 4. Then the Poincare' Sphere shown in FIG. 3 is rotated clockwise through 90° and superposed onto the plot of the Observable Polarization Sphere. The resulting plot, the Hybrid Polarization Sphere, is shown in FIG. 5. On the Hybrid Polarization Sphere the longitudinal great circles represent the angle α. The latitudinal great circles, on the other hand, represent the ellipticity angle χ. Similarly, the longitudinal small circles represents the rotation angle ψ. Lastly, the latitudinal small circles represent the phase shift δ. Physical rotations are described by the rotation angle θ and physical phase shifts are described by the phase angle φ. Physical rotations and physical phase shifts take place only on the small circles. Therefore, on the Hybrid Polarization Sphere all movements due to physical rotation and phase shifting take place only on the longitudinal and latitudinal small circles. Furthermore, clockwise rotation of the polarization ellipse, described by a positive rotation angle θ, corresponds to an upward motion along the small vertical (longitudinal) rotation circle. A counterclockwise rotation of the polarization ellipse is described by the negative rotation angle θ and corresponds to a downward motion along the small vertical (longitudinal) rotation circle. Similarly, moving along the small horizontal (latitudinal) circle to the right from the prime meridian corresponds to a positive phase shift of the angle φ. Movement from the prime meridian to the left corresponds to a negative phase shift of the angle φ.
[0080] We now show that the form of the Stokes vectors for linearly polarized light are identical on both the Poincare' Sphere and the Observable Polarization Sphere. On the Poincare' Sphere the Stokes vector is given by eq. (11),
S = ( S 0 S 1 S 2 S 3 ) = ( 1 cos 2 χ cos 2 ψ cos 2 χ sin 2 ψ sin 2 χ ) 0 ≤ ψ ≤ π , - π 4 ≤ χ ≤ π 4 ( 11 )
[0081] The Stokes vector for the Observable Polarization Sphere, on the other hand, is given by
S = ( S 0 S 1 S 2 S 3 ) = ( 1 cos 2 α sin 2 α cos δ sin 2 α sin δ ) 0 ≤ α ≤ π / 2 , 0 ≤ δ < 2 π ( 20 )
[0082] In general, the vectors are obviously very different from each other. However, on the prime meridian of the Hybrid Polarization Sphere both Stokes vectors reduce to the Stokes vectors for linearly polarized light, namely,
S LP = ( S 0 S 1 S 2 S 3 ) = ( 1 cos 2 α sin 2 α 0 )
and ( 22 ) S LP = ( S 0 S 1 S 2 S 3 ) = ( 1 cos 2 ψ sin 2 ψ 0 ) ( 13 )
[0083] Thus, the forms of these vectors are identical and so on both the Poincare' Sphere and the Observable Polarization Sphere we have a complete one-to-one correspondence between α and δ and ψ and χ for all linear polarization states. This means that the movements along the small circles are identical on both spheres and on the Hybrid Polarization Sphere.
[0084] In order to describe the effects of rotation of waveplates, the equation that is to be used is
M WP (φ,θ)= M ROT (−θ)· M WP (φ)· M ROT (θ) (32)
[0085] where the Mueller matrix M WP (φ) is given by eq. (7) and M ROT (θ) is given by eq. (8). Similarly, the equation for the rotation of an ideal linear polarizer is described by
M POL (θ)= M ROT (−θ)· M POL ·M ROT (θ) (33)
[0086] where M POL is given by eq. (9). The equations for the non-rotating polarizing elements, that is, where there is only phase shifting and attenuation, are given by eq. (7) and eq. (9), respectively.
[0087] The form of eq. (32) and eq. (33) indicate the manner in which the Stokes vector that propagates through a polarizing element is generated from an incident Stokes vector. In both cases the input and output Stokes vectors are related by the equations
S′=M ROT (−θ)· M WP (φ)· M ROT (θ)· S (34)
S′=M ROT (−θ)· M POL ·M ROT (θ)· S (35)
[0088] The two equations, eq. (34) and eq. (35), describe the steps to be taken in moving on the Hybrid Polarization Sphere.
[0089] We now consider the motion of rotation and phase shifting along the longitudinal and latitudinal small circles, respectively, on the Hybrid polarization sphere.
[0090] Rotation
[0091] An incident beam is represented by a Stokes vector S. The Stokes vector is located at the coordinates α and δ. The Mueller matrix for rotation is given by eq. (8)
M ROT ( θ ) = ( 1 0 0 0 0 cos 2 θ sin 2 θ 0 0 - sin 2 θ cos 2 θ 0 0 0 0 1 ) ( 8 )
[0092] The input Stokes vector is first rotated in a positive θ direction according to the equation,
S′=M ROT (θ)· S (36)
[0093] where S′ indicates that this is the Stokes vector of the beam emerging from the operation of rotation. A clockwise rotation on the Hybrid Polarization Sphere is carried out by moving upwards from S along the vertical (longitudinal) small circle through the angle θ to S 1 . Similarly, for a counter-clockwise rotation there is a downward rotation along the vertical (longitudinal) small circle through the angle θ to S 1 .
[0094] In FIG. 6, this rotation is seen to occur along the vertical longitudinal small circles on the Hybrid Polarization Sphere. For the sake of clarity, the latitudinal great circle is suppressed.
[0095] In FIG. 7, a flow chart is presented that describes rotation in terms of the mathematical operations along with the corresponding description of the rotational movement carried out on the Hybrid Polarization Sphere.
[0096] Phase Shifting
[0097] An incident beam is again represented by a Stokes vector S. The Stokes vector is located at the coordinates α and δ. The Mueller matrix for phase shifting is given by eq. (7)
M WP ( φ ) = ( 1 0 0 0 0 1 0 0 0 0 cos φ - sin φ 0 0 sin φ cos φ ) ( 7 )
[0098] The input Stokes vector moves along the horizontal (latitudinal) small circle in a positive direction according to the equation,
S′=M WP (φ)· S (37)
[0099] through an angle φ to S′.
[0100] In FIG. 8 the phase shifting is shown taking place on the horizontal small circles on the Hybrid Polarization Sphere. Again, for the sake of clarity, the longitudinal small circles are suppressed. In FIG. 9, another flow chart is presented that describes phase shifting in terms of the mathematical operations along with the corresponding description of the rotational movement on the Hybrid Polarization Sphere.
[0101] By these two simple motions for rotation and phase shifting, all polarization states can be found and described (determined) on the Hybrid Polarization Sphere.
[0102] The Rotated Waveplate
[0103] We now consider the movement of an input Stokes vector through a rotated waveplate, eq. (34),
S′=M WP (φ,θ)· S=M ROT (−θ)· M WP (φ)· M ROT (θ)· S (38)
[0104] According to eq. (38) the input Stokes vector is first rotated in a positive θ direction according to the equation,
S′=M ROT (θ)· S (39)
[0105] where S 1 indicates that this is the (first) Stokes vector of the beam emerging from the operation of rotation. A clockwise rotation on the Hybrid Polarization Sphere is carried out by moving upwards from S along the vertical (longitudinal) small circle through the angle θ to S 1 . Similarly, for a counter-clockwise rotation there is a downward rotation along the vertical (longitudinal) small circle through the angle θ to S 1 .
[0106] Next, the beam S 1 propagates through the waveplate and undergoes a positive phase shift φ. The Stokes vector that emerges from the waveplate is then
S 2 =M WP (φ)· S 1 (40)
[0107] On the Hybrid Polarization Sphere the point S 1 moves to the right along the horizontal small circle latitude line through a phase shift angle φ to the point S 2 . Finally, S 2 undergoes a negative rotation through an angle θ and the Stokes vector of the beam becomes
S 3 =M ROT (−θ)· S 2 (41)
[0108] This final rotation operation is accomplished by moving downward along the vertical small circle rotation line through an angle θ, which corresponds to −θ.
[0109] The behavior of the rotated waveplate is shown in FIG. 10 which is a flow chart showing the mathematical operations on the left side and the corresponding operations on the right side on the Hybrid Polarization Sphere.
[0110] The Rotated Linear Horizontal Polarizer
[0111] We now consider the behavior of a rotated ideal linear polarizer on the polarization state of an incident beam.
[0112] An incident beam is again represented by a Stokes vector S. According to eq. (35) this Stokes vector is first rotated in a positive θ direction according to the equation,
S 1 =M ROT (θ)· S (42)
[0113] where S 1 indicates that this is the (first) Stokes vector of the beam emerging from the operation of rotation. This rotation is shown on the Hybrid Polarization Sphere by again moving upwards from S along the vertical small circle (rotation) through the angle θ to S 1 . Next, the beam S 1 propagates through the linear polarizer. The Stokes vector of the beam that emerges from the linear polarizer is then
S 2 =M POL ·S 1 (43)
[0114] We saw earlier that the effect of the linear polarizer is that regardless of the polarization state of the incident beam, the beam that emerges from the linear polarizer is always linearly polarized. Thus, on the Hybrid Polarization Sphere the point S 1 moves directly to the point on the sphere that represents linearly horizontal polarized light, which is the north pole of the Hybrid Polarization Sphere. In fact, we see that the first rotation described by eq. (36) has no effect on the polarization state of the incident beam S, whatsoever, so we can move immediately to the north pole on the sphere to the point S 2 . Finally, S 2 undergoes a negative rotation through an angle θ and the Stokes vector of the beam becomes
S 3 =M ROT (−θ)· S 2 (44)
[0115] This final rotation operation is accomplished by moving downward on the vertical small circle on the Hybrid Polarization Sphere line through an angle θ.
[0116] [0116]FIG. 11 shows a flow chart that describes the mathematical operations and the corresponding movement for the rotation of a linear horizontal polarizer on the Hybrid Polarization Sphere.
[0117] Finally, a cascade of polarizing elements can easily be treated on the Hybrid Polarization Sphere. A flow chart of this process is shown in FIG. 12.
[0118] Examples of the Propagation of an Input Beam through a Rotator, a Rotated Linear Polarizer, and a Rotated Waveplate on the Hybrid Polarization Sphere
[0119] In order to make the preceding analysis concrete we consider specific examples of the propagation of a polarized beam through 1) a rotator, 2) a rotated linear horizontal polarizer, and 3) a rotated waveplate of arbitrary phase. In FIG. 13 the transformation equations that should be used to transform the Stokes parameters to the α, δ form or to the Cartesian form is shown. For the sake of simplicity we consider the same input Stokes vector for each of these polarizer examples and place the incident beam location at α=π/4 and δ=11π/6. Using this coordinate pair the Stokes vector is then seen from eq. (20) to be
S = ( 1 cos 2 α sin 2 α cos δ sin 2 αsin δ ) = ( 1 0 3 2 - 1 2 ) ( 45 )
[0120] Eq. (42) describes a point that is located on the equator (2α=90°) and 30° to the left of the prime meridian (δ=−30°). This point is shown as A on the Hybrid Polarization Sphere in FIG. 14.
[0121] 1) Optical Propagation through a Rotator on the Hybrid Polarization Sphere
[0122] Consider now that the input beam is rotated in a positive direction by means of a rotator. The output beam is then found from eq. (39) to be
S′=M ROT (θ)· S (46)
[0123] The rotator is rotated, say, clockwise through an angle of θ=15°. According to eq. (8) the Mueller matrix for rotation then becomes
M ROT ( θ = 15 ° ) = ( 1 0 0 0 0 3 2 1 2 0 0 - 1 2 3 2 0 0 0 0 1 ) ( 47 )
[0124] Using eq. (42) and eq. (44) the Stokes vector of the output beam is then calculated to be
S ′ = ( 1 3 4 3 4 - 1 2 ) ( 45 )
[0125] We immediately find that the calculated values of α′ and δ′ are
α ′ = 1 2 arccos ( 3 4 ) = 32.18 ° ( 46 a ) δ ′ = - arctan ( 2 3 ) = - 33.68 ° ( 46 b )
[0126] Inspecting the Hybrid Polarization Sphere in FIG. 14 we see that we move up from the point A on the equator along the vertical small circle through 30° to point B. Each point on the small circle corresponds to 7.5° so we move up to the 4 th tic mark on the small vertical circle. We see that this mark is slightly below the 30° latitudinal circle. In terms of the angle α, (actually 2α) we observe that the angle measured down from the north pole of the sphere is 2α′=64.36°. We move directly down the prime meridian to 2α′=64.36° and then move to the left along the latitudinal small circle to the point of intersection with the vertical small circle. We see that the point of intersection corresponds to the calculated values of 2α′ and δ′. Thus, we see that by merely moving along the small vertical circle upward or downward we arrive at the correct values of 2α′ and δ′ for the Stokes vector of the output beam.
[0127] 2) Optical Propagation through a Rotated Linear Horizontal Polarizer on the Hybrid Polarization Sphere
[0128] The Stokes vector of a beam that emerges from an ideal linear polarizer rotated through an angle θ is immediately determined from the equation,
S ′ = 1 2 ( S 0 + S 1 cos 2 θ + S 2 sin 2 θ ) ( 1 cos 2 θ sin 2 θ 0 ) ( 31 )
[0129] The initial polarization state is given by the Stokes vector, eq. (42),
S = ( 1 cos 2 α sin 2 α cos δ sin 2 αsin δ ) = ( 1 0 3 2 - 1 2 ) ( 42 )
[0130] We immediately see that these parameters, eq. (42), appear in the factor before the Stokes vector in eq. (31). This shows that the polarization state of the input beam does not affect the polarization state of the output beam. With a linear polarizer, the Stokes parameters of the input beam only affect the intensity of the output beam and not its polarization; the output beam always appears on the prime meridian. For a rotation of say θ=15°. eq. (31) shows that the beam is rotated through twice this angle measured from the equation so 2θ=30°. The Stokes vector of the output beam according to eq. (31) is then
S ′ = ( 1 cos ( π 3 ) sin ( π 3 ) 0 ) = ( 1 1 2 3 2 0 ) ( 47 )
[0131] We then find that
α ′ = 1 2 arccos ( 1 2 ) = 30 ° ( 48 )
[0132] and 2α′=60°. On the Hybrid Polarization Sphere, a physical rotation of 30° corresponds to 2α=60° and so we count down from the north pole by this amount. This is shown in FIG. 15. Because of the non-uniform spacing between latitude lines, however, it is easier to count (up) from the origin O on the equator using the complementary angle of 30° to the fourth point on the prime meridian.
[0133] 3) Optical Propagation through a Rotated Waveplate on the Hybrid Polarization Sphere
[0134] The third and final type of polarizer is the rotated variable/fixed phase waveplate. We now consider its behavior on an input polarized beam on the Hybrid Polarization Sphere. We again begin with an input beam characterized by a Stokes vector
S = ( 1 0 3 2 - 1 2 ) ( 49 )
[0135] We consider that we now have a waveplate with a phase shift of, say, 60° and rotated through an angle of 15°. For these conditions the Mueller matrix for the rotated waveplate, eq. (34), is found to be
M WPROT ( φ = 60 ° , θ = 15 ° ) = ( 1 0 0 0 0 7 8 3 8 3 4 0 3 8 5 8 - 3 4 0 - 3 4 3 4 1 2 ) ( 50 )
[0136] Multiplying eq. (50) by the Stokes vector of the input beam, eq. (49), the Stokes vector of the output beam is found to be
S ′ = ( 1 3 16 - 3 8 5 3 16 + 3 8 3 3 8 - 1 4 ) ( 51 )
[0137] The angles 2α′ and δ′ are then found to be
2 α ′ = arccos ( 3 16 - 3 8 ) = 91.66 ∘ ( 52 a ) δ = arctan ( 3 3 8 - 1 4 5 3 16 + 3 8 ) = 23.56 ∘ ( 52 b )
[0138] We now show that this value is obtained by moving on the Hybrid Polarization Sphere. The movement is shown in FIG. 16.
[0139] The Stokes vector for the incident beam is again given by
S A = ( 1 0 3 2 - 1 2 ) ( 42 )
[0140] The subscript “A” is used to indicate that this is the first Stokes vector in the polarization train. The Stokes vector S A now undergoes a clockwise rotation of θ=15°. According to eq. (32) a positive rotation is made by moving up the vertical small circle to the fourth point; this point corresponds to S B . The Stokes vector is calculated to be
S B = ( 1 3 4 3 4 - 1 2 ) ( 53 )
[0141] The angles 2α′ and δ′ are then found to be
2 α ′ = arccos ( 3 4 ) = 64.33 ∘ ( 54 a ) δ ′ = - arctan ( 2 3 ) = - 33.68 ∘ ( 54 b )
[0142] Inspecting FIG. 16 we see that these values correspond to the observed S B . Next, S B undergoes a phase shift of 60°. The phase shift is shown by moving S B along a latitude line through 60° to the longitudinal great circle slight to the left of the 30° longitudinal great circle line to the point S C . The Stokes vector is calculated to be
S C = ( 1 3 4 3 8 + 3 4 - 1 4 + 3 3 8 ) ( 55 )
[0143] The angles 2α′ and δ′ are then found to be
2 α ′ = arccos ( 3 4 ) = 64.33 ∘ ( 56 a ) δ ′ = - arctan ( - 1 4 + 3 3 8 3 8 + 3 4 ) = 26.30 ∘ ( 56 b )
[0144] We see that we have indeed moved along a latitude line characterized by the above value of 2α′. Furthermore, we also note that the total phase shift between S C and S B is
φ CB =26.30°−(−33.68°)=59.98° (57)
[0145] which is the value of the expected phase shift. Finally, according to eq. (42) a negative rotation is required corresponding to θ=15°. We see that S C is slightly below 2α′=60°. Counting down from S C through four points on the small vertical circle we arrive at S D . We see that this point is slightly below the equator. The Stokes vector, S D , is calculated to be
S D = ( 1 3 16 - 3 8 3 8 + 3 2 ( 3 8 + 3 4 ) - 1 4 + 3 3 8 ) ( 58 )
[0146] The angles 2α′ and δ′ are then found to be
2 α ′ = arccos ( 3 16 - 3 8 ) = 91.66 ∘ ( 59 a )
δ ′ = - arctan ( - 1 4 + 3 3 8 3 8 + 3 2 ( 3 8 + 3 4 ) ) = 23.56 ∘ ( 59 b )
[0147] Inspecting FIG. 16 we see the exact calculation shows that S D is slightly below the equator (eq. (59a)). Furthermore, counting from the prime meridian along the equator we also see that S D is slightly to the right of the 22.5° point, the exact value being given by eq. (59b). Finally, we see that values given in eq. (59) are exactly those obtained at the beginning of this section so that we have complete agreement.
[0148] Thus, we have shown that by moving along vertical and horizontal small circles on the Hybrid Polarization Sphere we can describe and calculate visually the Stokes vectors that propagate through rotators, linear polarizers, and waveplates. While we have restricted the foregoing analysis to the treatment of just each type of polarizing element, we see that the analysis can be used to deal with any arbitrary number of polarizing elements. Thus, we can calculate visually the Stokes vector of the optical polarization train at any point without having to do the mathematical (matrix algebra) calculations. The calculations have been included in the above examples to confirm that we have indeed arrived the correct points.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0149] This invention involves the use of a geometric form: a four-pole sphere. The simplest physical embodiment of this invention uses a sphere or globe that can be constructed of plastic or other rigid material, similar to that done by H. G. Jerrard for the Poincare' Sphere (Jerrard, 1954). On this four-pole sphere, latitudes and longitudes for the Poincare' Sphere are superposed onto those of the Observable Polarization Sphere in the relative orientation described earlier. Distinctive graphical treatments for the two coordinate systems (e.g., distinct colors and labels) unambiguously show the sphere's orientation. As the sphere may be used hand-held, mounting it in a frame or gimbal would be optional. Using the device, the SOP transformation caused by any sequence of waveplates, polarizers, and rotators may be estimated by visual interpolation, without requiring solution of trigonometric equations or matrix algebra or the use of any other external calculation aid (e.g., calculator, computer, protractor, or slide rule). This would enable practitioners to calculate visually the transformation of the SOP by a sequence of polarizing elements.
[0150] A variant of the first embodiment would be a flat map using two or more orthographic projections of the HPS. FIG. 5 shows one such projection: a “front view” centered on the intersection of the OPS Prime Meridian and Equator, or, in Stokes terms, looking down the positive S 2 axis toward the origin. Placing that front view side-by-side with the corresponding “back view” of the occluded hemisphere yields a complete map of the sphere that can readily be used for the same computations as the globe. One advantage of the map-based embodiment is the ease of scaling up a map relative to a globe. A larger map means more latitude and longitude lines, and hence greater accuracy and less demand on visual interpolation. Another advantage of this particular map projection is that rotations and phase shifts correspond to horizontal and vertical straight lines on a plane, which makes them easier to draw. A disadvantage of the map approach is that rotations and phase shifts that span both hemispheres require the user to be able to locate the continuation of a horizontal or vertical line when it crosses hemispheres.
[0151] The preferred embodiment of the invention, however, is as a computer display for polarization information. The block diagram in FIG. 17 shows the four interconnected functions of this embodiment.
[0152] The box labeled Plot Manager manages both static and dynamic data plots upon the hybrid polarization sphere. It plots two different kinds of graphic elements, as described in the summary of this invention:
[0153] loci of points, where each point represents a distinct SOP
[0154] directed arc segments representing angular displacements between two SOP
[0155] Plot Manager is also capable of creating animations of dynamic system behavior, as previously described in the summary.
[0156] The box labeled Sphere Renderer depicts the hybrid polarization sphere upon the display device. This includes three parts:
[0157] the outline and form of the sphere
[0158] latitude and longitude lines for both the Poincare' and OPS coordinate systems
[0159] data points and figures plotted upon the sphere's surface, as provided by the Plot Manager
[0160] This renderer contains the following capabilities, which are common in computerized displays of geometric forms:
[0161] A method to position the displayed HPS in any orientation under interactive or program control
[0162] A method to scale the size of the HPS under interactive or program control (“zoom”)
[0163] A method to identify the location of any specific point or feature on the sphere's surface using either Poincare' or OPS coordinates.
[0164] Some variant methods for reducing visual clutter when displaying four-pole spheres also apply to our preferred embodiment:
[0165] The display of one or the other of the two coordinate systems may be temporarily suppressed
[0166] Either the latitude or longitude lines of either or both coordinate systems may be temporarily suppressed
[0167] The resolution of the latitude and longitude lines in both coordinate systems may be changed, especially but not exclusively in conjunction with scaling.
[0168] The four-pole sphere may be rendered as two mutually orthogonal two-pole spheres, one Poincare' and one OPS, displayed side-by-side and moving in tandem, and upon which identical information is plotted
[0169] None of these techniques alters or sidesteps the fundamental relationship between the two coordinate systems that is the basis of the invention. They merely filter the visual presentation of this relationship.
[0170] The boxes labeled Display Device and Display Controller contain no technology specific to this application, but are necessary for its functioning. Display Device represents a physical device for displaying graphical information to a human, either in perspective on a two-dimensional plane, stereographically or holographically in three dimensions, or as multiple orthographic plots. Display Controller stores an electronic representation of an image to be displayed and provides the electrical signals required to operate and to refresh the display device. It provides a set of well-defined interfaces so that rendering engines may update the image being displayed in real time, and thus achieve animation capabilities.
[0171] In a reference implementation of the preferred embodiment created to support this patent application, the following realizations were used:
[0172] Plot Manager: a computer program
[0173] Hybrid Sphere Renderer: a computer program using the OpenGL graphics libraries
[0174] Display Controller: a CRT display controller card in a personal computer, together with its driver software
[0175] Display Device: a CRT monitor for a personal computer
[0176] However, this choice of realization is not integral to the invention; it merely demonstrates feasibility of satisfactory performance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0177] [0177]FIG. 1. The spherical coordinates of the Poincare' Sphere.
[0178] [0178]FIG. 2. The degenerate polarization states plotted on the Poincare' Sphere.
[0179] [0179]FIG. 3. The spherical coordinates of the Observable Polarization Sphere.
[0180] [0180]FIG. 4. The degenerate polarization states plotted on the Observable Polarization Sphere.
[0181] [0181]FIG. 5. The Hybrid Polarization Sphere showing the latitudinal great circles and the longitudinal small circles. The orientation is identical to the Observable Polarization Sphere.
[0182] [0182]FIG. 6. Rotation on the Hybrid Polarization Sphere.
[0183] [0183]FIG. 7. Flow chart to describe Rotation on the Hybrid Polarization Sphere.
[0184] [0184]FIG. 8. Phase shifting on the Hybrid Polarization Sphere.
[0185] [0185]FIG. 9. Flow chart to describe Phase Shifting on the Hybrid Polarization Sphere.
[0186] [0186]FIG. 10. Flow chart to describe the rotation of a phase shifter (waveplate) on the Hybrid Polarization Sphere.
[0187] [0187]FIG. 11. Flow chart for the rotation of a linear horizontal polarizer (attenuation) on the Hybrid Polarization Sphere.
[0188] [0188]FIG. 12. Flow chart for the visualization and calculation of a cascade of N polarizing elements on the Hybrid Polarization Sphere.
[0189] [0189]FIG. 13. Conversion Equations on the Hybrid Polarization Sphere.
[0190] [0190]FIG. 14. Rotation on the Hybrid Polarization Sphere.
[0191] [0191]FIG. 15. Rotation of a Linear Horizontal Polarizer on the Hybrid Polarization Sphere.
[0192] [0192]FIG. 16. Phase Shifting with Rotation on the Hybrid Polarization Sphere.
[0193] [0193]FIG. 17. Block Diagram of the Preferred Embodiment.
[0194] In Ken K. Tedjojuwono, William W. Hunter Jr., and Stewart L. Ocheltree, “Planar Poincare Chart: a planar graphic representation of the state of light polarization,” Applied Optics , 28 (1989) 1 July, no. 13, pp. 2614-2622 a planar presentation of the Poincare' sphere (i.e., the polarization sphere with a polar coordinate system based on rotations about the Stokes S 3 axis) was developed, using two side-by-side hemispheric stereographic projections in equatorial view. Likewise, they showed a similar planar presentation for the polarization sphere with an alpha-delta coordinate system based on rotations about the Stokes S 1 axis, this time using polar views. The authors then superimposed these two figures to display a planar plot of the polarization sphere with both Poincare' and alpha-delta coordinate systems. This produced a classic stereographic projection of a four-pole sphere, viewed along the horizontal polar axis. This work was an important precursor of the current invention, facilitating the diagramming of polarization transformations that involve rotations of the polarization sphere about both the S 1 and S 3 axes, such as with rotated waveplates.
[0195] This work had significant limitations, however, with respect to the current invention. First, the authors considered only planar, static representations of the polarization sphere, such as paper charts; they did not discuss three-dimensional realizations using either physical spheres or dynamic computer graphics.
[0196] Second, they used two fixed hemispheric viewpoints that combined equatorial and polar plots. Their technique is especially useful for monochrome, non-interactive media, but offers less clarity than the current invention, which can vary its viewpoints dynamically while using other visual cues, such as color, to disambiguate multiple coordinate systems.
[0197] Third, the current invention is not restricted to stereographic projections, even in its static planar embodiments. While stereographic projections have some useful geometric properties, and we can display them, orthographic projections are equally useful in static embodiments, and much more useful in a simulated 3D environment.
[0198] Fourth, the earlier work considered only two specific polar coordinate systems, one based on S 3 -rotation (Poincare') and the other on S 1 -rotation (alpha-delta). It did not discuss other types of transformations, such as TE-TM conversion, which corresponds to rotation of the polarization sphere about the Stokes S 2 axis. The current invention is applicable to displaying and analyzing polarization transformations modeled as successive rotations of the polarization sphere about any two mutually orthogonal axes. These axes may correspond to any two of S 1 , S 2 , and S 3 , or to none of these three. For example, polarization controllers based on liquid crystal retarders create variable linear birefringence about two mutually orthogonal axes, which may or may not correspond exactly to S 1 and S 2 .
[0199] Fifth, in its computer embodiments, the current invention is not limited to displaying only two orthogonal polar coordinate systems. It may manage the display of more than two (e.g., rotations about S 1 , S 2 , and S 3 ) coordinate systems, as long as no more than two are visually emphasized at one time. This last restriction is not a limitation of our invention per se, but a concession to human visual information processing.
[0200] Finally, the current invention can display coordinate systems that deviate from strict orthogonality. This is important for analyzing devices such as liquid crystal polarization controllers, which may deviate from the orthogonal ideal by a few degrees. The current invention can vary the angle between two displayed polar coordinate systems dynamically (e.g., in order to search visually for a best fit to measured data), an impossibility with a static paper plot. | We have invented a set of calculation and display methods for polarized light using a representation that we call the Hybrid Polarization Sphere (HPS). The HPS incorporates the Poincaré Sphere and its dual, the Observable Polarization Sphere (OPS). The HPS uses a four-pole spherical polar coordinate system to map the transformation of the state(s) of polarization (SOP) of a beam of light as the beam propagates through one or more polarizing elements (polarizer, waveplate, or rotator). A simple computing aid based on the HPS leads to methods for solving optical polarization problems directly by visual measurement and interpolation. These avoid both the linear algebra and trigonometry of the underlying mathematics and the external apparatus needed to use the Poincaré Sphere for computing phase shifts. Furthermore, simulating and animating these methods on an electronic graphical display produces helpful visual explanations of numerical solutions to polarization problems. | 6 |
PRIOR RELATED APPLICATIONS
This patent application claims priority to U.S. Provisional Application Ser. No. 60/548,629, filed on Feb. 27, 2004, the disclosure of which is incorporated by reference in its entirety herein.
STATEMENT OF GOVERNMENT SPONSORED RESEARCH
At least a portion of this invention was funded by SBIR contract number DMI-0319766.
FIELD OF THE INVENTION
The present invention relates to the field of nucleic acid-based therapeutics where nucleic acid stability and retention are improved by a 3′ conjugation to a therapeutic protein. More specifically, the present invention relates to methods for production of aptamers, antisense and other nucleic acid based therapeutics that are blocked at their 3′ ends with a protein, or other large macromolecule such as a nanotube or biocide. The 3′ blocked nucleic acids have surprisingly increased stability, increased retention in the body, and with the judicious selection of conjugate can have additional therapeutic benefit as well.
For example, the therapeutic nucleic acid, such as an aptamer can be conjugated to a biocidal protein. Thus, the aptamer functions to selectively deliver the biocide to the desired target, such as a bacteria, virus or cancer cell, which is then killed by the biocide. Similarly, nanotubes can effect the delivery of small molecule drugs contained by the lattice structure of the nanotube or ball.
BACKGROUND OF THE INVENTION
Aptamers, derived from the latin aptus, meaning, ‘to fit’, are oligonucleotides that have a specific three dimensional shape and consequent biological activity. Aptamers are generally produced through a process named “systematic evolution of ligands by exponential enrichment” or “SELEX,” which is an iterative selection and amplification process. Nucleic acids that bind to a target are selected (non-binders are simply washed away) and then subjected to a round of amplification. As this process is iterated, tightly binding aptamers are enriched in the population, and extremely tight and specific binding between the aptamer and the target can be achieved. The reader is referred to U.S. Pat. No. 5,270,163 and the very large family of related patents for detailed SELEX protocols.
The extraordinary capacity of aptamers to bind tightly to specific targets underlines their tremendous potential as molecular therapeutics. For example, aptamers can be used to selectively target cells (such as tumor cells or pathogens) for death.
For example, U.S. Pat. No. 6,566,343 discusses the potential for aptamers directed at cell surface components of bacteria, cancer cells and parasites to activate the complement system and bring about the lysis of target cells. The patent discloses the linkage of two aptamers—one directed against the target cell and a second one against a component of the complement system (thus recruiting the complement cascade to the target cell)—to achieve complement activation and targeted cell death.
There are two distinct disadvantages to this approach. First, the aptamer-aptamer conjugates are subject to degradation from serum nucleases and second, the aptamer-aptamer conjugates are subject to rapid clearance by the kidneys. Thus, although aptamers are a powerful targeting system, in vivo nucleic acid stability remains a problem.
A Canadian team of researchers (Dougan et al., 2000) demonstrated that 3′-biotinylation of DNA significantly increased its resistance to serum nuclease activity. This was presumably due to steric hindrance and suggests that any 3′ or 5′ capping or nucleic acid modification should improve nucleic acid stability in vivo.
However, our research surprisingly indicates that 5′-biotinylation is not very effective against serum degradation of DNA, nor is the incorporation of 2′-Fluoro modified deoxynucleotide triphosphates (2′F-dNTPs). Thus, the stability issue is not as simply addressed as one might predict. Hence, improved methods of stabilizing nucleic acids for in vivo therapeutic use are still needed and the invention addresses this problem.
BRIEF SUMMARY OF THE INVENTION
The invention presents a novel means to conjugate nucleic acid at its 3′ end to proteins or other large macromolecules (e.g., polyethylene glycols, nanotubes, and the like). The 3′ conjugation inhibits the action of serum nucleases that would otherwise rapidly breakdown the DNA in blood, and it dramatically increases retention of the aptamers in blood, which would otherwise be rapidly filtered out by the kidneys.
The invention allows the production of aptamers, antisense and other nucleic acid based therapeutics that are blocked at their 3′ ends with therapeutic proteins and therapeutic uses for the nucleic acid-3′-conjugates. Generally speaking, ds-DNA is conjugated at its 3′ end, followed by conversion to single strand (ss) DNA-3′-conjugates. The 3′ conjugates show remarkable serum nuclease resistance and retention in the body and exhibit enhanced therapeutic efficacy as compared with same DNA in a naked (unconjugated) form.
The conjugation requires the addition of adenine (A), cytosine (C), or guanine (G) to the 3′ end of double strand (ds) DNA by means of various enzymes (thymine has no free primary amine group). In particular, Thermus aquaticus (Taq) DNA polymerase adds a 3′-A overhang during the PCR process and the template independent enzyme terminal deoxynucleotide transferase (TdT) can add A, C, or G to the 3′ end of blunt ended ds-DNA, if only A, C, and G are supplied (i.e., no thymine is provided). With TdT, the undesired complementary strand will become conjugated to the protein as well, but it will be nonfunctional and nonallergenic, because DNA is of low immunogenicity.
Free primary amines in the terminal A, C, or G's can then be used to link the DNA to a protein (or other conjugate) via a bifunctional linker with an N-hydroxy-succinimide or other suitable functionality. The conjugate is specifically added to the 3′ overhang because the remainder of the DNA molecule is double-stranded and cannot participate in conjugation.
After conjugation, the ds-DNA is converted to ss-DNA by means of heating beyond the DNA's melting temperature (T m ) for a brief period. Care should be taken to avoid protein denaturation during the melting step. Melting is followed by purification of the ss-DNA-3′-conjugate by chromatographic or other physical and chemical means including affinity separation methods, differential or density centrifugation, and preparative electrophoresis.
Such aptamer-3′-conjugates have a variety of applications. A key application is the targeted killing of pathogens or tumor cells. For example, if the protein conjugate is human or animal Clqrs (or some portion of the complex) it will activate the complement cascade as shown herein, thus targeting the cell for destruction by the immune system. The Clqrs is delivered to the target cell by virtue of being coupled to an aptamer specific for that cell.
Alternatively, one can couple aptamers to carbon nanotubes or other types of nanotubes to bind the surface of an undesirable target cell and kill it by puncturing the cell membrane or cell wall with the attached nanotube. To be effective at killing, aptamer-3′-nanotube conjugates would require energy input via a molecular motor driven by adenosine triphosphate (ATP), creatine phosphate, or other innovative means of energetically driving the nanotube into the target cell membrane to puncture and lyse the target cell.
Another key application of aptamer-3′-conjugates would be neutralization of toxins (e.g., botulinum toxins, cholera and diphtheria toxins, digitalis, ricin, staphylococcal enterotoxins, etc.) by use of specifically developed ss-aptamers linked to serum albumin (SA) to prevent aptamer breakdown and clearance from the blood. The aptamer-3′-SA binds tightly to the toxin, thus neutralizing its effect.
Coupling of aptamers to the complement system could be advantageous in the killing of antibiotic-resistant bacteria, cancer cells, parasites and other target cells. Carbon nanotubes, toxins, and destructive enzymes might also be coupled to the 3′-end of aptamers to create highly effective and long-lived therapeutics against invading cells or target cells.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic of the process for conjugation of a known DNA aptamer sequence at its 3′ end to an effector protein of choice (in this example, Clqrs to activate the complement cascade).
FIG. 2 shows the theoretical aptamer-3′-Clqrs conjugate bacterial killing mechanism. In the figure, IgG antibodies are replaced by the aptamer-3′-Clqrs conjugate and activate the Classical complement cascade. Lipopolysaccharide (LPS) is shown as a target surface antigen for Gram negative bacteria, but LPS could be replaced by any bacterial cell surface component that is accessible.
FIG. 3 illustrates how an aptamer can be used to inhibit or inactivate a toxin, such a botulinum toxin. The aptamer-3′-protein conjugate is not shown in this figure, but human serum albumin would be a good candidate for such conjugation to ensure no allergic reaction in human patients. The figure shows botulinum toxin as an example and illustrates binding and inhibition of the holotoxin and the 50 kiloDalton zinc endopeptidase subunit, which is enzymatically active on the SNAP25 peptide in neurons and is used as the basis for a fluorescence resonance energy transfer (FRET) assay known as the SNAPtide™ assay.
FIG. 4 shows clear inhibition (decreased light levels) of botulinum toxin serotype A (BoNT A) by DNA aptamers developed against BoNT A holotoxin (panel A) and the 50 kD zinc endopeptidase subunit (panel B) using the SNAPtide™ FRET assay. In the SNAPtide™ FRET assay, the greater the fluorescence intensity, the greater the BoNT A activity, because more SNAP 25 FRET substrate is cleaved.
DETAILED DESCRIPTION OF THE INVENTION
The following examples are illustrative of various embodiments the invention and are not intended to be limiting. For example, we have exemplified the invention using aptamers, but it is equally applicable to antisense, ribozymes, gene therapy, and other therapeutic nucleic acids. Additionally, we have added the 3′-conjugate using the free primary amine of A, C, or G, which is a convenient means of specifically conjugating the 3′ end, but other means of conjugation to the 3′ end can be used. For example, the free carbonyl on G, T, C and U, can be used. Alternatively, a modified nucleotide equipped with target moieties for conjugation can be added as the 3′ overhang. The diol on the 3′-ribose residue of RNA may be oxidized to result in two aldehyde groups using sodium meta-periodate and the aldehydes then can be conjugated to the amine groups on a protein using reductive amination with sodium cyanoborohydride. Nucleic acid conjugation techniques are well known in the art and need not be further detailed herein.
In the examples given herein, the bifunctional linker SULFO-EGS™ (PIERCE CHEMICAL CO.™) was used to couple the free primary amine from adenine to a protein conjugate. However, any biocompatible, nonallergenic, bifunctional linker could be used including EDP=3-[(2-aminoethyl)dithio]propionic acid; BMPH=N-[beta-maleimidopropionic acid]hydrazide; BMPS N-[beta-maleimidopropyloxy]succinimide ester; SULFO-DST=disulfosuccinimidyl tartrate; SULFO-EMCS=N-[epsilon-maleimidocaproyloxy]sulfosuccinimide ester.
Additionally, we have exemplified the invention using a protein conjugate, because such conjugates significantly improve the efficacy of the invention by conferring the activity of the protein to the therapeutic nucleic acid. However, experiments are planned to broaden the inventions application to include nanotubes or other large macromolecules with desirable properties. All that is required of the conjugate is that it be large enough to prevent the nucleic acid-3′-conjugates from being rapidly cleared by the kidneys, and that it protect the nucleic acid from degradation, without the conjugation adversely affecting the activity of either component.
Where the conjugate has biocidal activity, the nucleic acid-3′-conjugate can be used to selectively target and kill pathogens or cancer cells. Biocides include toxic proteins such as peptide toxin mellitin, peroxidase, TNF-alpha, Bacillus thuringensis crystal (cry) proteins, and the like; proteins that recruit the natural cell killing mechanisms, such as Clprs, Fc, C3b, C4b, C5a, and C567; phage lysis proteins, such as the SPO1 genes 40, 50 and 51; chemicals such as polystyrenes, eugenol, thymol, trichlorocarbanalide (TCC), didecyldimethylammonium chloride (DDDMAC) and C10-16-alkyldimethyl, N-oxides (ADMAO), Pentachlorophenol (PCP), and nanotobes containing small molecule drugs, such as antibiotics, or when used as a pore to penetrate target cells.
Other conjugates are designed merely to protect the therapeutic nucleic acid from degradation and retain its activity in the bloodstream, such as serum albumin (SA), human serum albumin (HSA), alpha1 and alpha2 globulins, beta-globulins, gamma-globulins, hemoglobin, and the like. Other conjugates can include antibodies or antibody fragments, designed to recruit other proteins or cell types to the therapeutic nucleic acid. These are particular useful in gene therapy techniques, such as suicide gene therapy or rescue gene therapy, where particular cells are to be targeted with a cytotoxic or functional gene.
Example 1
Nucleic Acid-3′-Protein Conjugation
Two prime (2′) modifications of nucleotides in RNA aptamers have been reported to work well for nuclease resistance (Bell et al., 1999 and Ulrich et al., 2002) against certain specific bacterial nucleases and against serum nucleases. Some researchers claim that DNA aptamers can be protected by 2′-Fluoro-deoxynucleotide (dNTP) incorporation (Ono et al., 1997). However, there is not much definitive data on this topic in the literature. Further, it is difficult to incorporate 2′F-dNTPs into DNA by PCR (Ono et al., 1997) or other means as most DNA polymerases either will not incorporate 2′F-dNTPs (i.e., reject them as substrates or they are poorly incorporated) or the 2′-F-dNTPs are excised by the polymerase's editing function.
An alternative method for conferring resistance to serum nucleases is capping of the DNA termini, especially the 3′ end as shown by Dougan et al. (2000). Dougan capped aptamers with the small molecule biotin and successfully preserved the aptamers in serum. However, we theorized that a larger peptide or protein could be conjugated to the 3′ end of the aptamer with the added benefits of increasing aptamer retention in the blood (i.e., decreasing clearance by the kidneys, because the low molecular weight aptamer is attached to a large protein that cannot be filtered by the kidneys). In addition, a protein conjugate would provide the benefit of adding the functionality of the protein conjugate to the aptamer. The latter advantage can then be used for adding a wide variety of functions such as biocidal activity, enzymatic activity, enhancing phagocytosis (opsonization), cell recruitment or cell activation, or serum stability. It remained to be proven, however, that aptamer function and protein function could be retained when coupled together.
The goal of the process shown schematically in FIG. 1 was to terminate the aptamer in a deoxynucleotide containing a free amine group at the 3′ end to enable covalent coupling to the protein conjugate. The aptamer may or may not have a free 3′ amine group originally, but conjugation of a single-stranded aptamer would surely lead to a family of conjugates at different positions on the aptamer and no guarantee of serum nuclease resistance, or retention of aptamer activity. Hence, the aptamer was subjected to a round of the polymerase chain reaction (PCR) to create a complementary strand (dotted line) and a 3′-adenine (A) overhang that has a free amine moiety.
This 3′-A overhang was on the complementary strand, not on the desired aptamer strand. Therefore at least one more round of PCR was required to place the 3′-A overhang on the original template strand (solid line) and enable conjugation to the protein conjugate by means of a common bifunctional linker such as SULFO-EGS™ (ethylene glycol-bis (sulfosuccinimidylsuccinate)).
Once the aptamer was conjugated to a given protein at its 3′ end, the double strand was melted by means of heating, which may denature the protein if the temperature is too high for an extended period of time, or by way of mild chemical treatments such as low concentrations of urea, which could again denature the protein if the concentration is too high. Other means of separating ds-DNA include the use of biological tools, such as SSB (Single-stranded DNA Binding Protein).
Finally, the single-stranded aptamers and the aptamer-3′-protein conjugates can be separated by a variety of physical means such as size exclusion gel chromatography on materials such as Sephadex, density gradient centrifugation, or preparative electrophoresis, etc. The aptamer-3′-conjugate can also be separated by affinity chromatography using an antibody against the protein conjugate, and this system can be coupled with mild denaturation, thus allowing purification and separation in a combined step.
Bruno (1997) and Bruno and Kiel (2002) as well as Murphy et al. (2003) have described a method for immobilizing target molecules onto magnetic microbeads (MBs) and using these target-MBs to magnetically separate out aptamers from a randomized oligonucleotide library which bind the target with high affinity. Then using standard SELEX techniques (Bruno and Kiel 2002), a family of aptamers can be selected that will bind the target with high affinity and can be conjugated at their 3′ ends by way of the process shown in FIG. 1 .
Example 2
Aptamer-3′-LPS
Sulfo-EGS was dissolved at 10 mg/mL in sterile PBS and 132 μL of this stock solution added to 0.1 mg of human Clqrs protein (molecular weight of 750 kD). This ratio provided the 20-fold molar excess of Sulfo-EGS recommended for Sulfo-EGS conjugations.
One hundred μL (approximately 33 μg) of SELEX round 5 or greater DNA aptamers in their cold (double-stranded) form was added to the solution. The reactants were allowed to stand at RT for 1 hour and were then added to a PHARMACIA™ PD-10 desalting column (SEPHADEX™ G-25) equilibrated with several void volumes of sterile PBS. Twelve to fifteen 1 mL fractions were eluted in PBS and collected as individual fractions. Absorbance readings were taken for all fractions at 260 nm and 280 nm. In addition, 5 μL of each fraction was added to 5 μL of native polyacrylamide gel electrophoresis (PAGE) loading buffer and run on 8-10% polyacrylamide gels that were fixed and silver stained to verify successful conjugation.
The following steps were performed for E. coli O111:K58(B4):H— (ATCC No. 33780) killing experiments. Twenty tryptic soy agar (TSA) petri plates were warmed to RT and labeled to represent four groups of five plates each. The five plates cover arbitrary E. coli ten-fold dilutions from 10 −4 to 10 −8 where the aptamer-Clqrs conjugates “antibiotic” effect was anticipated. One loopful of freshly cultured E. coli O111:K58(B4):H— (i.e., grown overnight at 35° C. on TSA agar) was added to 1 mL of Gelatin Veronal Buffer (GVB; SIGMA-ALDRICH CO.™, St. Louis, Mo.) at RT. Clumps were broken up by use of a 5 mL syringe and 20 gauge needle that was used to vigorously eject the bacterial sample ten times to achieve a uniform single cell suspension, as confirmed by phase-contrast microscopy at 400× magnification.
This stock bacterial suspension was used to make eight ten-fold dilutions in sterile polypropylene tubes. Both the stock bacterial suspension and nascent dilution were thoroughly mixed throughout the experiments to ensure random sampling. Fifty μL of each bacterial dilution was added to four other polypropylene microfuge tubes (representing the four treatment groups for each specified dilution of interest).
Ten μL of human serum complement proteins (SIGMA-ALDRICH™ #S-1764) diluted 1:500 (to avoid activation of the alternate complement pathway by LPS) in GVB was added to each tube in Groups 1 and 2.
One hundred μL of the aptamer-3′-Clqrs conjugate was added to five separate PCR tubes, and all were heated at 80° C. in the thermal cycler block for 5 minutes to make the anti-LPS aptamer portion of the conjugate single-stranded (Tm of the 60 mer was 78.5° C.). This temperature and duration did not appear to cause damage to the Clqrs part of the conjugate, because it still appeared to initiate bacterial killing, as shown below.
Fifty μL of the hot aptamer-Clqrs conjugate was added to Groups 1 and 4 of each killing experiment (50 μL×10 tubes=500 μL). Total volume of all tubes was equalized to 110 μL by addition of GVB as appropriate. Tubes were capped, shaken ten times, and incubated at 35° C. for 2 hours.
The tubes were decanted onto the TSA plates and the contents spread. Plates were placed face up at RT for 30 minutes and then inverted and incubated overnight at 35° C. The following day, plate counts were obtained and all plates were photographed.
It is well known that LPS from E. coli and other Gram negative bacteria can activate the complement cascade by the Alternate pathway. To eliminate or minimize the Alternate pathway of complement activation, a series of dilutions containing only human serum complement protein (HSCP) were added to the test bacteria to determine the lowest concentration (i.e., highest dilution) of HSCPs that did not kill significant numbers of E. coli bacteria by the Alternate pathway after a two hour incubation at 35° C. The results of the HSCP dilution experiment are given in Table 1 and indicate that between a 1:800 to 1:500 dilution of the HSCPs was appropriate for use in the later killing experiments, since that is where the killing effect of HSCP itself becomes apparent (i.e., significantly fewer than 300 colonies were seen per plate).
TABLE 1
Colony Counts of E. coli O111:B4 as a Function of HSCP Dilution
Colony Forming Units (cfu)
HSCP Dilution
Trial 1
Trial 2
1:10,000
>300
>300
1:1,000
287
283
1:400
98
90
1:200
57
63
1:100
18
21
Note: An arbitrary 10 −4 dilution of E. coli was used. Grey indicates that at those dilutions there was sufficient complement to begin activating the alternate pathway of cell killing.
The aptamer-3′-Clqrs-mediated killing experiments contained four treatment groups as follows:
Group 1: Full Test Group—Contained 50 μL of the bacterial dilution plus 50 μL of anti-LPS aptamer-Clqrs conjugate and 10 μL of 1:500 dilution of HSCPs per tube.
Group 2: Control for Alternate Pathway Activation—Contained 50 μL of bacterial dilution and 10 μof 1:500 dilution of HSCPs plus 50 μL GVB per tube.
Group 3: Bacterial Growth Control—No chemical additives. This group indicates baseline growth levels of the bacteria. The group contained only 50 μL bacterial dilution and 60 μL of GVB per tube.
Group 4: Aptamer-Clqrs Conjugate Control—Contained only 50 μL of bacterial suspension plus 50 μL of aptamer-Clqrs conjugate and 10 μL of GVB (no HSCPs added, therefore the remainder of the complement cascade should not be present).
In the three aptamer-Clqrs bacterial killing experiments (Table 2), it became clear that, at certain higher dilutions, Groups 1 and 4 consistently showed fewer colonies than Groups 2 and 3. If the classical pathway of complement activation was being invoked by the anti-LPS aptamer-Clqrs conjugate, then one would predict a significantly lower number of colonies in Group 1. However, the lower number of colonies in Group 4 (conjugate only group) is somewhat perplexing. One possible explanation of the lowered colony numbers in Group 4 is that traces or residues of the other complement proteins (HSCPs) are present in the aptamer-Clqrs conjugate preparation and synergize with the conjugate to bring about elevated levels of bacterial killing. If that is not the case, then the aptamer-Clqrs conjugate may be able to kill bacteria by an unknown alternate mechanism that does not involve invoking the action of the complement cascade.
TABLE 2
Colony Counts from Three E. coli Aptamer-C1qrs Killing Experiments
Dilution
Group
10e−4
10e−5
10e−6
10e−7
10e−8
Experiment 1
1
TNTC
TNTC
1
0
1
2
TNTC
TNTC
267
16
3
3
TNTC
TNTC
265
15
2
4
TNTC
TNTC
132
5
1
Experiment 2
1
TNTC
TNTC
141
13
0
2
TNTC
TNTC
TNTC
TNTC
207
3
TNTC
TNTC
TNTC
TNTC
216
4
TNTC
TNTC
TNTC
TNTC
67
Experiment 3
1
TNTC
199
34
4
0
2
TNTC
TNTC
167
55
2
3
TNTC
TNTC
155
74
3
4
TNTC
212
32
7
0
Note:
TNTC = Too Numerous to Count
Example 3
Antitoxin Aptamer-3′-HSA
FIG. 3 illustrates the general concept of aptamer (or aptamer-3′-protein conjugate) binding to toxins to inhibit or inactivate the toxin. If the toxin is a small molecule that is inherently toxic to biological systems, then the binding of target-specific developed aptamers should ameliorate or eliminate toxicity by stoichiometrically wrapping around the toxin to disallow it from interacting within a biological system. If the toxin is an enzyme, then binding of a specific aptamer or aptamer-3′-protein (albumin) conjugate to the active site should diminish or cease enzymatic activity.
One example of DNA aptamer-mediated enzymatic toxin inhibition can be seen in the binding of specific botulinum A toxin (BoNT A) aptamers to BoNT A, thereby inhibiting the toxin's ability to cleave its SNAP 25 peptide substrate. Using a specific SNAP 25 FRET assay known as the SNAPtide™ assay, aptamers developed against both the holotoxin and the 50 kD zinc endopeptidase subunit of BoNT A showed evidence of significant toxin inhibition as seen in FIG. 4 . Thus, it is shown that conjugation to a protein did not decrease either the aptamer or the protein conjugate's activity.
The SNAPtide™ assay procedure and buffer formulations are given here. 100 mL of Buffers A and B were made in nuclease-free sterile water according to Table 3 below. The pH was adjusted to 8.0 with strong base or acid, as needed, and the solutions filter sterilized and stored in a refrigerator, but warmed to RT before use.
A SNAPtide™ vial (fluorescein/dabcyl labeled peptide; LIST BIOL. LABS,™ No. 521) was reconstituted in 80 μL of DMSO to a stock concentration of 2.5 mM. 10 μL of Bot A (10 μg/mL) was preincubated in 190 μL of Buffer A (see composition below) at 37° C. for 30 minutes to activate the toxin.
10 μL of round 5 anti-BoNT A aptamers was added to 90 μL of Buffer B, mixed and preheated to 95° C. for at least 5 minutes in a closed Eppendorf tube under a vented chemical or biological hood.
Hot aptamer solution (100 μL) was added to 100 μL of activated BoNT A in an Eppendorf tube and allowed to bind at 37° C. for 15 minutes. This tube was labeled “Test.” Similarly, 100 μL of Buffer B was added to 100 μL of activated BoNT A labeled “Control” and incubated at 37° C. for 10 minutes.
3 μL of stock SNAPtide™ (SNAP 25 FRET peptide fragment) were added to both tubes along with 2.7 mL of Buffer B. The contents of the tubes (3 mL each) were transferred to separate 10 mm methacrylate cuvettes and readings taken by spectrofluorometer with excitation at 490 nm and emission at >520 nm for the next 30 minutes in 1 to 2 minute intervals.
TABLE 3
Buffer Recipes for the SNAPtide ™ Assay
Components
1M
1M
Tween
Nuclease Free
Buffer
HEPES
ZnCl 2
DTT
BSA
20
Water*
A
2 mL
4 mg
500 μL
100 mg
0
97.5 mL
B
2 mL
4 mg
125 μL
0
100 μL
97.775 mL
Abbreviations:
DTT = dithiothreitol,
BSA = bovine serum albumin.
Example 4
Aptamer-3′-Fc or Aptamer-3′-C3b Conjugate
If aptamers are conjugated at their 3′ end to the Fc fragment of IgG antibodies or the C3b component of complement, they could conceivably be used to opsonize encapsulated bacteria. To test this contention, tosyl-MBs (Dynal Corp.) were conjugated to poly-D-glutamic acid (PDGA) as previously described by Bruno and Kiel (2002). PDGA is the major component of the capsule of Bacillus anthracis (anthrax) pathogenic strains, which enables the vegetative cells to escape phagocytosis. PDGA-conjugated MBs were used to emulate vegetative anthrax bacteria and determine if aptamer-3′-Fc conjugates could enhance the phagocytosis of PDGA-MBs and by inference, opsonize encapsulated bacteria. The following describes the protocols used in these experiments.
RAW264.7 murine macrophages were split by scraping and add 10 5 cells into each well of a sterile six-well culture plate using fresh RPMI-1640 cell culture medium plus 10% fetal bovine serum (FBS). In practice, 1 mL of cell suspension was used with 4 mL of fresh RPMI-1640 plus 10% FBS. The plate sat overnight to allow the cells to attach.
Five different tubes were labeled per Table 4 as follows (all volumes in μL):
TABLE 4
Tube Contents
Rd 5 Apt*
—
—
20
—
—
Fc-Apt*
—
—
—
20
20
2XBB
50
50
30
30
30
Final Volume
60
60
60
60
60
*Note:
Round 5 aptamer heated at 95° C. for 5 minutes prior to adding to tube;
Apt. = aptamer, Fc-Apt conjugate heated at 65° C. for 5 minutes prior to adding to tube. Heating is performed to ensure single-strandedness of the aptamers before they bind PDGA.
2XBB = 2X aptamer binding buffer (Bruno and Kiel, 2002).
Each tube was incubated for 30 minutes at RT to allow binding of any aptamers or aptamer-Fc conjugates with PDGA-MBs or other targets to occur Tube contents were loaded to the appropriate wells of a 6-well plate, and incubated at 37° C. and 5% CO 2 and then counted at 1, 2, and 24 hours using an inverted microscope.
Data were evaluated using a “phagocytic index” parameter. The formula used for the phagocytic index according to Welkos et al., 2001 was:
Phagocytic Index=Mean number of MBs/cell X % of cells with at least one MB
Table 5 summarizes the raw data from the opsonization studies, as well as the phagocytic indices, which were derived from the above equation using the raw data. The controls that appeared to show enhanced phagocytosis may be due to some nonspecific binding of the aptamers to other targets or the innate ability of macrophages to recognize certain types of foreign matter (MBs or coated MBs). It also appears from Table 5 that there was some dose-dependence to the Fc-aptamer enhancement because in the first experiment the percentage of cells showing phagocytosis jumped from 74.67% to 96% with an increased level of Fc-aptamer conjugate (see highlighted data in Table 5).
TABLE 5
Raw Data and Phagocytic Indices for All Macrophage Studies in Phase I
Macrophage Test No. 1: 24 hr. Count
# of
Mean # of
cells
# w/o MB
MB per
% cell w/
Phagocytic
Well
counted
association
# of MB
Cell
MB
Index
Blank (2XBB)
300
300
0
0
0.00%
0.00
5 uL Tosyl-
300
138
416
1.39
54.00%
0.75
MBs
50 uL PDGA-
300
12
586
1.95
96.00%
1.88
MB + FcApt
5 uL
300
76
402
1.34
74.67%
1.00
PDGA + FcApt
Macrophage Test No 2: 1 hr. Count
Well (total
# of
Mean # of
volume added
cells
# w/o MB
MB per
% cell w/
Phagocytic
30 uL)
counted
association
# of MB
Cell
MB
Index
Blank (2XBB)
300
300
0
0
0.00%
0.00
Tosyl-MBs
300
273
52
0.17333333
9.00%
0.02
PDGA-MBs
300
272
67
0.22
9.33%
0.02
Tosyl + FcApt
300
218
139
0.46
27.33%
0.13
PDGA + FcApt
300
187
243
0.81
37.67%
0.31
Macrophage Test No. 3: 1 hr. Count
Well (total
# of
Mean # of
volume added
cells
# w/o MB
MB per
% cell w/
Phagocytic
60 uL)
counted
association
# of MB
Cell
MB
Index
Blank
300
300
0
0.00
0.00%
0.00
2-Tosyl
300
246
83
0.28
18.00%
0.05
3-PDGA
300
246
116
0.39
18.00%
0.07
Tosyl + FcApt
300
252
116
0.39
16.00%
0.06
PDGA + FcApt
300
206
195
0.65
31.33%
0.20
Macrophage Test No. 3: 2 hr. count
Well (total
# of
Mean # of
volume added
cells
# w/o MB
MB per
% cell w/
Phagocytic
60 uL)
counted
association
# of MB
Cell
MB
Index
Blank (2XBB)
300
300
0
0.00
0.00%
0.00
Tosyl
300
186
512
1.71
38.00%
0.65
PDGA
300
158
256
0.85
47.33%
0.40
Tosyl + FcApt
300
212
264
0.88
29.33%
0.26
PDGA + FcApt
300
136
498
1.66
54.67%
0.91
Macrophage Test No. 3: 24 hr. count
Well (total
# of
Mean # of
volume added
cells
# w/o MB
MB per
% cell w/
Phagocytic
60 uL)
counted
association
# of MB
Cell
MB
Index
Blank (2XBB)
300
300
0
0.00
0.00%
0.00
Tosyl-MB
300
44
676
2.25
85.33%
1.92
PDGA-MB
300
53
628
2.09
82.33%
1.72
Tosyl + FcApt
300
92
854
2.85
69.33%
1.97
PDGA + FcApt
300
52
804
2.68
82.67%
2.22
Each of these references is incorporated by reference in its entirety:
U.S. Pat. No. 5,270,163 et seq., U.S. Pat. No. 5,475,096, U.S. Pat. No. 6,566,343, U.S. Pat. No. 6,623,926. Bell et al., “Oligonucleotide NX1838 Inhibits VEGF165-Mediated Cellular Responses In Vitro,” In Vitro Cell Devlop. Biol. Animal. 35:533-542 (1999). Bruno, “In Vitro Selection of DNA to Chloroaromatics Using Magnetic Microbead-Based Affinity Separation and Fluorescence Detection,” Biochem. Biophys. Res. Comm. 234:117-120(1997). Bruno and Kiel, “Use of Magnetic Beads in Selection and Detection of Biotoxin Aptamers by ECL and Enzymatic Methods,” BioTechniques. 32:178-183 (2002). Dougan et al., “Extending the Lifetime of Anticoagulant Oligodeoxynucleotide Aptamers in Blood,” Nuclear Med. Biol. 27:289-297 (2000). Murphy et al., “An improved method for the in vitro evolution of aptamers and applications in protein detection and purification.” Nucleic Acids Res. 31:e110-e118 (2003). Ono et al., “2′-Fluoro modified nucleic acids: polymerase-directed synthesis, properties and stability to analysis by matrix assisted laser desorption/ionization mass spectrometry,” Nucl. Acids Res. 25:4581-4588 (1997). Ulrich et al., “In Vitro Selection of RNA Aptamers that Bind the Cell Adhesion Receptors of Trypanosoma cruzi and inhibit cell invasion,” J. Biol. Chem. 277:20756-20762 (2002). Welkos et al., “The Role of antibodies to Bacillus anthracis and anthrax toxin components in inhibiting the early stages of infection of anthrax spores.” Microbiology. 147:1677-1685 (2001). | Methods are described for improvement of the serum half life of therapeutic nucleic acids by 3′ conjugation to useful target proteins, or other large molecules with useful function. In one embodiment, a 3′ A, C or G overhang is added to ds-DNA and the primary amines conjugated using biocompatible bifunctional linkers to proteins. The resulting nucleic acid-3′-conjugates are serum nuclease-resistant and retained in vivo for long periods without rapid kidney clearance. Further, the choice of conjugate imparts additional functionality to the nucleic acid-3-conjugate.
For example, if the protein in the DNA-protein conjugate is the first component of the complement cascade (Clq or Clqrs) and the DNA aptamer has been developed against surface components of a target cell, it can be used to treat bacterial or parasitic infections and cancers. If the protein is serum albumin or another common (nonimmunogenic) blood protein and the aptamer is directed against a toxin or venom, the aptamer-protein conjugate can be used as an antidote that binds and neutralizes the toxin or venom. Similar DNA (aptamer)-nanotube, -enzyme, and -toxin conjugates could also be used to target and selectively kill bacteria, parasites, and cancer cells in vivo. If the protein is an Fc antibody fragment or C3b protein from the complement system and the aptamer is developed against a bacterial cell capsular material, other cell surface component or viral cell surface component, then the aptamer-3′-protein conjugate can aid in opsonization of the target cells or viruses by phagocytic leukocytes. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
This is a continuation in part of application Ser. No. 09/966,622 filed Oct. 1, 2001, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to hurricane shutters and more particularly to a hurricane shutter that protects requisitely against storm-borne objects, wind and rain while also venting buildups and bursts of pressure and vacuum that react on buildings from hurricanes and other severe storms.
Devastation from severe hurricanes has resulted in storm-area legal requirements and personal interest in adequate storm protection that also is attractive, convenient and, if possible, low cost. Numerous storm-protective shutters have occurred as a result. None, however, help to deflect strong hurricane force winds while addition to providing requisite protection against storm-borne objects, wind and rain in a manner taught by this invention.
Examples of the most-closely related known but different devices are described in the following patent documents:
Number
Inventor
File Date
Issue Date
Classification
U.S. 6,536,174 B
Foster et al.
May 07, 2001
Mar. 25, 2003
52/473
U.S. 3,039,155
Iacovoni
Oct. 07, 1959
Jun. 19, 1962
49/67
U.S. 5,737,874
Sipos et al.
Dec. 15, 1994
Apr. 14, 1998
49/67
U.S. 5,907,929
Poma et al.
Nov. 21, 1997
Jun. 01, 1999
49/62x
U.S. 5,617,683
Ney
Mar. 25, 1996
Apr. 08, 1997
52/202
U.S. 4,368,594
Milam et al.
Feb. 12, 1981
Jan. 18, 1983
49/67
U.S. 2,013,824
Ensminger
September 1935
160/77
U.S. 1,646,522
Berg
October 1927
49/356
U.S. 2,716,785
Schoen
Oct. 21, 1953
Sep. 06, 1955
49/67
U.S. 3,667,161
Sassano
Oct. 16, 1970
Jun. 06, 1972
49/56
U.S. 3,691,687
Economou
Aug. 06, 1971
Sep. 19, 1972
49/74
The Foster et al., Iacovoni, and Sipos et al. shutters do not provide weld guides to keep shutters from turning in during hurricane forces as taught by this invention. The Poma et al. shutter requires a removable rigid support for requisite protection. Shutters described by Ney, Milan et al., Ensminger, Berg and Schoen do not have pressure venting as taught by this invention. The Sassano patent does not disclose shutters, but rather a shutter operating mechanism. The Economou shutter teaches slidable slats not requiring weld guides for support.
SUMMARY OF THE INVENTION
Objects of patentable novelty and utility taught by this invention are to provide a pressure-vent hurricane shutter which:
vents damaging buildups and bursts of pressure and vacuum that react on buildings from hurricanes;
provides legally requisite protection against storm-borne objects, wind and rain;
can be made attractive in a variety of structural styles; and
can be cost-effective for the level of protection provided.
This invention accomplishes these and other objectives with a pressure-vent hurricane shutter having preferably at least legally-requisite strength of framework encompassing slatted-louver apertures for protection against storm-borne objects, wind and rain in addition to venting damaging buildups and bursts of pressure and vacuum that react on buildings from hurricanes. The framework includes structural beams to which ends of slanted slats are attached rigidly and to which inward edges of the slanted slats are attached to the inward edge of the slat-support guide cover and the outward edges of the slanted slats are attached to the front wall of the slat-support guide. The framework is hinged with the requisite strength to at least one side of a building aperture in accordance with desired shutter style and structure which include top-hinged Bahama and sides-hinged Colonial styles.
BRIEF DESCRIPTION OF DRAWINGS
This invention is described by appended claims in relation to description of a preferred embodiment with reference to the following drawings which are explained briefly as follows:
FIG. 1 is a partially cutaway front elevation view of a Bahama-Shutter embodiment;
FIG. 2 is a is a section view through section line 2 — 2 of FIG. 1 ;
FIG. 3 is a is a section view through section line 3 — 3 of FIG. 1 ;
FIG. 4 is an end view of a framework member;
FIG. 5 is an end view of a slat-support guide;
FIG. 6 is a partially cutaway side elevation view of a Bahama-Shutter embodiment mounted on a building structure and being in an open mode;
FIG. 7 is the FIG. 6 illustration in a closed mode;
FIG. 8 is a front elevation view of a colonial-shutter embodiment having double-louver sections for average-sized doors and windows in a closed mode;
FIG. 9 is a fragmentary view of a colonial-shutter hinge shown hinging two portions of the Colonial Shutter together;
FIG. 10 is a fragmentary end view of a preferred shutter hinge that can be used either horizontally for hang-hinging Bahama Shutters or vertically for swing-hinging Colonial Shutters;
FIG. 11 is an end view of a single shutter hinge that is shown in the FIG. 10 illustration;
FIG. 12 is an end view of a flat shutter hinge that is shown in the FIG. 10 illustration;
FIG. 13 is a top view of the single shutter hinge that is shown in the FIG. 10 illustration;
FIG. 14 is a top view of the flat shutter hinge that is shown in the FIG. 10 illustration;
FIG. 15 is a fragmentary side view of the preferred shutter hinge in which the single hinge is shown attached to a metallic or other rigid form as seen from a left side of the FIG. 10 illustration and the flat hinge is shown from a bottom of the FIG. 10 illustration;
FIG. 16 is a fragmentary side view of the preferred shutter hinge in which the single hinge is shown attached to the build-out frame which is attached to the building structure from a top side of the FIG. 10 illustration and the flat hinge is shown from the bottom of the FIG. 10 illustration;
FIG. 17 is a perspective view of a flat shutter hinge with ribs;
FIG. 18 is a side view of a flat shutter hinge with ribs;
FIG. 19 is a section view through section line 19 — 19 of FIG. 1 ;
FIG. 20 is an end view of a mullion slat-support guide assembly;
FIG. 21 is a side view of a left slat-support guide;
FIG. 22 is a side view of a right slat-support guide;
FIG. 23 is a perspective view of a left slat-support guide;
FIG. 24 is a perspective view of a right slat-support guide;
FIG. 25 is a front view of a slat-support guide;
FIG. 26 is a section view through section line 26 — 26 of FIG. 25 ; and
FIG. 27 is a front view of a hold down tab.
DESCRIPTION OF PREFERRED EMBODIMENT
Listed numerically below with reference to the drawings are terms used to describe features of this invention. These terms and numbers assigned to them designate the same features throughout this description.
1.
shutter framework
2.
face walls
3.
edge walls
4.
shutter spacer
5.
slanted slats
6.
right slat-support guide
7.
left slat-support guide
8.
mullion slat-support guide
9.
slat-support cover
10.
mullion slat-support cover
11.
build out framework
12.
hold down tab
13.
shutter hinge assembly
14.
flat hinge assembly
15.
building structure
16.
single hinge
17.
flat hinge
18.
hinge pin
19.
rib
20.
inward edge of slat
21.
outward edges of guide
22.
side wall of slat-support guide
23.
front wall of slat-support guide
24.
inward side of slat-support cover
25.
outward edge of slat
26.
window opening
27.
hold open rod
28.
slot
29.
bahama shutter
30.
colonial shutter
31.
slatted-louver aperture
32.
hole
Referring to FIGS. 1–5 , a pressure-vent hurricane shutter has at least one shutter framework 1 that includes structural beams that preferably are structural metal tubes having face walls 2 that are about one to two inches wide and edge walls 3 that are one-and-one half inches wide. A shutter spacer 4 is located proximate to the shutter framework and is oriented horizontally. The face walls 2 and the edge walls 3 are about one-eighth inch thick and made preferably of structural aluminum alloy 6063-T52 or a substantial equivalent.
The substantial equivalent can be a ferrous alloy that is preferably stainless and rustproof with either an adequate coating or content of nickel, chrome, aluminum or other stainless constituent.
The shutter framework 1 encompasses slatted-louver apertures 31 having slanted slats 5 with slat ends affixed to the shutter framework 1 . The slanted slats 5 have inward edges 20 and outward edges 25 that are oriented horizontally and attached to the right slat-support guide 6 , the left slat-support guide 7 , and the slat-support cover 9 . The slat-support guides 6 and 7 are oriented vertically with ends attached to horizontal portions of the shutter framework 1 . Both the inward edges of the slats 20 and the outward edges of the slats 25 are orthogonal to the slat-support guides 6 and 7 . The inward edges of the slats 20 are attached to the inward side of the slat-support cover 24 . The outward edges of the slats 25 are attached to the front wall of the slat-support guide 23 . The slats 5 feed into the slots 28 located on the side walls of the slat-support guide 22 .
The shutter framework 1 also encompasses hold down tabs 12 located on the horizontal portions of the shutter framework 1 . The hold down tabs 12 on Bahama Shutters 29 are located on the bottom horizontal shutter framework 1 . The hold down tabs 12 on Colonial Shutters 30 are located on the top and bottom horizontal shutter framework 1 . A quarter-inch screw is inserted through the hold down tab 12 into build out framework 11 correspondingly mounted onto the building structure 15 . The hold down tabs 12 hold the shutter framework 1 to the build out framework 11 to keep the shutter framework 1 from blowing open during a storm. Flat hinges 17 with ribs 19 are located on the shutter framework 1 to keep the shutter framework 1 from hitting the single hinge 16 , thus preventing paint from rubbing off of the single hinge 16 .
The slatted-louver apertures 31 includes an entire slatted enclosure of a plurality of apertures between the slanted slats 5 and the shutter framework 1 . The plurality of apertures individually are slanted with preferably about one-half inch of distance of slant orthogonally between surfaces of the slanted slats 5 . The slanted slats 5 are preferably flat aluminum bar stock about one-quarter inch thick and one inch wide. Between bottoms and tops of adjacent slanted slats 5 , there are horizontal apertures about one-eighth inch high and having a length that is a length of the slanted slats 5 , less a width of the slat-support guides 6 and 7 . The slat-support guides 6 and 7 have a side wall 22 , a front wall 23 , and a back slat-support cover 9 . The slat-support guides 6 and 7 are attached to the inward edges of the slats 20 as well as the outward edges of slats 25 to keep the slanted slats 5 from turning in and maintaining proper separation and angle when under pressure from high winds and wind borne objects. The slat-support guides 6 and 7 and the mullion slat support cover 10 have the appearance of a rectangular mullion so as to give a more aesthetic appearance.
A pressure-vent object of this hurricane shutter is to allow predeterminedly slight passage of wind and rain horizontally straight through slatted-louver apertures of the shutter framework 1 and slightly more directional-change passage while also providing structural strength to prevent breakage by storm-borne objects, wind and rain of hurricanes. Allowing directional-change passage of hurricane-force wind and rain while stopping large storm-borne objects and directional-change diversion of small objects like gravel and small debris eliminates directly damaging aspects of hurricanes.
Included on fronts of slatted-louver apertures 31 of Bahama Shutters 29 shown in FIGS. 1–7 and Colonial Shutters 30 shown in FIGS. 8–10 are portions of the slat-support guides 6 and 7 that are straight through horizontally between bottoms and tops of vertically adjacent slanted slats 5 . Also shown are portions of a mullion slat-support guide 8 that are slanted between the slanted slats 5 that are juxtaposed vertically.
Referring to FIGS. 6–7 , the shutter framework 1 is sized, shaped and designed predeterminedly for a Bahama Shutter 29 having a shutter hinge assembly 13 mounted on top of the shutter framework 1 with which it is hinged to the shutter framework 1 and build out framework 11 on a building structure 15 . The top mount shutter hinge assembly 13 is representative of a selection of Bahama Shutter hinges having appropriate strength and operativeness for legal and other predetermined requisites for hinging hurricane shutters to building apertures.
Referring to FIG. 8 , the shutter framework 1 is sized, shaped and designed predeterminedly for a Colonial Shutter 30 having a mount shutter hinge assembly 13 mounted on the side of the shutter framework 1 and build out framework 11 on a building structure 15 . The structural member includes a Colonial build out frame 15 on the building. The Colonial Shutter 30 includes a flat hinge assembly 14 with which pluralities of the shutter frameworks 1 are hinged together for side-folding.
The build out framework 11 is shown in FIG. 8 . The building apertures in the buildings are not shown separately from structural members which include the build out framework 11 in FIG. 8 .
Referring to FIG. 9 , the flat hinge assembly 14 can include a selection of aluminum hinges and other frame-fold hinges which can be positioned in accordance with folding characteristics of Colonial Shutters. Flat hinge assembly 14 in this illustration are shown on back sides of the shutter framework 1 with the slanted slats 5 and the slat-support guides 6 and 7 being seen in front of the slanted slats 5 .
Referring to FIG. 10 , the shutter hinge assembly 13 is a preferred hinge that can be used either horizontally for hang-hinging Bahama Shutters 29 or vertically for swing-hinging Colonial Shutters 30 . The flat hinges 17 have ribs 19 to keep the shutter framework 1 from hitting the single hinge 16 , thus preventing paint from rubbing off of the single hinge 16 . For the Colonial Shutters 30 , the shutter hinge assembly 13 can be swing-hinged and include a fold-back mode with single hinge 16 attached to the build out framework 11 and with a flat hinge 17 attached to the shutter framework 1 and joined by a shutter-hinge pin 18 as depicted in FIG. 17 .
As shown in FIGS. 6–7 and 16 for the Bahama Shutters 29 , the flat hinge 17 with ribs 19 can be hang-hinged and include a hanging mode with single hinge 16 attached to the build out framework 11 , with which is attached to the building structure 15 . The flat hinges 17 are attached to the shutter framework 1 and joined by a hinge pin 18 as depicted in FIG. 16 . The hold down tabs 12 are located on the horizontal portion of the shutter framework 1 . A one-quarter inch screw is inserted through the hold down tab 12 into the build out framework 11 correspondingly mounted onto the building structure 15 . The hold down tabs 12 hold the shutter framework 1 to the build out framework 11 , helping to keep the shutter framework 1 from blowing open during a storm.
Referring to FIGS. 17 and 18 , the flat hinge 17 is shown with ribs 19 in detail.
Referring to FIG. 19 , a cross-section of slanted slat 5 is shown affixed to slat-support guides 6 and 7 . The slat-support guides 6 and 7 and the ends of the slanted slats 5 in turn, are affixed to the shutter framework 1 . The slat-support cover 9 is affixed to the back of the slat-support guides 6 and 7 and to the edge walls 3 of the shutter framework 1 .
Referring to FIG. 20 , the end view of a mullion slat-support guide 8 is shown. The mullion slat-support guide 8 consists of one right slat-support guide 6 , one left slat-support guide 7 , one mullion slat-support cover 10 affixed to form a rectangular cross-section.
Referring to FIG. 21 , a side view of a left slat-support guide 7 is shown without the slanted slats 5 . The side wall 22 has slots 28 where the slanted slats 5 feed into. A slat-support cover 9 would be affixed to the inward edge of slats 20 once placed into the slots 28 .
Referring to FIG. 22 , a side view of a right slat-support guide 6 is shown without the slanted slats 5 . The side wall 22 has slots 28 where the slanted slats 5 feed into.
Referring to FIG. 23 , a perspective view of a left slat-support guide 7 is shown by itself with slots 28 on the side wall 22 .
Referring to FIG. 24 , a perspective view of a right slat-support guide 6 is shown by itself with slots 28 on the side wall 22 .
Referring to FIG. 25 , a front view of a mullion slat-support guide 8 is shown.
Referring to FIG. 26 , a cross-section of a right slat-support guide 6 is shown. The inward edges 20 of the slanted slats 5 are affixed to the slat-support cover 9 .
Referring to FIG. 27 , a front view of a hold down tab 12 with a hole 32 is shown.
The single hinge 16 and the flat hinge 17 of the shutter hinge assembly 13 and flat hinge assembly 14 are made preferably of structural aluminum alloy 6063-T5, 6061-T6 or a substantial equivalent. As for other metallic components, the substantial equivalent can be a ferrous alloy that is preferably stainless and rustproof with either an adequate coating or having suitably alloyed content of nickel, chrome, aluminum and/or other stainless constituent.
A new and useful pressure-vent hurricane shutter having been described, all such foreseeable modifications, adaptations, substitutions of equivalents, mathematical possibilities of combinations of parts, pluralities of parts, applications and forms thereof as described by the following claims and not precluded by prior art are included in this invention. | A pressure-vent hurricane shutter having predetermined requisite strength of shutter framework ( 1 ) encompassing slatted-louver apertures ( 31 ) with slat-support guides ( 6 ) and ( 7 ) for protection against storm-borne objects, wind and rain and venting harmful buildups and bursts of pressure from vacuums created on building from hurricane forces. The shutter framework includes structural beams to which ends of slanted slats ( 5 ) are attached rigidly. Ends of slat-support guides ( 6 ) and ( 7 ) are affixed intermediate the ends of both the inward edges of the slanted slats ( 20 ) and the outward edges of the slanted slats ( 25 ). The shutter framework ( 1 ) have hold down tabs ( 12 ) to keep the shutter framework ( 1 ) from being blown open during a storm. The shutter framework ( 1 ) has ribbed hinges ( 17 ) to at least one side of a building aperture in accordance with desired shutter style and structure which include top-hinged Bahama Shutters ( 29 ) and sides-hinged Colonial Shutters ( 30 ). | 4 |
This invention was made with Government support under contracts HL 01849, HL 40784, and HL 45582 awarded by the National Institutes of Health. The Government has certain rights in this invention.
This application is a divisional of U.S. patent application Ser. No. 08/034,935, filed Mar. 19, 1993, now U.S. Pat. No. 5,389,522.
BACKGROUND
The present application relates in general to methods and apparatus for performing assays for disease states, and in particular to methods and apparatus for performing assays for adult respiratory distressed syndrome (ARDS).
ARDS is an acute inflammatory process characterized by lung neutrophil accumulation, lung edema and progressive hypoxemia [Repine, Lancet, 339, 466-469 (1992)]. ARDS occurs as a complicating factor in patients with sepsis as well as numerous other predisposing conditions. Since many common and diverse risk factors lead to the development of ARDS, but ARDS develops only relatively rarely, pretreating everyone at risk for ARDS is not practical [Fowler et al., Ann. Intern. Med., 98, 593-597 (1983)]. Because a better understanding of ARDS is emerging and various interventions which can limit inflammation are forthcoming, it has become a major goal to identify accessible and repeatable markers in at risk patients which predict the development of ARDS. This will enable experimental therapies to be prospectively and effectively evaluated in smaller, better-defined groups of patients.
SUMMARY OF THE INVENTION
The present invention provides a method for identifying septic patients for prospective treatment of adult respiratory distress syndrome including the step of determining a high (greater than an established baseline) serum level of manganese superoxide dismutase.
The present invention also provides a method for identifying septic patients for prospective treatment of adult respiratory distress syndrome including the step of determining a high (greater than an established baseline) serum level of catalase.
According to the present invention, apparatus for identifying septic patients for prospective treatment of adult respiratory distress syndrome includes means for determining a high (greater than an established baseline) serum level of manganese superoxide dismutase.
The present invention also provides apparatus for identifying septic patients for prospective treatment of adult respiratory distress syndrome including means for determining a high (greater than an established baseline) serum level of catalase.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph of MnSOD levels for healthy control subjects (squares); and of septic patients who did not develop ARDS (triangles) and septic patients who developed ARDS (circles) at three times: at diagnosis of sepsis (1), at diagnosis of ARDS (2) and after diagnosis of ARDS (3);
FIG. 2 is a graph of CAT activity for healthy control subjects (squares); and of septic patients who did not develop ARDS (triangles) and septic patients who developed ARDS (circles) at three times: at diagnosis of sepsis (1), at diagnosis of ARDS (2) and after diagnosis of ARDS (3);
FIG. 3 is a graph of GPX activity for healthy control subjects (squares); and of septic patients who did not develop ARDS (triangles) and septic patients who developed ARDS (circles) at three times: at diagnosis of sepsis (1), at diagnosis of ARDS (2) and after diagnosis of ARDS (3);
FIG. 4 is a graph of LDH activity for healthy control subjects (squares); and of septic patients who did not develop ARDS (triangles) and septic patients who developed ARDS (circles) at three times: at diagnosis of sepsis (1), at diagnosis of ARDS (2) and after diagnosis of ARDS (3);
FIG. 5 is a graph of Factor VIII levels for healthy control subjects (squares); and of septic patients who did not develop ARDS (triangles) and septic patients who developed ARDS (circles) at three times: at diagnosis of sepsis (1), at diagnosis of ARDS (2) and after diagnosis of ARDS (3); and
FIG. 6 is a graph of levels of α 1 Pi-elastase complexes for healthy control subjects (squares); and of septic patients who did not develop ARDS (triangles) and septic patients who developed ARDS (circles) at three times: at diagnosis of sepsis (1), at diagnosis of ARDS (2) and after diagnosis of ARDS (3).
In the experiments illustrated in FIGS. 1-6, septic patients were enrolled (0 h) and studied sequentially for the next 48 h. Points were plotted at the diagnosis of sepsis (0 h at 1), at the diagnosis of ARDS (6-24 h after the diagnosis of sepsis at 2) and after the diagnosis of sepsis (6-24 h after the diagnosis of ARDS at 3). Each value is the mean ±SE of 3-20 determinations.
DETAILED DESCRIPTION OF THE INVENTION
In the present investigation, three antioxidant enzymes [manganese superoxide dismutase (MnSOD), catalase and glutathione peroxidase (GPX)] were compared with three other potential markers [Factor VIII [Carvalho et al., N. Engl. J. Med., 307, 1113-1119 (1982) and Rubin et al., J. Clin. Invest., 86, 474-480 (1990)] LDH [Ward et al., J. Clin. Invest. 76, 517-527 (1985) and Dwenger et al., In: Sturm, ed. Adult Respiratory Distress Syndrome, Berlin Heidelberg: Springer-Verlag, 91-127 (1991)]] and α 1 Pi-elastase complexes [Rocker et al., Lancet, 1, 120-123 (1989) and Hilgenfeldt et al., Eur. J. Clin. Pharmacol, 38, 125-131 (1990)] for their ability to predict the development of ARDS in patients with sepsis.
Alterations occur in the oxidant-antioxidant balance in ARDS and in other disease states that appear to involve oxygen radicals in their pathogenesis [Leff et al., Free Radical Biol. Med., 13, 143-149 (1992); Leff et al., Am. Rev. Respir. Dis, 146, 985-989 (1992); Buhl et al., Lancet, 2, 1294-1298 (1989); Bernard et al., Am. Rev. Resp. Dis., 139, A221 (Abstract) (1989); and Pacht et al., Chest, 100, 1397-1403 (1991)]. In addition, patients with established ARDS have elevated serum catalase activity [Leff et al., Am. Rev. Respir. Dis, 146, 985-989 (1992)]. Serum catalase activity increased in a rat model of burn-induced acute lung injury [Leff et al., Inflammation (In Press) (1992)].
EXAMPLE
Patient Consent and Selection. After written consent was obtained from the patient or a family member, each subject was studied using a protocol which was approved by an institutional human subjects review committee. All patients (n=26) who were identified within 8 h of the diagnosis of sepsis were eligible for enrollment. Patients with sepsis had a serious bacterial infection and either (a) a rectal or core temperature exceeding 39° C. or (b) a peripheral leukocyte count of >12,000 cells/mm 3 or >20% immature neutrophils. Septic patients also had at least one of the following: a positive blood culture involving a commonly accepted pathogen, a strongly suspected or proven source of systemic infection, gross pus in a closed space, unexplained systemic arterial hypotension (systolic blood pressure less than 80 mm Hg), systemic vascular resistance less than 800 dyn×s×cm 2 and/or unexplained metabolic acidosis [Parsons et al., Am. Rev. Resp. Dis., 140, 294-301 (1989)].
Patients with ARDS (n=6) met the following criteria: (1) acute respiratory failure requiring mechanical ventilation, (2) bilateral pulmonary infiltrates, (3) pulmonary capillary wedge pressure <18 mm Hg, (4) static pulmonary compliance <50 ml/cm H 2 O, and (5) arterial to alveolar partial pressure of oxygen ratio of <0.25 [Parsons et al., Am. Rev. Resp. Dis., 140, 294-301 (1989)]. Serum and plasma samples were obtained at the diagnosis of sepsis (0 h) and at the diagnosis of ARDS (6-24 h after the diagnosis of sepsis) and after the diagnosis of ARDS (6-24 h after the diagnosis of ARDS) either through an indwelling arterial or venous catheter or by direct venipuncture. Patients were divided into two groups: septic patients who did not develop ARDS and septic patients who later developed ARDS. Patients were prospectively and sequentially studied until death or discharge. All assays were performed by personnel who were unaware of the diagnoses. Control subjects (n=15) were healthy individuals.
Source of reagents. Hanks' balanced salt solution (HBSS) was purchased from Gibco Laboratories (Grand Island, N.Y.). All other reagents were obtained from Sigma Chemical Company (St. Louis, Mo.).
Measurement of serum markers. MnSOD [Kawaguchi et al., Biochem. Biophys. Res. Commun. 171, 1378-1386 (1990)], Factor VIII antigen [Cejka, Clin. Chem., 28(6), 1356-1358 (1982)] and α 1 Pi-elastase complexes [Duswald et al., Surgery, 98, 892-899 (1985)] were measured by ELISA. Catalase was assessed by polarographic assessment of O 2 evolution [Leff et al., J. Appi. Physiol., 71(5), 1903-1906 (1991)]. GPX was measured as the oxidation of NADPH at 340 nm in glutathione reductase, glutathione and t-butyl hydroperoxide [Beutler, A Manual of Biochemical Methods, Orlando, Grune & Stratton, Inc., 1-172 (1984)], LDH [Beutler, A Manual of Biochemical Methods, Orlando, Grune & Stratton, Inc., 1-172 (1984)] and albumin [Corcoran et al., Clin. Chem., 23, 765-766 (1977)] were assayed spectrophotometrically. Uric acid was measured by HPLC [Terada et al., J. Appl. Physiol., 65, 2349-2353 (1988)].
Statistical analyses. Patient groups were compared using an analysis of variance with a Student-Newman-Keuls test of multiple comparisons. An unpaired t test was used to compare the clinical characteristics of septic patients with or without ARDS. For calculations of sensitivity, specificity, positive or negative predictive values and efficiency, 95% confidence intervals were determined based on the binomial distribution [Cochran, In: Sampling Techniques, 2nd ed., New York, John Wiley & Sons, Inc., 54-59 (1963)]. Significance was accepted at a p value of <0.05.
Clinical Parameters. Septic patients who subsequently developed ARDS and septic patients who did not develop ARDS were the same (p>0.05) with respect to age, gender, hematocrit, hemoglobin, blood leukocyte count, blood neutrophil count, serum SGOT, bilirubin, albumin, uric acid levels and APACHE II score [Leff et al., Ann. Rev. Respir. Dis., 146, 985-989 (1992); Knaus et al., Crit. Care Med., 13, 818-289 (1985)]. The mortality of septic patients who developed ARDS was 50% (3 of 6) compared to a mortality of 30% (6 of 20) in septic patients who did not develop ARDS.
Blood markers patterns. Septic patients had increased (p<0.05) serum MnSOD levels compared to control subjects (FIG. 1). However, at the initial diagnosis of sepsis (approximately 6-24 h before diagnosis of ARDS), septic patients who eventually developed ARDS had increased (p<0.05) serum MnSOD levels compared to septic patients who did not develop ARDS. Serum MnSOD levels remained elevated for the next 48 h in patients who developed ARDS while MnSOD levels returned to control levels during the next 48 h in septic patients who did not develop ARDS.
Similarly, at the diagnosis of sepsis, serum from septic patients had more (p<0.05) catalase activity than serum from control subjects. Again, at the initial diagnosis of sepsis, patients who later developed ARDS had more (p<0.05) serum catalase activity than septic patients who did not develop ARDS (FIG. 2). During the next 48 h, serum catalase activity increased progressively in septic patients who developed ARDS but did not change in septic patients who did not develop ARDS.
In contrast to MnSOD levels and catalase activities, serum GPX activity was essentially the same (p>0.05) in control subjects and septic patients regardless of whether ARDS ensued (FIG. 3).
Serum from septic patients who subsequently developed ARDS also had increased (p<0.05) LDH activity compared to serum from septic patients who did not develop ARDS. Serum from septic patients who did not develop ARDS had the same (p>0.05) LDH activity as serum from control subjects (FIG. 4). Serum LDH measurements increased during the 48 h study period in septic patients who developed ARDS but not in septic patients who did not develop ARDS.
Septic patients who did or did not develop ARDS (FIG. 5) had similarly increased (p<0.05) serum Factor VIII levels compared to control subjects. Septic patients who did and did not develop ARDS had similar (p>0.05) Factor VIII levels.
Finally, plasma α 1 Pi-elastase complexes were increased in all septic patients at the initial diagnosis of sepsis but differences between septic patients who did or did not develop ARDS were manifest only at the time of diagnosis of ARDS (6-24 h after the diagnosis of sepsis) (FIG. 6). By 48 h after the initial diagnosis of sepsis, α 1 Pi-elastase complexes had similarly decreased in septic patients independent of the development of ARDS.
Analyses of serum markers. First, no correlations were found at any time between any of the six markers; Second, the positive and negative predictive values and the sensitivity and specificity of Serum MnSOD levels (±450 ng/ml), catalase activity (±30 U/ml), LDH activity ±250 U/L and Factor VIII levels ±445% control were comparable in predicting the development of ARDS in septic patients (Table 1). Third, serum MnSOD levels, catalase and LDH activity exceeded 450 ng/ml, 30 U/ml and 250 U/L, respectively, approximately 9 h, 12 h and 12 h, on average, respectively, before the diagnosis of ARDS. Further results appear in Table 1.
TABLE 1__________________________________________________________________________Comparison of the Sensitivity and Specificity of Blood Markers asPredictors of ARDS in Septic Patients Positive Negative Predictive PredictiveParameter Sensitivity Specificity Value Value Efficiency__________________________________________________________________________MnSOD ≧ 450 ng/ml 67% (42-94) 88% (75-98) 67% (4-94) 88% (75-98) 83% (70-94)Catalase ≧ 30 U/ml 83% (61-99) 65% (49-82) 42% (25-68) 93% (81-100) 69% (55-84)GPX ≧ 0.72 U/ml 50% (27-85) 47% (31-69) 25% (12-53) 73% (53-92) 48% (34-66)LDH ≧ 250 U/L 67% (42-94) 78% (62-92) 50% (29-81) 88% (74-98) 75% (61-89)Factor VIII ≧ 445% Control 83% (61-99) 67% (42-94) 45% (27-73) 92% (80-100) 71% (57-85)α.sub.1 Pi-elastase > 940 ng/ml 67% (37-98) 64% (50-80) 18% (8-47) 94% (84-100) 64% (51-79)__________________________________________________________________________
In Table 1 each value represents 3-20 determinations at study entry (t=0 h). Values in parentheses represent 95% confidence intervals. Also in Table 1; Sensitivity=TP/TP+FN; Specificity=TN/TN+FP; Positive Predictive Value=TP/TP+FP; Negative Predictive Value=TN/TN+FN; and Efficiency=TP+TN/TP+FP+TN+FN.
In Table 1, results are shown for six sequentially measured factors in the blood of septic patients who were predisposed to develop ARDS. Nine to twelve hours before the development of ARDS, two serum antioxidant enzymes, MnSOD and catalase, were increased in septic patients who later developed ARDS compared to septic patients who did not develop ARDS and that both of these factors predicted the development of ARDS in septic patients with as good a sensitivity, specificity and efficiency as measurements of LDH and Factor VIII. By comparison, measurements of GPX and α 1 Pi-elastase complexes were neither different in septic patients who did or did not subsequently develop ARDS nor effective in predicting the development of ARDS in septic patients.
Assessment of MnSOD and catalase are useful for defining the pathogenesis of ARDS or identifying patients with similar pathophysiologies. Each measurement is accessible, repeatable and relatively easy to perform. Based on assessment of these markers, study of prophylactic treatment is facilitated by reducing the number of at risk individuals who need to be studied to obtain patients with ARDS.
Increases in serum MnSOD levels and serum catalase activity may also have functional importance. MnSOD and catalase may diminish oxidant insults mediated by superoxide anion(O -2 .) or hydrogen peroxide (H 2 O 2 ) or their products such as hydroxyl radical (.OH). This possibility may be especially relevant because accelerated intravascular generation of oxygen radicals from stimulated neutrophils, circulating xanthine oxidase or other sources are implicated in the pathogenesis of sepsis and ARDS [McGuire et al., J. Clin. Invest., 69, 543-553 (1982); Cochrane et al., J. Clin. Invest. 71, 754-758; (1983); Baldwin et al., Lancet, 1, 11-14 (1986) and Grum et al., J. Crit. Care, 2, 22-26 (1987)].
Because the patterns were different for various markers and no two markers correlated with each other, each factor may represent a distinct process and these factors may more correctly reflect various processes occurring in septic patients with ARDS rather than ARDS per se. The present work has focused on sepsis-induced ARDS, so different mechanisms may be present in patients who develop ARDS following trauma and other predispositions.
The origins of the factors, although unclear, most likely are multiple. Lung tissue injury is a possible source for increases in LDH, MnSOD, catalase and Factor VIII levels. Endothelial cells are rich in these factors and, if perturbed, may readily increase the levels of these factors in the blood. However, intravascular neutrophil activation may be responsible for increases in α 1 Pi-elastase complexes because elastase may be present only in neutrophils. Notably, increases in α 1 Pi-elastase complexes occurred relatively later, at the diagnosis of ARDS, and then decreased by 48 h after the diagnosis of sepsis, which may indicate a decline in neutrophil activity. Red blood cell (RBC) hemolysis may be a source for increases in serum catalase and LDH activity, but not MnSOD or Factor VIII levels may not, because RBCs do not contain the latter. Serum catalase activity is also increased in the serum of rats subjected to skin burn [Leff et al., Inflammation (In Press) (1992)], and patients with the acquired immunodeficiency syndrome [Leff et al., Am. Rev. Respir. Dis, 146, 985-989 (1992)], but again, in these situations, the source is unclear. Elevations of IL-1, tumor necrosis factor (TNF) and endotoxin have been found in ARDS patients [Parsons et al., Am. Rev. Resp. Dis., 140, 294-301 (1989); Suter et al., Am. Rev. Resp. Dis., 145, 1016-1022 (1992); Siler et al., Exp. Lung Res., 15(6), 881-894 (1989); Hyers et al., Am. Rev. Respir. Dis., 144, 268-271 (1991) and Marks et al., Am. Rev. Resp. Dis., 141, 94-97 (1990)] and may cause increases in antioxidants such as MnSOD and catalase [White et al., J. Appl. Physiol., 66, 1003-1007 (1989); Wong et al., Science, 242, 941-944 (1988); Brown et al., Proc. Natl. Acad. Sci. (USA), 86, 2516-2520 (1989) and Taniguchi, Adv. Clin. Chem., 29, 1-59 (1992)].
Although the present invention is illustrated by the above embodiments, it is expected that variations and modifications will occur to those skilled in the art upon consideration of the present disclosure. Accordingly, it is intended that the present invention include all modifications and variations which come within the scope of the claims. | At the initial diagnosis of sepsis (6-24 h before the development of ARDS), serum lactate dehydrogenase (LDH) activity level is increased in septic patients who subsequently develop ARDS compared to healthy patients and septic patients who do not develop ARDS. A method is disclosed for predicting the occurrence of ARDS in a septic patient from the patient's serum level of LDH activity, which method facilitates identification of subsets of patients destined to develop ARDS and allows prospective treatment of such septic patients. | 6 |
FIELD OF THE INVENTION
[0001] This invention relates to encoding and decoding images. More specifically, the invention relates to encoding and decoding video in streaming media solutions. Streaming media means that a video is transmitted through a network from a sending party to a receiving party in real-time when the video is shown on the terminal of the receiving party.
BACKGROUND OF THE INVENTION
[0002] A digital video consists of a sequence of frames—there are typically 25 frames per second—each frame consisting of M1×N1 pixels, see FIG. 1. Each pixel is further represented by 24 bits in some of the standard color representations, such as RGB where the colors are divided into red (R), green (G), and blue (B) components that are further expressed by a number ranging between 0 and 255. A capacity of a stream of M1×N1×24×25 bits per second (bps) is needed for transmitting all this information. Even a small frame size of 160×120 pixels yields 11,5 Mbps and is beyond the bandwidth of most fixed and, in particular, all wireless Internet connections (9.6 kbps (GSM) to some hundreds of kbps within the reach of WLAN). However, all video sequences contain some amount of redundancy and may therefore be compressed.
[0003] Any video signal may be compressed by dropping some of the frames, i.e., reducing the frame rate, and/or reducing the frame size. In color videos, a clever choice of the color representation may further reduce the visually relevant information to one half bit count or below, for example the standard transition from RGB to YCrCb representation. YCrCb is an alternative 24 bit color representation obtained from RGB by a linear transformation. The Y component takes values between 0 and 255 corresponding to the brightness or the grayscale value of the color. The Cr and Cb components take values between −128 and +127 and define the chrominance or color plane. In radial coordinates, the angle around the origin or hue determines the actual color while the distance from the origin corresponds to the saturation of the color. In what follows, these origin corresponds to the saturation of the color. In what follows, these kinds of steps are assumed taken and the emphasis is on optimal encoding of the detailed information present in the remaining frames.
[0004] All video compression techniques utilize the existing correlations between and within the frames, on the one hand, and the understanding of the limitations of the human visual system, on the other. The correlations such as immovable objects and areas with constant coloring, may be compressed without loss, while the omission of invisible details is by definition lossy. Further compression requires compromises to be made in the accuracy of the details and colors in the reproduced images.
[0005] In absence of cuts (a change of scene) in a video, the consecutive frames differ only if the camera and/or some of the objects in the scene have moved. Such a series of frames can be efficiently encoded finding the directions and magnitudes of these movements and conveying the resulting motion information to the receiving end. This kind of procedure is called motion compensation; the general idea of referring to the previous frame is known as INTER (frame) encoding. Thus an INTER frame closely resembles the previous frame(s). Such a frame can be reconstructed with the knowledge of the previous frame and some amount of extra information representing the changes needed. To get an idea of the achievable compression ratios, let us consider an 8×8 pixel block 2 (see FIGS. 2 and 3), which corresponds to 8×8×24=1536 bits in the original form. If the movement of the block between two consecutive frames 1 is limited between, e.g., −7 and 7 pixels, the two-dimensional motion vector can be expressed with 8 bits resulting in a compression ratio of 192.
[0006] In order for this method to work, the first frame after each cut needs to be compressed as such—this is called INTRA encoding. Thus an INTRA frame is a video frame that is compressed as a separate image with no references made to any other frame. INTRA frames are needed at the beginning of a video stream, at cuts, and to periodically refresh the video in order to recover from errors.
[0007] Retaining good visual quality of the compressed videos is just one of the many requirements facing any practical video compression technology. For commercial purposes, the encoding process should be reasonably fast in order to facilitate the encoding of large amounts of video content. Apart from a possible initial buffering of frames in the computer's memory, the viewing of a video typically occurs in real time demanding real time decoding and playback of the video. The range of intended platforms from PC's (personal computers) to PDA's (personal digital assistant) and possibly even to third generation mobile phones sets further constraints on the memory usage and processing power needs for the codecs (coder-decoder).
[0008] Fast decoding is even more important for the so-called streaming videos, which are transmitted to the receiver in real time as the user watches. For streaming videos, a limited data transmission capacity imposes a minimum compression ratio over the full length of the video. This is because the bit rate for transmitting the video must remain within the available bandwidth at all times.
[0009] Most video compression technologies comprise two components: an encoder used in compressing the videos and a decoder or player to be installed in the prospective viewing apparatus. Commonly, such decoders are downloaded into the viewing apparatus for being installed permanently or just for the viewing time of a video. Although this downloading needs to be done only once for each player version, there is a growing interest towards player-free streaming video solutions, which can reach all internet users. In such solutions, a small player application is transmitted to the receiving end together with the video stream. In order to minimize the waiting time due to this overhead information, the application, i.e., the decoder, should be made extremely simple.
[0010] For present purposes in this text it is sufficient to consider gray-scale frames/images (color images and different color representations are straight-forward generalizations of what follows). The gray-scale values of the pixels are denoted as the luminance Y. These form a two-dimensional array in a frame and the challenge to the encoding process is to perform the compression and decompression of this array in a way that retains as much of the visually relevant information in the image as possible.
[0011] In the INTRA mode, (video or image compression technique used in encoding INTRA frames) each frame is just a gray-scale bitmap image. In practice the image is typically divided into blocks of N×N pixels 2 and each block is analysed independent of the others, see FIG. 3.
[0012] The simplest way to compress the information for an image block is to reduce the accuracy in which the luminance values are expressed. Instead of the original 256 possible luminance values one could consider 128 (the values 0,2, . . . ,254) or 64 values (0,4, . . . ,252) thereby reducing the number of bits per pixel needed to express the luminance information by 12.5% and 25%, respectively. Simultaneously such a scalar quantization procedure induces encoding errors; in the previous exemplary cases the average errors are 0.5 and 1 luminance unit per pixel, respectively. The scalar quantization is very inefficient, however, since it neglects all the correlations between neighbouring pixels and blocks that are present in any real image.
[0013] One way to account for the correlations between the pixels is to conceive the image, i.e., the luminance values of the pixels, as a two dimensional surface. Many of the existing image compression algorithms are based on functional transforms in which the functional form of this surface is decomposed in terms of some set of basis functions.
[0014] The most widely used transforms are the discrete cosine transform (DCT) and the discrete wavelet transform (DWT), where the basis is formed by cosines and wavelets, respectively. The larger block sizes account for correlations between the pixels over longer distances; the number of basis functions increases as N 2 at the same time. In the JPEG and MPEG standards, for example, the block size for the DCT coding is 8×8. The key difference between DCT and DWT is that, in the former, the basis functions are spread across the whole block while, in the latter, the basis functions are also localized spatially.
[0015] In the INTER mode, (An INTER mode is a video compression technique used in compressing INTER frames or blocks therein. INTER modes refer to the previous frame(s) and possibly modify them. Motion compensation techniques are representative INTER modes.) the motion compensated blocks may not quite match the originals. In many cases, the resulting error is noticeable but still so small that it is easier to convey the correction information to the receiving end rather than to encode the whole block anew. This is because the errors are typically small and they can be expressed with a lower number of bits than the luminance values in an actual image block. Apart from this distinction, the difference blocks can be encoded in a similar fashion as the image blocks themselves.
[0016] As an alternative to the functional transforms one can employ vector quantization (VQ). In VQ methods, the N×N image blocks 2 , or N 2 vectors 3 (see FIG. 3), are matched to vectors of the same size from a pre-trained (trained prior to the actual use) codebook (a collection of codevectors). For each block, the best matching code vector is chosen to represent the original image block. All the image blocks 2 are thus represented by a finite number of code vectors 4 , i.e., the vectors are quantized. The indices of the best matching vectors are sent to the decoder and the image is recovered by finding the vectors from the decoder's copy of the same codebook.
[0017] The encoding quality of VQ depends on the set of training images used in preparing the codebook and the number of vectors in the codebook. The dimension of the vector space depends quadratically on the block dimension N (N 2 pixel values) whereas the number of possible vectors grows as 256 N 2 —the vectors in the codebook should be representative for all these vectors. Therefore in order to maintain a constant quality of the encoded images while increasing the block size, the required codebook size increases exponentially. This fact leads to huge memory requirements and quite as importantly to excessively long search times for each vector. Several extensions of the basic VQ scheme have been proposed in order to attain good quality with smaller memory and/or search time requirements.
[0018] Some extensions such as the tree-search VQ only aim at shorter search times as compared to the codebook size. These algorithms do not improve the image quality (but rather deteriorate it) and are of interest here only due to their potential for speeding up other VQ based algorithms.
[0019] The VQ algorithms aiming at improving the image quality typically use more than one specialized codebook. Depending on the details of the algorithm, these can be divided into two categories: they either improve the encoded image block iteratively, see FIG. 4, such that the encoding error of one stage is further encoded using another codebook thereby reducing the remaining error, or they first classify the image material in each block and then use different codebooks ( 411 , 412 , 413 ) for different kinds of material (edges, textures, smooth surfaces). The multi-stage variants are often denoted as cascaded or hierarchical VQ, while the latter ones are known as classified VQ. The motivation behind all these is that by specializing the codebooks, one reduces the effective dimension of the vector space. Instead of representing all imaginable image blocks, one codebook can dedicated, for example, to the error vectors whose elements are restricted below a given value (cascaded) or blocks with an edge running through them (classified). In cascaded VQ variants, the vector dimension is often further reduced by decreasing the block size between the stages.
[0020] The key advantages in transform coding technologies are their analytically predictable properties and the resulting decorrelated coefficients ranked in terms of their relative importance. These aspects enable efficient rate-distortion control and scalability of a stream according to an available transmission line bandwidth.
[0021] Transforms such as DCT, where all the basis functions extend over the same block area, are more prone to blocking artefacts than DWT like approaches, where the spatial location and extension of the basis function varies. This difference is evident, e.g., when encoding image blocks containing sharp edges (sharp transitions between dark and bright regions). The DCT of such a block yields, in principle, all possible frequencies in at least one spatial direction. In contrast to this, the DWT of the block may lead to just a few nonzero coefficients. The DCT, on the other hand, is more efficient for encoding larger smoothly varying surfaces or textures, which in turn would require large numbers of nonzero wavelet coefficients.
[0022] In most actual image blocks, the number of zero transform coefficients is larger than that of the nonzero ones. Hence the encoding efficiency of the transform techniques is to a large extent determined by the efficiency of expressing the zeros without using and transmitting several bits for each and every one of them. In DCT, the coefficients are ranked from the most important and frequently occurring to the least important and rarest. The zeros often occur in sequences and are thus efficiently run-length codable. In DWT, the coefficients are ranked into spatially distinct hierarchies, where the zero coefficients often occur at once in whole branches of the hierarchy. Such branches can then be collectively nullified by one code word.
[0023] All the transform coding technologies share one major drawback, namely their computationally heavy decoding side. The decoding involves inverse functional transformations and requires a PC class or better processors, or specialized hardware decoders, to provide sufficient decoding speed. These requirements leave out PDA devices and mobile phones. Typically transform coding is also tied to specific player solutions that need to be downloaded and installed before any video can be viewed.
[0024] Another disadvantage of the transform codecs occurs in the context of difference encoding. The difference between the original and the encoded frames and individual blocks depends on the methods used in the initial encoding of the image. For transform coding methods, the remaining difference is only due to quantization errors induced but, for motion compensation schemes or VQ type techniques, the difference is often relatively random although of small magnitude. In this case, the functional transformations yield arbitrary combinations of nonzero components that may be even more difficult to compress than the coefficients of the actual image.
[0025] The advantages and disadvantages of vector quantization techniques are quite the opposite from those produced by transform codecs. The compression techniques of VQ codecs are always asymmetric with the emphasis on an extremely light decoding process. In its simplest form, the decoding merely consists of table lookups for the code vectors. The player application can be made very small in size and sent at the beginning of the video stream.
[0026] A code vector corresponds to a whole N×N block or alternatively to all the transform coefficients for such a block. If one vector index is sent for each block, the compression ratio is bigger the larger the block size is. However, a big codebook is needed in order to obtain good quality for large N. This implies longer times for both the encoding—vector search—and the transmission of the codebook to the receiving end.
[0027] On the other hand, the smaller the blocks, the more accurate the encoding result becomes. Smaller blocks or vectors also require smaller codebooks, which require less memory and are faster to send to the receiving end. Also the code vector search operation is faster rendering the whole encoding procedure faster. The disadvantage of smaller block size is the larger amount of indices to be transmitted.
[0028] In the improved VQ variants, vector space is split into parts and one codebook is prepared for each part. In the cascaded VQ, in particular, the image quality is improved by an effective increase in the number of achievable vectors V achieved with the successive stages of encoding. In the ideal case, where the vectors in the different stages were orthogonal, adding a stage i with a codebook of V i vectors would increase V to V×V i . This procedure can significantly improve the image quality with reasonable total codebook size and search times. This improvement is done at the expense of the number of bits needed to encode each block; this increases by n if V i =2 n . The image quality is further improved if the block size is reduced between stages.
[0029] There are two problems with the cascaded VQ, however. Firstly, the codebooks are typically trained on realistic difference blocks but with no reference to the human visual system. Consequently, the vectors do not necessarily make the corrections, which are visually the most pleasing. Secondly, the number of bits needed to encode each block grows with the number of stages used and even more rapidly if the block size is reduced on the way since a number of indices increases. In other words reduction of block size causes even more pronounced rise in the number of bits required for transmitting the video.
[0030] The intention of the invention is to alleviate the above-mentioned drawbacks.
SUMMARY OF THE INVENTION
[0031] Unless otherwise is implied by the context, the following definitions should be taken into account when reading these specifications.
[0032] Basic mode. Image or video compression technique designed to encode an image or a video frame. The term is used as a distinction from difference modes.
[0033] Coding. Generally denotes compression, and/or encoding. Since compression is a basic action when coding in this context, the coding can be understood as acts for making the compression. Thus the terms ‘coding’, ‘encoding’, or ‘compression’, stand generally for any act of transforming an image or video data to render it better suitable for transmission.
[0034] Decoding. indicates generally the reversal of the coding process, i.e. transforming the encoded data back to a representation of the information content prior to encoding. Such decoding may or may not be ‘lossy’, or ‘noisy’, i.e. the decoded information content may be less than the original information content, or have additional ‘noise’ artefacts.
[0035] Difference mode. Image or video compression technique used to encode the difference between two frames, usually between the original and encoded frames. In the latter case, the difference is denoted as the encoding error.
[0036] Distortion. Measure of the encoding error. Typically Euclidian norm of the pixel-wise differences in the original and encoded luminance values.
[0037] The solution according to the invention combines the best properties of several of the existing solutions. In short, it is a variant of the cascaded VQ with certain improvements acquired from the DCT and DWT approaches. The fundamental aspects of the invention are that codebooks are pre-processed when training them for predetermining the frequency distribution of the resulting codevectors, and each block is independently coded and decoded using a number of stages of difference coding needed for coding the particular block. When training codebooks, the codebooks are taught using special training images to correspond to certain image features. The invention takes a difference block as input and encodes it further in order to reduce the remaining error in an efficient manner as compared with the additional bits required. The difference block may be the result from any conceivable basic encoding including basic VQ encoding, motion compensation, DCT, and DWT. The invention significantly improves the image quality in proportion to the bit rate (bps) used, regardless of both the INTER and the INTRA encoded frames.
[0038] In accordance with the above-mentioned matters the invention concerns an encoding method for compressing data, in which method the data is first encoded and difference data between the original data and the encoded data is formed, the difference data is divided into one or more primary blocks, which are encoded at least at one stage, each encoding stage comprising the action of the encoding and, if needed for the next encoding stage, an action of calculating a following difference blocks between the current difference blocks and the encoded current difference blocks, performing the consecutive stages in a way that the calculated difference blocks at the previous stage are an input for the following stage, at each stage using a codebook, which is specific for the encoding of the stage, until at a final stage, final difference blocks between the previous difference blocks and the encoded previous difference blocks are encoded using the last codebook, the codebooks for said difference blocks containing codevectors trained with training difference material, and in that prior the training, the training difference material is preprocessed for individually adapting frequency distribution of each codevector for weighting to particular information of the data, and encoding each block independently using a necessary number of the stages needed for the particular block.
[0039] Yet the invention concerns an encoder, which utilizes the inventive encoding method in a way that at least one codebook used for coding differences has been weighted to a specific frequency distribution, and the encoder comprises evaluation means for assigning a necessary number of the stages needed for the particular block.
[0040] Furthermore taking into account the inventive encoding, the invention concerns a decoding method for decompressing data, the method comprising codebooks for the decompression of encoded difference data, wherein at least one of said codebooks contains codevectors, which have been weighted to a specific frequency distribution, and using the codebooks together performing a decompression result, which comprises at least the most significant frequencies.
[0041] And furthermore, the invention concerns a decoder using codebooks for the decompression of encoded difference data, wherein at least one of the codebooks has been weighted to a specific frequency distribution.
[0042] Thus it is an aspect of the present invention to provide an encoding method for compressing data, the method comprising the steps of encoding the data to produce encoded data and forming difference data between the data and the encoded data. The next steps comprises dividing the difference data into one or more primary blocks, forming difference blocks, and using a selected codebook re-encoding a difference block to produce an encoded difference block; calculating a following difference block between said difference block and the encoded difference block, forming secondary difference blocks. These steps are iteratively repeated for a plurality of selected primary and secondary difference blocks until a desired level of compression is achieved. The codebook for re-encoding is selected for each iteration from a plurality of codebooks. At least one of the codebooks contains codevectors trained with training difference material, wherein prior to the training, said training difference material is preprocessed for individually adapting frequency distribution of at least one of said codevectors for weighting to particular portions of the data. A plurality of codebooks may be used in combination. Preprocessing may be carried out usig a discrete cosine transform, or any other functional transform.
[0043] In a preferred embodiment, in at least at one of said repetitions the difference blocks are divided into sub-blocks at least one of which to be used as difference blocks at a subsequent repetition.
[0044] Preferably the method further comprises evaluating the cost of a repetition using a cost function which produces a cost result, and deciding if to perform the next repetition based on the basis of said result. More preferably, the cost function utilizes a remaining difference, and a number of bits used for representing said difference block, to calculate a cost of further repetitions. Most preferably, the number of bits is weighted.
[0045] Optionally, in at least at one repetition the difference blocks are preprocessed before encoding.
[0046] It is yet another aspect of the invention to provide a decoding method for pre-compressed data, the method comprising the steps of producing a plurality of codebooks for the decompression of encoded difference data, wherein at least one of said codebooks contains codevectors, which have been weighted to a specific frequency distribution; and, decompressing data using the codebooks in combination, to produce a decompression result which comprises at least a plurality of significant frequencies contained in said data prior to compression.
[0047] Yet another aspect of the invention teaches an encoder for compressing data, comprising means for encoding the data, means for forming difference data between the data and the encoded data, means for dividing the difference data into one or more primary blocks, forming the latest difference data blocks. This aspect of the invention further comprises means for iteratively repeating the following step of re-encoding and calculating independently for each block, until a desired accuracy level of compressed data is achieved, means for re-encoding a step-specific difference data block, which is the latest difference data block, using a codebook, elected suitable for each repetition, the codebook for said step-specific difference block containing codevectors, and means for calculating a following difference block between the step-specific difference block and the encoded step-specific difference block, forming the latest difference data block. At least one of said codebooks contains codevectors trained with training difference material, wherein prior the training, said training difference material is preprocessed for individually adapting frequency distribution of each codevector for weighting to particular information of the data.
[0048] The encoder preferably implements all or some of the method described above.
[0049] The invention further contemplates in another aspect, a decoder for decompression of encoded data, the encoded data containing a plurality of encoded difference data said decoder comprising a compressed data input module; a decompression module adapted to utilize at least one codebook that has been weighted to a specific frequency distribution, and a decompressed data output module. Similarly to the encoder, the decoder preferably utilizes all or some of the different features described in the decoding method above or other reciprocating feature of the encoding method described.
[0050] While the method above describes iterative repetition, it should be clear that such iterations are not limited to loops and include methods such as recursion and other well known techniques either by a single or multiple processing units for performing the step described repeatedly on the data or various portions thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0051] In the following the invention is described in more detail by means of FIGS. 1 - 11 in the attached drawings where.
[0052] [0052]FIG. 1 illustrates an example of a frame of size N1*M1 pixels,
[0053] [0053]FIG. 2 illustrates an example of a division of a frame into blocks of size N*N pixels,
[0054] [0054]FIG. 3 illustrates an example of a block of size N*N pixels, a vector representing the block, and a code vector for quantizing the vector,
[0055] [0055]FIG. 4 illustrates an example of a known vector quantization arrangement,
[0056] [0056]FIG. 5 illustrates an example of the training of difference material according to the invention,
[0057] [0057]FIGS. 6 and 7 illustrate a simple example of the inventive way to code each block with a block specific number of coding stages,
[0058] [0058]FIG. 8 illustrates an example of an arrangement containing evaluation means according to the invention,
[0059] [0059]FIG. 9 illustrates an example of a flow chart describing the inventive method, and
[0060] [0060]FIG. 10 illustrates an example of an arrangement for the invention,
[0061] [0061]FIG. 11 illustrates an example of a decoder adapted to use at least one inventive codebook.
DETAILED DESCRIPTION OF THE INVENTION
[0062] [0062]FIG. 4 illustrates an example of a known vector quantization arrangement. The invention significantly improves the performance of the arrangement, expanding the fields to which the arrangement is applicable. It should be noted that if in this text a block is mentioned in the singular, it is done in order to increase the readability and understanding of the invention, while in practice all blocks of images are coded/decoded.
[0063] Let us consider an original 8×8 block. At the first stage, this block is coded 41 using either one codebook 45 or alternatively several codebooks 411 . As described earlier, classified codebooks can be used in a cascaded VQ. Since the coding concerns the original block, the first stage belongs to the basic mode. The difference 416 between the original block and the coded block is calculated 48 . The difference, i.e. the encoding error, can, for example, be measured in standard terms as the distortion
d tot 2 = ∑ i = 1 N ∑ j = 1 N d i , j 2 = ∑ i = 1 N ∑ j = 1 N ( Y i , j o - Y i , j e ) 2 ,
[0064] where d tot denotes the total distortion for an N×N block and d i,j the distortion of the pixel in the ith row and jth column of the block; Y i,j o and Y i,j e are the luminance values of that pixel in the original and encoded blocks, respectively.
[0065] The distortion block is divided 414 into four 4×4 subblocks 417 , which are encoded 42 at a second stage (the difference mode) using codebook A 46 or alternatively several codebooks 412 . Each difference coded 4*4 block is subtracted 49 from the original 4*4 difference block. The remaining differences 418 are then further divided 415 into four 2×2 subblocks. Each 2*2 difference block 419 is encoded 43 using another codebook E 47 or alternatively codebooks 413 . Each coded 2*2 difference block is subtracted 410 from the original 2*2 difference block for achieving final remaining difference. It should be noted that the block sizes might alternatively remain at each stage, in which case the divisions of the blocks are not performed.
[0066] Each codebook is trained with realistic ‘image’ material, i.e., at the difference mode with actual difference blocks occurring at the stage where the codebook is to be used. The training consists of finding a given number of vectors, which represent the training set as best as possible. This is achieved using the standard k-means algorithm. The measure of goodness is the sum of the Euclidian distances between the training vectors and the code vectors closest to them.
[0067] This far the described procedure is equivalent to the usual cascaded VQ and possesses the same virtues such as the simple decoding. The invention consists of two modifications, thereof, that are designed to solve the main weaknesses and strengthen the performance.
[0068] Firstly, as shown in FIG. 5, the training material used in the training of the codebooks is to be pre-processed 51 for predetermining the frequency distribution of the resulting codevectors. This is done by cosine transforming all the training blocks, removing some component of the transform, e.g. certain frequency components, by setting their coefficients to zero, and finally attaining the new training block via inverse transformation. It should be noted that DCT is not the only way to preprocess training material, but another suitable functional transform can be used.
[0069] The motivation behind this procedure is twofold. For one thing, it is visually more important to focus the limited number of bits on correcting the low-frequency errors than trying to correct the whole block containing all frequencies. The coefficients, representing frequencies, can be ranked in terms of their importance for the human observer: the eye is more sensitive to the lower spatial frequencies than to the higher ones. This does not necessarily indicate low frequencies in some absolute terms smaller block sizes necessarily generate higher frequencies, and a thus more limited spread of the DCT function. In other words, the resulting code vector (or vectors) is adapted to a desired frequency distribution.
[0070] Secondly, all the code vectors in two or more codebooks trained with distinct frequency regimes are at least nearly orthogonal and can be efficiently used together to complement each other. This notion increases the number of possible code vectors achieved with the combination of the basic encoding and two or more stages of difference encoding. The restriction of the code vectors to a limited number of DCT frequencies effectively reduces the vector dimension. For this reason, a codebook of a given size matches the training vectors better than if no frequency selection has been done. This fact leads to still more effective encoding of the visually important components in the difference blocks.
[0071] Some possible frequency selections with practical applications include: blocks with just the lower frequencies, blocks with zero mean value, and blocks with intermediate frequencies (higher than the lowest frequency blocks, but not the highest ones). After the preprocessing, the actual training is performed 52 , from which the best matching code vectors 53 are found, and codebooks are formed.
[0072] The other modification to the standard cascaded VQ concerns the spatial adaptability of the difference encoding. In the spirit of DWT, the usage of further difference modes is decided separately for each block, i.e., the encoding of one block may involve several successive stages of difference encoding while its neighbouring block is decided to be encoded well enough with the mere basic mode.
[0073] The encoded data sent to the decoder comprises the indices of M1, M2, M3, etc, shown in FIG. 4.
[0074] [0074]FIGS. 6 and 7 illustrate a simple example of the inventive way to code each block with a block specific number of coding stages, FIG. 6 shows an 8*8 block ORG which is coded (compare FIG. 4, 41) and the difference between the original and the coded block is divided (FIG. 4, 417) into 4*4 blocks D 1 A to D 1 D at the first encoding stage. After this, each block is examined for the need of a further stage of coding. Since the original 8*8 block illustrates a line 61 across a uniform background, the coding of the first stage is sufficient for block D 1 A wherein only the uniform background information exist. The examination reveals that the other blocks, D 1 B to D 1 D may benefit from further coding in a second compression stage.
[0075] [0075]FIG. 7 shows a division of the coded 4*4 difference blocks (FIG. 4, 415) into 2*2 blocks D 22 A-D 22 D, D 23 A-D 23 D, and D 24 A-D 24 D at the second compression stage. After the division, each block is examined for the need of a further stage of coding. Since blocks D 22 A, D 22 B, D 22 C, D 23 A, D 23 B, D 23 C, D 24 B, D 24 C, and D 24 C illustrate only a minor part of the line 61 across the uniform background or purely the background, the coding of the second stage is sufficient for these blocks. The other blocks D 22 D, D 24 A, and D 23 D need further a third stage of coding. As a result of coding the original 8*8 block, one 4*4 block, i.e. block D 1 A, has been coded using one stage, several 2*2 blocks (blocks D 22 A, D 22 B, D 22 C, D 23 A, D 23 B, D 23 C, D 24 B, D 24 C, and D 24 C) have been coded using two stages, and three 2*2 blocks (D 22 D, D 24 A, and D 23 D) have been coded using three stages.
[0076] The decision for using additional stages of coding is based on rate-distortion considerations in the form of a cost function involving the relative cost for using further bits while achieving some reduction in the block's distortion. In other words, if the cost of using additional stage is too high, the use of additional stage(s) is unnecessary. The cost function may be weighted in a desired way, i.e. weighting the cost of the bits used in proportion to distortion. Preferably, the weighting takes into account the weighted use of bits per a distortion value (such as a distortion value of luminance or chrominance components). The use of bits may be weighted linearly or nonlinearly over the range of distortion values. The selection of the most appropriate cost function may be preselected, or determined by conditions at the time of transmission, by user selection, or any other convenient method.
[0077] The advantage of this procedure is the increased flexibility of the bit allocation across each frame. Consequently, the difficult regions can be encoded with a succession of difference modes and code vectors while simpler regions can be corrected once or left as they are. This flexibility increases the usage of the difference stages for any given bit rate.
[0078] Due to the abovementioned matters the inventive arrangement may benefit from evaluation means for examining the need of using additional coding stages. As FIG. 8 shows, the evaluation means 102 can preferably be implemented into the division modules (compare FIG. 4, 414, 415 , and 410 ) used 101 , but the evaluation means can be an individual module.
Preferable Implementation of the Invention
[0079] The inventive arrangement takes a difference block as input at each difference mode stage and encodes it further in order to reduce the remaining error in an efficient manner as compared with the additional bits required. The difference block may be the result from any prior encoding such as basic VQ encoding, motion compensation, DCT, or DWT.
[0080] The inventive solution consists of two parts: the training of the codebooks and a method for utilizing them in video encoding. Let us, for example, consider a frame from a gray-scale video, which has been encoded with some combination of VQ and motion compensation using 8×8 block size. The resulting difference image is divided into 4×4 blocks, which are to be encoded in two further stages.
[0081] Several training algorithms are known in the art. By way of example, the reader is referred to Lloyd's algorithm presented in Y. Linde, A. Buzo, and R. M. Gray, “An algorithm for vector quantizer design”, IEEE Transactions on Communications, 28(1), pp. 84-95, January 1980. An alternative algorithm known as k-means or C-means. This was first presented in J. B. McQueen, “Some Methods of classification and analysis of multivariate observations”, Proceedings of 5th Berkeley Symp. Mathemat. Statist. Probability 1, pp. 281-296, University of California, Berkeley, 1967.
[0082] The training of the first difference codebook, codebook A, has been performed with realistic difference material, but with the lowest frequency, i.e., the constant component removed. The standard k-means algorithm tends to emphasize the lower frequencies, but cannot generate fictitious finite averages to the resulting vectors. For a codebook with 256 vectors, the frequencies are concentrated to the lower half of the frequency table.
[0083] The second stage codebook, codebook B, is trained with difference blocks where, e.g., one third of the lowest frequencies have been removed. The resulting code vectors do have some weight in these frequencies due to the training algorithm but the emphasis is on the higher frequencies. Therefore the code vectors from codebooks A and B can efficiently complement each other. The fact that there is some overlap between the codebooks can be utilized by combining two vectors from A or two vectors from B or one from each. The overlap can be avoided by performing the training with the transform coefficients before the inverse transformation.
[0084] The actual encoding proceeds by first searching for the best matching vector from codebook A for each 4×4 block. Then the blockwise reductions in the distortion are calculated and the induced rate-distortion cost is compared with the cost without using the difference vectors. A typical cost function is C=d+λb, where d is the distortion, λ is a weighting factor, and b the number of bits used for the block. It should be noted that the weighting factor can also be attached to d, or the weighting can be handled using separate weighing factors attached to d and b. Code vectors are chosen only for those blocks for which this reduces the cost. In the next step, best matching code vectors in codebook B are searched for the remaining 4×4 difference blocks. Again code vectors are chosen only when it is cost efficient. The positions for the code vectors can be expressed by single bits so that one byte is enough to determine which subblocks of the original 8×8 block are corrected with vectors from codebook A and which from codebook B.
[0085] Finally, the code vectors are centered around zero and have predominantly very small values. Such codebooks can be efficiently compressed before being transmitted to the receiving end, thereby reducing the initial waiting time for the video recipient.
[0086] [0086]FIG. 9 illustrates an example of a flow chart describing the inventive method. First step 81 is to pre-process training material for predetermining frequency distribution of codevectors to be trained. Preferably the pre-processing is made beforehand, it is an important step for achieving the desired performance of any arrangement according to the invention. The next step 82 is to train codevectors using the pre-processed training material. Codebooks are formed. Finally, information is coded/decoded 83 using a cascaded VQ in a way that a necessary number of stages of coding or decoding is used individually for each original block.
[0087] [0087]FIG. 10 illustrates an example of an arrangement for the invention. In practical usage, the invention is embedded as a part of complete video compression/decompression software. The compression, i.e. coding, software 91 is normally situated in a sending terminal 93 . The software typically consists of a user interface; media readers for reading in the video and audio information; some form of basic encoding; the difference encoding methods and codebooks proposed in this invention; communication link for sending the stream; and a small decoding software package 92 to be transmitted in the beginning of the video stream to a receiving terminal 94 . However, alternatively, the decoding software may be permanently situated in the receiving terminal
[0088] [0088]FIG. 11 represent an example of a decoder 111 adapted to use at least one inventive codebook. The decoder comprises an input module 117 for compressed data, which contains data that has been compressed using some encoding method, such as DCT or a codebook of a VQ method, and compressed difference data. The compressed difference data has been formed using codebooks of VQ, the difference data is in the form of indices (M1, M2, M3) of the codebooks. The input module directs the compressed data to a decompression module 112 , containing a decoding module 113 and several codebooks 114 , 115 , 116 , in a way that the encoded data is directed to the decoding module and the difference data to the codebooks according to the indices. After the decompression in the decompression module the decompressed data is combined in a output module 118 , from where the combined data is sent for later use. At least one of the codebooks 114 , 115 , 116 , has been weighted according to the invention, but preferably all codebooks have been weighted. It should be noted that alternatively it is also possible to combine the decompressed data in a separate module before the output module 118 , and the direction of the compressed input data in another separate module after the input module.
[0089] The invention combines the best properties of several of the existing solutions. It should be noted that the encoding of original information can be made using any encoding technique, such as VQ, motion compensation, or some functional transform, and difference information is handled using VQ. The invention may benefit from a number of fast-search algorithms, such as the tree-search VQ, to increase the speed of codebook searches.
[0090] Although the inventive encoding is mostly described in this context, it is clear that the invention also concerns decoding. When decoding, the codebooks used must contain codevectors, which are weighted for certain frequency distribution. Using these codebooks together, a decompression result obtains at least the most significant frequencies. There also exist many alternative forms and adaptations for the invention. For example, any form of ‘basic’ encoding of intra and inter frames (i.e. blockwise or non-blockwise), functional transform or vector quantization, can be an underlying technique for the inventive arrangement, since they all leave a residual or difference between the original images and the encoded/decoded ones. The invention may also be used as one step in a sequence of difference encoding with optional variation of block size in each step. In other words, in each sequence (stage) the difference block may be processed, for example using DCT, before coding the difference block. That is to say a pre-encoding before an actual coding. The difference can be encoded blockwise with any block size. A vector library for the difference vectors may be trained in any basis, i.e., as image blocks or functional transforms thereof. Codebook(s) may also be adaptively modified during the encoding process. The encoding procedure and ideas presented herein are applicable to any color presentation such as RGB, YUV, YCrCb, CieLAB, etc.
[0091] It will be clear to those skilled in the art that an encoder or decoder in accordance with the present invention may be implemented as software being executed on a general purpose, a special purpose computerized system. Alternatively, the encoder or decoder may be implemented as a dedicated hardware solution, or as a combination of hardware and software. Thus the invention aims to cover both implementations
[0092] To conclude in light of the above demands, there is a need for a video compression technology, which achieves high compression ratios while retaining good perceptual image quality and whose decoding side requires only minimal processing power. It is also evident that the invention provides a solution for that need, and can be implemented in many solutions within the scope of the invention, as will be clear to a person skilled in the art. | This invention relates to encoding and decoding images. The invention is a variant of the cascaded VQ with certain improvements acquired from the DCT and DWT approaches. The fundamental aspects of the invention are that codebooks are pre-processed when training them for predetermining the frequency distribution of the resulting codevectors, and each block is independently coded and decoded using a variable number of stages of difference coding needed for coding the particular block. | 6 |
TECHNICAL FIELD OF THE INVENTION
The present invention is directed, in general, to air conditioning and, more particularly, to a control system for air conditioning systems employing dehumidification and re-heat.
BACKGROUND OF THE INVENTION
Air conditioning systems with a re-heating system for active humidity control can overcool the air provided to the conditioned space while performing active dehumidification. This occurs because the re-heat coil is not sized to provide neutral supply air temperature. For example, condenser re-heat systems, like the Lennox Humiditrol® EDA, still have a Sensible cooling-to-Total cooling ratio (S/T) of about 0.25 so that some sensible cooling is occurring while dehumidification is being required by the humidistat setting.
A typical control scheme uses “cooling priority” first to satisfy the cooling requirement from the thermostat, and then, if there is excess humidity detected by the humidity sensor, the vapor compression circuit and evaporator continue to cool the air so that the excess humidity can be removed. Since, under most conditions, there is a positive S/T ratio, the space continues to be cooled during this continued dehumidification mode. This results in overcooling of the air and conditioned space. Some thermostats even employ an “overcooling limit” to stop the dehumidification mode from lowering the conditioned air too far below the temperature setpoint even if the desired relative humidity has not been met. The fact that enhanced dehumidification is only enabled after the temperature setpoint has been achieved means that more than the minimum amount of energy is being used to provide the space with conditioned air.
Accordingly, what is needed in the art is an air conditioning system that avoids the wasted energy of overcooling the air in order to achieve the desired relative humidity.
SUMMARY OF THE INVENTION
To address the above-discussed deficiencies of the prior art, the present invention provides, in one aspect, an air conditioning system comprising an air mover for circulating air to a space; a vapor compression circuit including a compressor, a condenser, and an expansion device; an evaporator; an air-reheat heat exchanger; and a control system. In a preferred embodiment, the evaporator receives refrigerant from the vapor compression circuit and is adapted to provide a cooled stream of air to the space. In a further aspect, the air-reheat heat exchanger is positioned to receive the cooled stream of air. In one embodiment, the vapor compression circuit, the evaporator, and the air-reheat heat exchanger are operable in combination to provide a plurality of modes of operation. In a preferred embodiment, the control system is configured to compute a Sensible cooling-to-Total cooling (S/T) process ratio and to control an operation of at least one of the vapor compression circuit, the evaporator, and the air-reheat heat exchanger. A method of manufacturing the air conditioning system is also provided.
The foregoing has outlined preferred and alternative features of the present invention so that those skilled in the pertinent art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the pertinent art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing or modifying other structures for carrying out the same purposes of the present invention. Those skilled in the pertinent art should also realize that such equivalent constructions do not depart from the spirit and scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawing, in which:
FIG. 1 illustrates a schematic diagram of an air conditioning system constructed according to the principles of the present invention;
FIG. 2 illustrates a flow diagram for an enhanced dehumidification control algorithm assembled in accordance with the principles of the present invention as implemented in the controller of FIG. 1 ;
FIG. 3 illustrates a performance chart of three modes of operation of the air conditioning system of FIG. 1 with a 75° F. indoor dry bulb temperature and a 66% indoor relative humidity; and
FIG. 4 illustrates a psychrometric chart covering normal indoor temperature and humidity ranges.
DETAILED DESCRIPTION
Referring initially to FIG. 1 , illustrated is a schematic diagram of an air conditioning system 100 constructed according to the principles of the present invention. The air conditioning system 100 comprises a conventional electric motor-driven compressor 110 connected via a conduit 114 to a refrigerant fluid, primary condenser heat exchanger 116 disposed typically outdoors. The heat exchange between fluid flowing through the condenser heat exchanger 116 and ambient outside air is controlled by a fan 118 having a plurality of fixed pitch blades 118 a and which is driven by a variable-speed electric motor 120 . The variable-speed electric motor 120 may be an electrically-commutated type operating on variable frequency and voltage AC electric power as supplied to the motor 120 via a suitable controller 122 . Fan 118 propels a heat exchange medium, such as ambient “outdoor” air through condenser heat exchanger 116 in a known manner. Condenser heat exchanger 116 may also operate with other forms of heat exchange medium at controlled flow rates thereof. Control of heat exchange medium flowing over condenser heat exchanger 116 may take other forms such as a constant-speed variable pitch fan, air flow control louvers, or control of a variable flow of a liquid heat exchange medium. Condenser heat exchanger 116 is also operably connected to a conventional refrigerant fluid filter and dryer 124 disposed in a conduit 126 for conducting condensed refrigerant fluid to a power-operated or so called motor-controlled valve 128 . Valve 128 may be controlled by a solenoid, for example, and may be of a type commercially available. The solenoid for the valve 128 is also adapted to be controlled by a suitable humidity sensor 130 through controller 122 disposed in a space 132 to be conditioned by the system 100 . In a preferred embodiment, the humidity sensor 130 may be a conventional humidistat with capability to receive input of a desired relative humidity called a relative humidity setpoint RH sp . The humidity sensor 130 is also operably connected to controller 122 . A temperature sensor 134 , disposed within the conditioned space 132 , is also operably connected to the controller 122 . In a preferred embodiment, the temperature sensor 134 may be a conventional thermostat with capability to receive input of a desired temperature called a temperature setpoint T sp . Controlled and conditioned space 132 is represented only schematically in the drawing figures and a return air path from space 132 or another source of air to be conditioned is omitted in the interest of conciseness.
Conduit 126 is connected by way of valve 128 to further refrigerant conducting conduits 136 and 138 to a conventional refrigerant fluid expansion device 140 and to an air-reheat heat exchanger 142 , respectively. The compressor 110 , condenser 116 , and expansion device 140 together may be properly termed a vapor compression circuit. The vapor compression circuit is sized so as to enable conditioning of the air returned to space 132 at the desired relative humidity RH sp . Conduit 136 is operable to deliver refrigerant fluid to a heat exchanger or so called evaporator 144 by way of the expansion device 140 . Expansion device 140 is coupled to a remote temperature sensor 140 a which is adapted to sense the temperature of refrigerant fluid leaving the heat exchanger 144 by way of a conduit 146 . Conduit 146 is commonly known as the suction line leading to compressor 110 whereby refrigerant fluid in vapor form is compressed and recirculated through the system 100 by way of condenser heat exchanger 116 . A suitable valve operator vent conduit 147 is connected between valve 128 and conduit 146 . Heat exchangers 116 , 142 and 144 may be conventional multiple fin and tube type devices, for example.
Air-reheat heat exchanger, also known as an air-reheat condenser 142 is adapted to receive refrigerant fluid from condenser heat exchanger 116 through conduit 138 and discharge such fluid through a conduit 143 and a check valve 145 to conduit 136 upstream of expansion device 140 . The air-reheat condenser 142 is capable of and may be used to raise the temperature of air returned to space 132 to the desired temperature T sp . Under certain operating conditions refrigerant fluid may also be advantageously permitted to bypass the condenser heat exchanger 116 through a conduit 149 and a pressure relief valve 150 . Pressure relief valve 150 includes a closure member 150 a which is biased into a valve-closed position by resilient means, such as a coil spring 150 b . In response to a predetermined pressure, or range of pressures, acting on the closure member 150 a , the pressure relief valve 150 operates to bypass fluid flowing through conduit 114 around the condenser heat exchanger 116 directly to conduit 126 downstream of the filter/dryer 124 , as shown, and to the air reheat heat exchanger 142 .
In the operation of the air conditioning system 100 , controller 122 operates to control a drive motor 152 for a supply air blower or fan 154 of a conventional type. Ambient outdoor air, or air being circulated as return air from space 132 , is propelled by motor driven blower 154 through a suitable duct 156 wherein the heat exchangers 142 and 144 are disposed. Specifically, air-reheat heat exchanger 142 is downstream of heat exchanger 144 . One who is skilled in the art will recognize that the system 100 includes elements of a conventional vapor compression air conditioning system wherein compressor 110 compresses a suitable refrigerant fluid which is condensed in condenser heat exchanger 116 and is conducted to heat exchanger or evaporator 144 through expansion device 140 wherein the condensed refrigerant fluid is expanded and absorbs heat from the air flowing through the duct 156 to provide cooled air to space 132 . This operation is controlled by controller 122 using data demanded by temperature sensor 134 and humidity sensor 130 . Controller 122 operates to control fan motor 152 as well as motor driven compressor 110 and the variable speed fan motor 120 which controls the amount of cooling air flowing over condenser heat exchanger 116 . Controller 122 comprises a microprocessor 125 for management of an algorithm to be described below.
If the relative humidity requirements of the space 132 are not being met by operation of the system 100 wherein all refrigerant fluid is being directed from conduit 126 directly to conduit 136 , control valve 128 will be actuated to force refrigerant fluid to and through air-reheat heat exchanger 142 giving up heat to air flowing through the duct 156 into the space 132 thereby raising the temperature of such air and reducing the rate of sensible cooling occurring. Since refrigerant fluid condensed and highly subcooled in the air-reheat heat exchanger/condenser 142 then flows via conduit 143 to expansion device 140 and evaporator 144 , substantial cooling effect is imparted to air being discharged by blower 154 and flowing through evaporator 144 to thereby condense moisture in the air flowing through duct 156 . Blower 154 may also be termed an air mover. Accordingly, air propelled by blower 154 is first cooled by heat exchanger 144 to condense moisture therein and is then reheated by air-reheat heat exchanger 142 to meet the temperature and humidity requirements of the space 132 . If the humidity requirements of space 132 are not being met by the aforementioned operation of system 100 , the controller 122 reduces the speed of the fan motor 120 and fan 118 , thereby reducing the heat exchange taking place by air flow through the condenser heat exchanger 116 . Fan motor 120 may be controlled to continuously vary the speed of fan 118 or motor output speed may be varied in discrete steps. In this way a greater heat rejection load is placed on air-reheat heat exchanger 142 , progressively, thus raising the temperature of the air flowing into space 132 to further reduce the relative humidity. Commonly, the blower 154 is also reduced in speed during enhanced dehumidification operation.
In those circumstances where the reduced exchange of heat at the condenser heat exchanger 116 occurs, the configuration of the condenser heat exchanger 116 may be such as to impose a relatively large fluid pressure drop thereacross for refrigerant fluid flowing therethrough, particularly if a substantial amount of such fluid is remaining in gaseous form. However, since a greater amount of condensation is occurring in air-reheat heat exchanger 142 , as the fluid condensing load is shifted from heat exchanger 116 to air-reheat heat exchanger 142 , refrigerant fluid in gaseous form may bypass heat exchanger 116 by way of pressure relief valve 150 and conduit 149 without degrading the performance of the system 100 .
Another advantage of the system 100 is that only two refrigerant fluid conduits are required to extend between the indoor portion of the system 100 , as indicated by dashed line 160 , wherein the indoor portion is that generally below the line as shown in the figure. The outdoor portion of system 100 typically includes the compressor 110 and the condenser heat exchanger 116 , as well as the condenser fan and motor 118 , 120 . In other words only conduits 126 and 146 and control wiring for compressor 110 and motor 120 are required to extend between the indoor and outdoor parts of the system as diagrammatically separated by dashed line 160 . This improved arrangement provides for retrofitting of certain air conditioning systems, since the outdoor portion of an existing system may be unaffected by replacing the original indoor portion of the existing system with the indoor portion of system 100 .
At this point, it is desirable to define terms to be used later in the description. Relative humidity setpoint RH sp and temperature setpoint T sp have been previously described as the commanded relative humidity and temperature for the space 132 . The humidistat 130 senses and reports to the controller 122 the current relative humidity RH id of the space 132 . In like manner, the thermostat 134 senses and reports to the controller 122 the current indoor temperature T id of the space 132 . The absolute humidity ratio for the setpoint ω sp conditions is defined as the pounds of water (H 2 O) per pound of air for the relative humidity setpoint RH sp and temperature setpoint T sp conditions. The absolute indoor humidity ratio ω id is defined as the pounds of water per pound of air. To calculate the absolute humidity ratio for the setpoint ω sp conditions, empirical equation 1 is used:
ω sp = [ ( RH sp 0.4 ) * ( 7.875 + 0.00010438 * T sp 3 ) + ( 0.0005 * ( T sp - 50 ) 2.2 ) ] * [ 1 7000 ] Eq . 1
To calculate the absolute indoor humidity ratio ω id , empirical equation 2 is used:
ω id = [ ( RH id 0.4 ) * ( 7.875 + 0.00010438 * T id 3 ) + ( 0.0005 * ( Tid - 50 ) 2.2 ) ] * [ 1 7000 ] Eq . 2
To calculate the process latent load in Btu/lb of air:
L= 1050*(ω id −ω sp ) Eq. 3
To calculate the process sensible load in Btu/lb of air:
S= 0.24*( T id −T sp ) Eq. 4
To calculate the Process Sensible to Total cooling ratio (S/T):
S
T
=
(
S
S
+
L
)
Eq
.
5
Referring now to FIG. 2 , illustrated is a flow diagram for an enhanced dehumidification control algorithm 200 assembled in accordance with the principles of the present invention as implemented in the controller 122 of FIG. 1 . Commencing at Step 205 , the microprocessor 125 within the controller 122 determines if the humidistat 130 is calling for dehumidification. If the answer is NO, then the algorithm proceeds to Step 210 wherein the microprocessor 125 determines if the thermostat 134 is calling for cooling. If the answer is NO, then the algorithm proceeds to Step 215 confirming that both cooling and dehumidification are OFF. The microprocessor 125 then continues to loop 220 and returns to Step 205 wherein the algorithm 200 continues.
Returning to Step 210 , if the microprocessor 125 determines that the thermostat 134 is calling for cooling, i.e., the answer is YES, the algorithm 200 proceeds to Step 218 , and normal cooling is commanded by the controller 122 . The microprocessor 125 then continues to loop 220 and returns to Step 205 wherein the algorithm 200 continues. This portion of the algorithm 200 as described constitutes a normal cooling cycle as one who is of skill in the art would expect, except that the algorithm 200 is arranged for dehumidification priority as compared to conventional cooling priority.
Continuing from Step 205 , if the microprocessor 125 determines that the humidistat 130 is calling for dehumidification, i.e., the answer is YES, the algorithm 200 proceeds to Step 230 . At Step 230 , the microprocessor 125 determines if the thermostat 134 is calling for cooling. If the answer is NO, the algorithm 200 proceeds to Step 235 , and dehumidification at the minimum S/T is commanded by the controller 122 . If the answer is YES, the algorithm 200 proceeds to Step 240 .
At Step 240 , the microprocessor 125 calculates ω sp from the setpoint temperature T sp and setpoint relative humidity RH sp in accordance with Equation 1. The algorithm 200 proceeds to Step 245 where ω id is calculated from current indoor temperature T id and current indoor relative humidity RH id in accordance with Equation 2. The algorithm 200 then proceeds to Step 250 where latent load L is calculated from ω id and ω sp in accordance with Equation 3. At Step 255 sensible load S is calculated in accordance with Equation 4 from T id and T sp . At Step 260 , the Process S/T Ratio is calculated from the Sensible load S and the Total load T=L+S in accordance with Equation 5.
Within the microprocessor 125 , there are resident dehumidification modes 1 through n corresponding to n configurations of the various variable elements of the system 100 . In one embodiment, the variable elements may include, but are not limited to, outdoor fan speed, air-reheat condenser 142 active or inactive, indoor fan speed, etc. Associated with each of the dehumidification modes 1 through n is a pre-calculated S/T ratio. The microprocessor uses these pre-calculated S/T ratios, i.e., S/T 1 , S/T 2 , . . . S/T n-1 , S/T n , for comparison with the Process S/T Ratio. At Step 265 , commencing with the first dehumidification mode n=1, i.e., S/T 1 , the Process S/T ratio is compared to the pre-calculated S/T ratios until a condition is found wherein S/T process <S/T m . For example, if S/T 1 <S/T process <S/T 2 , then the microprocessor 125 selects Mode 2 and adjusts settings of the various variable elements to correspond to the corresponding stored configuration for Mode 2 .
Referring now to FIG. 3 , illustrated is a performance chart of three modes of operation of the air conditioning system 100 of FIG. 1 with a 75° F. indoor dry bulb temperature and a 66% indoor relative humidity. A normal cooling without reheat performance of the system 100 is shown in a first graphical plot 310 . A second graphical plot 320 shows a system configuration of dehumidification (air-reheat condenser 142 active) with the outdoor fan operating at 100 percent and the indoor fan operating at 65 percent. A third graphical plot 330 shows a configuration of dehumidification (air-reheat condenser 142 active) with the outdoor fan operating at 30 percent and the indoor fan operating at 65 percent. With an abscissa scale of outdoor ambient temperature and an ordinate of S/T ratio, the performance of the system 100 will follow the appropriate graph for the selected configuration. As shown in the first graphical plot 310 , the S/T ratio for the normal cooling without reheat stays relatively flat at about 0.61 to about 0.63 over the temperature range from about 75° F. to about 104° F. The S/T ratio for the second configuration is shown to vary substantially linearly from about 0.4 at 75° F. to about 0.25 at about 95° F. The third configuration S/T ratio is shown to vary substantially linearly from about 0.2 at 75° F. to about 0.08 at about 85° F.
An example will be helpful in understanding the algorithm 200 . With current indoor temperature at 77° F. and indoor relative humidity at 49%, it is desired to find a process line and system configuration to avoid overcooling and to more directly condition the indoor air to 75° F. and 50% relative humidity. Entering the algorithm 200 of FIG. 2 at Step 205 , we conclude that both dehumidification and cooling are required, advancing to Step 240 calculate ω sp . From Equation 1, with T sp at 75° F. and RH sp at 50% (0.50), ω sp evaluates to 0.0094. At Step 245 with T id at 77° F. and RH id at 49% (0.49), ω id evaluates to 0.0098 from Equation 2. At Step 250 with ω sp and ω id as just calculated, latent load L evaluates to 0.487 BTU/lb of air from Equation 3. At Step 255 with T id and T SP as above, sensible load S evaluates to 0.48 BTU/lb of air from Equation 4. At Step 260 , the S/T process ratio evaluates to 0.497 from Equation 5. At Step 265 , the S/T process ratio of 0.497 is compared to the known S/T ratios for the three configurations of the system 100 . Within Step 265 , the S/T process ratio of 0.497 is compared to the S/T Mode 1 ratio of about 0.18. The S/T process ratio is greater than the S/T Mode 1 ratio, however, it is not yet known if the S/T process ratio is greater than the S/T Mode 2 ratio. Upon comparing, the S/T process ratio of 0.497 is found to be greater than the S/T Mode 2 ratio of about 0.38. Again however, it is not yet known if the S/T process ratio is greater than the S/T Mode 3 ratio. Upon comparing, the S/T process ratio of 0.497 is found to be less than the S/T Mode 3 ratio of about 0.60. Having satisfied the condition that S/T Mode n <S/T process <S/T Mode n+1 , the algorithm 200 selects dehumidification mode 2 as requiring the least energy to achieve the desired temperature and relative humidity. Dehumidification mode 2 corresponds to a configuration of air-reheat condenser 142 active, outdoor fan speed at 100%, and indoor fan speed at 65%.
Referring now to FIG. 4 , illustrated is a psychrometric chart 400 covering normal indoor temperature and humidity ranges. Normal indoor temperature ranges from about 68° F. to about 82° F. and is indicated along the abscissa. The ordinate covers an absolute humidity ratio ranging from about 0.0 to about 0.020. Current temperature and absolute humidity ratio is represented as a first point 410 at 77° F. and about 0.011 humidity ratio. The desired temperature, 75° F. and about 0.0093 absolute humidity ratio is represented as a second point 420 . The path from the first point 410 to the second point 420 represents the desired process path. Operating the system 100 in dehumidification mode 2 with air-reheat condenser 142 active, outdoor fan speed at 100%, and indoor fan speed at 65% will approximate the desired process path.
Thus, an air conditioning system has been described that employs computation of a Process Sensible to Total Cooling ratio and the selection of the air conditioning system configuration having a reasonable close approximation to the Process Sensible to Total Cooling ratio. Of course, other parameters of the air conditioning system may also be included, thereby possibly more closely approaching the desired Process Sensible to Total Cooling ratio.
The control algorithm has a loop 220 arrangement. The status of the Process Sensible to Total Cooling ratio is repeatedly evaluated over time and adjustments in air conditioner operation are made in response to changes in the sensible and latent loads.
Although the present invention has been described in detail, those skilled in the pertinent art should understand that they can make various changes, substitutions and alterations herein without departing from the spirit and scope of the invention in its broadest form. | An air conditioning system comprising an air mover for circulating air to a space; a vapor compression circuit including a compressor, a condenser, and an expansion device; an evaporator; an air-reheat heat exchanger; and a control system. In one embodiment, the evaporator receives refrigerant from the vapor compression circuit and provides a cooled stream of air to the space. The air-reheat heat exchanger is positioned to receive the cooled stream of air. In one embodiment, the vapor compression circuit, the evaporator, and the air-reheat heat exchanger are operable in combination to provide a plurality of modes of operation. In a preferred embodiment, the control system is configured to compute a Sensible cooling-to-Total cooling (S/T) process ratio and to control an operation of at least one of the vapor compression circuit, the evaporator, and the air-reheat heat exchanger. A method of manufacturing the air conditioning system is also provided. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a load test system for a video data distributing server, and in particular, relates to a technique for monitoring video data packets corresponding to an imposed load and estimating the quality of distribution.
[0003] 2. Description of the Related Art
[0004] As is conventionally known, in a video data streaming distribution service, a video data distributing server streams and distributes video data, in parallel, to a plurality of clients who issue a request for video data distribution.
[0005] The transmitted video data (i.e., encoded video codes) in the video data streaming distribution are typically compressed. However, the amount of the compressed data is still large, and parallel processing is employed in several portions such as the processor, the storage device, and the data transmitting device of the video data distributing server.
[0006] In the load test for such a video data distributing server, a few tens of computers are provided as clients, and a plurality of clients simultaneously access the video data distributing server as an object to be tested, so as to test whether the distribution service is normally performed to the accessed clients.
[0007] In another testing method, a plurality of distribution requesting programs and data receiving programs are loaded in parallel in each computer as a client, so as to increase the number of loads which are simultaneously imposed on the video data distributing server.
[0008] In order to perform the test by using a few tens of computers, a great deal of preparation, relating to arrangement, setting, connection, installation, starting, operation, place, electrical power, air conditioning, and the like, is necessary. However, the frequency of use of such an arrangement for the test is relatively small, and the efficiency of the system is therefore low.
[0009] In addition, the amount of the received video encoded data, which are to be decoded and displayed, is very large. Therefore, even if a plurality of distribution programs or data receiving programs are loaded in parallel, a dozen parallel operations or the like are the actual limit for a single computer to perform, and thus the total number of parallel operations, which can be simultaneously performed, is a few hundred or the like.
[0010] In order to increase the number of simultaneous parallel operations or decrease the number of the computers, another method is known in which a large number of pseudo client software processes (called “pseudo clients” hereinbelow) are operated instead of operating the distribution requesting programs and the data receiving programs, where the pseudo clients function as a lower load on the client computer.
[0011] A concrete example of such a method will be explained below, by referring to FIG. 6 which is a diagram showing the structure of a conventional load test system for testing the video data distributing server.
[0012] As shown in FIG. 6, a distribution and synthesis device 603 is inserted between a client 602 and a video data distributing server 601 , and an access generating device 604 is connected to the distribution and synthesis device 603 . The distribution and synthesis device 603 may be a hub in a LAN (local area network).
[0013] The access generating device 604 captures a distribution request packet sent from the client 602 to the video data distributing server 601 and stores data of timing of the issue of the distribution request packet. The access generating device 604 then reproduces packets corresponding to a number of pseudo clients, where each packet has a different value, transferred from the original value, for indicating an address, a user name, or a client name. The access generating device 604 sends the reproduced packets to the video data distributing server 601 at specific timings.
[0014] In this case, the video data distributing server 601 recognizes that the server simultaneously receives the distributing request packets from many clients, and corresponding processes for distributing video data are simultaneously started. The data receiving situation of the client 602 , which receives the video data, is monitored by a quality monitor 605 so as to test and determine a limit for maintaining specific quality of video data distribution, that is, to determine when the quality of data distribution is degraded if the number of the simultaneous accesses increases.
[0015] However, the above-explained conventional load test system for the video data distributing server has the following first and second problems:
[0016] The first problem relates to the response of the client. Here, two methods are known for distributing video data by using the video data distributing server. In the first method, when a distribution request is received by the server, designated contents (i.e., video data) are continuously distributed until all the contents are distributed. In the second method, the distribution is continued while the response from the client is continued.
[0017] That is, in order that the client terminates the data reception after issuing the distribution request, the above second method employs a process of terminating the video data distribution when the video data distributing server receives no intermittent response for a specific time. This method is generally used in the latest networks, so as to efficiently use resources not only in a stable environment in which a termination request issued from the client is always normally received by the video data distributing server, but also in environments in which (i) packet loss may occur, (ii) the client (computer) may be stopped, (iii) an erroneous operation may be performed, or the like.
[0018] In an improved method of the above second method, a value indicating the packet loss rate (i.e., the rate of packets which were not decoded and used) is included in the response packet from the client. Accordingly, even if the throughput of a router or a specific network segment between the client and the video data distributing server temporarily decreases, the video frame may be thinned out or the image quality may be degraded so as to send video data at a decreased encoding rate. Accordingly, it is possible to prevent loss of video data caused by packet loss.
[0019] In this case, the video data distributing server performs dynamic distribution by reading out the packet loss rate included in the response packet and decreasing the encoding rate according to the read-out value. An example of such a response packet is described in RTCP (real-time transport control protocol) defined by the RFC1889 standard in IETF (Internet engineering task force).
[0020] On the other hand, in order to calculate the packet loss rate at the client side, a method is known in which a sequence number is added to each video data packet to be sent. When using this method, the client detects the absence of any sequence number, and the ratio of the number of packets, whose sequence numbers are absent, to the increment of the sequence number for the packets which have been received for a specific period indicates the packet loss rate, which can be easily calculated using a computer. An example of such a packet, to which the sequence number is added, is described in RTP (real-time transport protocol) defined by the RFC1889 standard in IETF.
[0021] When video data distribution is performed using a protocol such as RTP, RTCP, or the like, the above-explained conventional load test system for the video data distributing server can issue a number of distribution requests. However, the system does not have a function of sending a response packet of each of several clients to the video data distributing server, so that a period during which the server receives no response is produced and the distribution from the server is terminated. In this case, the load is not continued, and thus the load test cannot be performed.
[0022] The second problem is that the quality of distribution for each of the clients is unclear. In the above-explained load test system for the video data distributing server, the quality of distribution is monitored only by a single client. However, the quality of the distribution of the video data distributing server is not always equal between a number of clients, and the quality of distribution to a specific client may be relatively degraded.
[0023] Therefore, while only a single client is monitored, (i) degradation of the quality of distribution which is simultaneously provided to any other client is overlooked, or (ii) the test is repeated several times so as to detect and not overlook such degradation, thereby reducing the efficiency of the system.
[0024] Additionally, in order to simultaneously monitor the quality of distribution to a number of clients, the amount of unused computer resource, which can be used for the monitoring operation, should be large.
[0025] Furthermore, a simple method is required for monitoring the quality of packet distribution or the quality of distributed video image.
SUMMARY OF THE INVENTION
[0026] In consideration of the above circumstances, an object of the present invention is to provide a load test system for the video data distributing server, by which the quality of distribution to all the clients can be monitored without decreasing the number of simultaneous accesses.
[0027] Therefore, the present invention provides a load test system, inserted between real clients and a video data distributing server, for performing a load test for the video data distributing server, comprising:
[0028] pseudo clients having:
[0029] a pseudo access generator for reproducing distribution request packets by rewriting distribution request packets from the real clients, and sending the reproduced packets to the video data distributing server;
[0030] a response section for sending response packets to the video data distributing server; and
[0031] a manager for controlling each process of the load test and for collecting, analyzing, and displaying data relating to the load performance of the video data distributing server, and
[0032] a packet quality monitor for monitoring a state of video data transmission by capturing packets communicated between the load test system and the video data distributing server,
[0033] wherein the packet quality monitor sends monitored results to the manager; and
[0034] the quality of video images, which correspond to the video data distributed from the video data distributing server to the pseudo clients, is evaluated based on the data analyzed and displayed by the manager.
[0035] According to the above structure, it is possible to realize a load test system for the video data distributing server, by which the quality of distribution to all clients can be monitored without decreasing the number of simultaneous accesses.
[0036] In a typical example, the packets reproduced by the pseudo access generator are pseudo distribution request packets which are sent to the video data distributing server;
[0037] the response packets sent by the response section to the video data distributing server are pseudo response packets, each including a packet loss rate with respect to each pseudo client;
[0038] the video data distributing server starts video data distribution processes in response to the pseudo distribution request packets, and continues the video data distribution according to the pseudo response packets sent from the response section;
[0039] the packets captured by the packet quality monitor are the pseudo response packets;
[0040] the packet quality monitor has a packet loss rate extracting section for extracting the packet loss rate with respect to each pseudo client from each pseudo response packet, and sends the extracted packet loss rate to the manager; and
[0041] the manager calculates the number of packets received by each pseudo client or a distribution bandwidth with respect to each pseudo client, based on the packet loss rate.
[0042] According to this structure, the quality of distribution of packets to a number of clients can be monitored, and the limit at which the quality of distribution to any client is degraded can be evaluated.
[0043] In another typical example, the packets reproduced by the pseudo access generator are pseudo distribution request packets which are sent to the video data distributing server;
[0044] the video data distributing server sends each pseudo client video data packets to which a series of sequence numbers are added;
[0045] the packets captured by the packet quality monitor are the video data packets;
[0046] the packet quality monitor has a sequence number extracting section for extracting the sequence numbers with respect to each pseudo client from the video data packets; and
[0047] the manager calculates the number of packets received by each pseudo client or a distribution bandwidth with respect to each pseudo client, based on a packet loss rate with respect to each pseudo client, where the packet loss rate is calculated by detecting absence of any sequence number.
[0048] According to this structure in which a sequence number is added to each video data packet, the video data packets are captured to extract each sequence number, and the packet loss rate is calculated by detecting absence of any sequence number, thereby calculating the number of packets received by each pseudo client or the distribution bandwidth with respect to each pseudo client. Therefore, the quality of distribution of packets can be monitored without referring to response packets which include the packet loss rates.
[0049] The present invention also provides a load test system, inserted between real clients and a video data distributing server, for performing a load test for the video data distributing server, comprising:
[0050] pseudo clients having:
[0051] a pseudo access generator for reproducing distribution request packets by rewriting distribution request packets from the real clients, and sending the reproduced packets to the video data distributing server; and
[0052] a manager for controlling each process of the load test and for collecting, analyzing, and displaying data relating to the load performance of the video data distributing server, and
[0053] a packet quality monitor for monitoring a state of video data transmission by capturing packets communicated between the load test system and the video data distributing server, the packet quality monitor including:
[0054] a response section for sending response packets to the video data distributing server,
[0055] wherein the packet quality monitor sends monitored results to the manager; and
[0056] the quality of video images, which correspond to the video data distributed from the video data distributing server to the pseudo clients, is evaluated based on the data analyzed and displayed by the manager.
[0057] According to the above structure, it is possible to realize a load test system for the video data distributing server, by which the quality of distribution to all clients can be monitored without decreasing the number of simultaneous accesses.
[0058] As a typical example, the packets reproduced by the pseudo access generator are pseudo distribution request packets which are sent to the video data distributing server;
[0059] the video data distributing server sends each pseudo client video data packets to which a series of sequence numbers are added;
[0060] the packets captured by the packet quality monitor are the video data packets;
[0061] the packet quality monitor has a sequence number extracting section for extracting the sequence numbers with respect to each pseudo client from the video data packets;
[0062] the packet quality monitor calculates a packet loss rate with respect to each pseudo client by detecting absence of any sequence number; and
[0063] the response packets sent by the response section to the video data distributing server are pseudo response packets, each including the calculated packet loss rate with respect to the corresponding pseudo client.
[0064] According to this structure in which a sequence number is added to each video data packet, the video data packets are captured to extract each sequence number, the packet loss rate is calculated by detecting absence of any sequence number, and the pseudo response packets, each including the calculated packet loss rate, are produced and sent to the video data distributing server. Therefore, it is unnecessary to provide a pseudo response section in advance.
[0065] In the above-explained load test systems, the manager may evaluate a video frame loss rate with respect to each pseudo client by using a conversion table for determining the video frame loss rate from the packet loss rate of the pseudo client.
[0066] In this case, the video frame loss rate can be evaluated by using the conversion table, thereby evaluating the load performance of the video data distributing server based on the quality of the video image.
[0067] Also in this case, the load test system may further comprise:
[0068] a pseudo network inserted between the real clients and the video data distributing server, where a predetermined packet loss rate is assigned to the pseudo network and the packet loss rate is variable; and
[0069] a client quality monitor for calculating a video frame loss rate with respect to video data received by the real clients,
[0070] wherein the video frame loss rates, calculated while the packet loss rate is varied, and the corresponding packet loss rates are stored in the conversion table.
[0071] According to this structure, the packet loss rate is variable in the pseudo network, the client quality monitor calculates the video frame loss rate with respect to the video data received by the real clients, and the video frame loss rates corresponds to different packet loss rates are stored. Therefore, the load performance of the video data distributing server can be evaluated based on the quality of the video image, which is evaluated by the packet loss rate.
[0072] In the above-explained load test systems, the packets captured by the packet quality monitor may be video data packets sent from the video data distributing server; and
[0073] the packet quality monitor has a video frame header extracting section for extracting a video frame header, reads out a video frame number included in the video frame header, calculates a video frame loss rate by detecting absence of any image frame number.
[0074] According to this structure, the ratio of the number of lost video frames to the increment of the video frame number for a specific period can be the video frame loss rate. Therefore, the load performance of the video data distributing server can be evaluated based on the quality of the video image.
BRIEF DESCRIPTION OF THE DRAWINGS
[0075] [0075]FIG. 1 is a diagram showing the structure of the load test system for testing the video data distributing server as the first embodiment of the present invention.
[0076] [0076]FIG. 2 is a diagram showing the structure of the load test system for testing the video data distributing server as the second embodiment of the present invention.
[0077] [0077]FIG. 3 is a diagram showing the structure of the load test system for testing the video data distributing server as the third embodiment of the present invention.
[0078] [0078]FIG. 4 is a diagram showing the structure of the load test system for testing the video data distributing server as the fourth embodiment of the present invention.
[0079] [0079]FIG. 5 is a diagram showing the structure of the load test system for testing the video data distributing server as the fifth embodiment of the present invention.
[0080] [0080]FIG. 6 is a diagram showing the structure of a conventional load test system for testing the video data distributing server.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0081] Hereinafter, embodiments according to the present invention will be explained with reference to the drawings.
[0082] First Embodiment
[0083] [0083]FIG. 1 is a diagram showing the structure of the load test system 10 for testing the video data distributing server as the first embodiment of the present invention. The structure and function of this system will be explained by referring to FIG. 1.
[0084] As shown in FIG. 1, the load test system 10 is provided between a video data distributing server 201 and a plurality of clients 202 , and the load test system 10 has a function of evaluating the quality and performance of video or moving images which are distributed from the video data distributing server 201 to the clients 202 .
[0085] The load test system 10 comprises (i) a plurality of pseudo clients 11 a which have a pseudo access generator 101 , a response section 102 , and a manager 203 , and (ii) a packet quality monitor 12 a which has a packet filtering section 204 and a packet loss rate extracting section 205 .
[0086] In FIG. 1, the clients 202 access the video data distributing server 201 so that the video data streaming service is provided to the clients 202 . A distribution and synthesis device 302 is inserted between the clients 202 and the video data distributing server 201 , and the pseudo access generator 101 is connected to this distribution and synthesis device 302 .
[0087] The pseudo access generator 101 has a function of capturing distribution request packets, which are sent from the clients 202 to the video data distributing server 201 . The pseudo access generator 101 then reproduces packets by rewriting the address, the user name, or the client name, and sends the reproduced packets to the video data distributing server 201 .
[0088] The pseudo access generator 101 then connects the response section 102 and the manager 203 to the distribution and synthesis device 302 , and the response section 102 continuously sends the video data distributing server 201 response packets so as to respond to the video data distribution from the server.
[0089] Here, the response packet includes data which indicates the packet loss rate. The response packet may have a function defined by the above-explained RTCP. The manager 203 controls each process of the load test for the video data distributing server, collects data of relevant sections so as to analyze results of the test or display a graph which indicates the results.
[0090] If the response section 102 and the pseudo access generator 101 can be more easily realized by using the same computer, then a plurality of computers, each including the response section 102 and the pseudo access generator 101 , may be provided so as to increase the number of clients which simultaneously access the server.
[0091] This case corresponds to a conventional case using a load generating tool for the video data distributing server, in which the pseudo access generator and the response section cannot be separated. The load test can be performed by adding a section for monitoring the quality of distribution, to the structure of the pseudo clients 11 a.
[0092] As shown in FIG. 4 which will be explained below, the quality of the clients 202 can be monitored by adding a client quality monitor 301 .
[0093] In the next process, the packet quality monitor 12 a is connected to the distribution and synthesis device 302 . The packet quality monitor 12 a filters data input into the monitor 12 a by using the packet filtering section 204 , so as to receive only the response packets. The packet quality monitor 12 a extracts the value indicating the packet loss rate from each received response packet by using the packet loss rate extracting section 205 . The packet quality monitor 12 a then stores the extracted value and the corresponding client name, and sends the value and the client name to the manager 203 . That is, the manager 203 receives or collects the data.
[0094] Therefore, it is possible to monitor the quality of data distribution to a plurality of pseudo clients 11 a from the video data distributing server 201 .
[0095] In the example of the response packet defined by RTCP, the length of the response packet corresponding to any one of the clients 202 is approximately a few tens of bytes. Therefore, if the response packet is issued at an interval of approximately a few seconds, the total length of the response packet is a few kilobytes to a few hundred kilobytes during video data distribution for a few hours. Therefore, the commercially-available computer resource can afford to store and process the response packets from, for example, 1000 clients.
[0096] The process of the load test will be explained below. First, the clients 202 send distribution request packets to the video data distributing server 201 , and the video data distributing server 201 starts the video data distribution. This distribution is continued by transmitting the response packets until the distribution is normally completed. In this process, the pseudo access generator 101 generates a number of distribution request packets which are sent to the video data distributing server 201 under the control of the manager 203 .
[0097] The video data distributing server 201 receives many accesses and starts video data distribution simultaneously to the relevant clients. The response section 102 calculates the packet loss rate for each pseudo client and sends the video data distributing server 201 a response packet which includes the calculated value. The packet quality monitor 12 a receives this response packet and stores the packet loss rate of each of the pseudo clients 11 a. The manager 203 collects the packet loss rates sent from the packet quality monitor 12 a. When the video data distribution is completed, the number of the (pseudo) clients which simultaneously access is changed and the processes from the pseudo accessing to the collection of the packet loss rates are repeated.
[0098] An amount of packets to be received and a suitable distribution bandwidth are predetermined for each number of simultaneous clients (i.e., simultaneously-accessing pseudo clients). The manager 203 calculates, for each number of simultaneous clients, the number of packets received by each pseudo client or the distribution bandwidth of each pseudo client, based on the packet loss rate. It is possible to determine, based on the calculated results, whether the predetermined amount of packets or distribution bandwidth is acquired. If the predetermined amount or bandwidth is not acquired, the load performance of the video data distributing server 201 is insufficient at the relevant number of simultaneous clients.
[0099] Second Embodiment
[0100] [0100]FIG. 2 is a diagram showing the structure of the load test system for the video data distributing server, as the second embodiment of the present invention. The structure and function of the load test system 20 in the second embodiment will be explained below with reference to FIG. 2.
[0101] In the following explanations with respect to the second embodiment, parts identical to those which were explained by referring to FIG. 1 are given identical or corresponding reference numerals, and explanations thereof are simplified or omitted.
[0102] As shown in FIG. 2, the packet quality monitor 12 b of the present embodiment comprises a packet filtering section 204 , a packet loss rate extracting section 205 , and a sequence number extracting section 206 .
[0103] In the present embodiment, a sequence number is assigned to each video data packet, and the response packet does not include the packet loss rate. The sequence number is extracted by the sequence number extracting section 206 .
[0104] The video data packet to which the sequence number is added may be defined by the above-explained RTP. Instead of extracting the packet loss rate from the response packet, in the present embodiment, the video data packet is captured by the packet quality monitor 12 b so as to detect the absence of any sequence number.
[0105] The ratio of the number of packets, whose sequence numbers are absent, to the increment of the sequence number for a specific period indicates the packet loss rate. The ratios of a plurality of pseudo clients 11 a are calculated in the packet quality monitor 12 b and are collected by the manager 203 .
[0106] The number of the video data packets is larger than the number of the response packets by one order of magnitude (i.e., ten times or more). Therefore, large-scale processing is necessary for processing the video data packets in comparison with the case of processing only the response packets.
[0107] In the load test system 20 of the present embodiment, a process of calculating the packet loss rate according to the absence of the sequence number is necessary, so as to further calculate the number of packets received by each pseudo client, or the distribution bandwidth for each pseudo client. Therefore, the processes performed in the present embodiment are relatively heavy, and the following third embodiment may be employed so as to improve the efficiency of the system.
[0108] Third Embodiment
[0109] [0109]FIG. 3 is a diagram showing the structure of the load test system for the video data distributing server, as the third embodiment of the present invention. The structure and function of the load test system 30 in the third embodiment will be explained below with reference to FIG. 3.
[0110] In the following explanations with respect to the third embodiment, parts identical to those which were explained by referring to FIGS. 1 and 2 are given identical or corresponding reference numerals, and explanations thereof are simplified or omitted.
[0111] As shown in FIG. 3, in the load test system 30 in the present embodiment, the packet quality monitor 12 c comprises a packet filtering section 204 , a packet loss rate extracting section 205 , a sequence number extracting section 206 , and a response section 102 , and the pseudo clients 11 b comprises a pseudo access generator 101 and a manager 203 . Therefore, the distinctive feature of the present invention in comparison with the first and second embodiments is that the response section 102 is included in the packet quality monitor 12 c.
[0112] In the present embodiment, the response packet to be sent to the video data distributing server 201 is produced by using the device for capturing the video data packet, to which the sequence number is added. That is, the response packet is a pseudo response packet.
[0113] Similar to the second embodiment, in the present embodiment, the video data packet, to which the sequence number is added, is captured by the packet quality monitor 12 c, so as to calculate the packet loss rate. Then, a response packet including the packet loss rate, which was written based on a specific format of the response packet, is sent to the video data distributing server 201 .
[0114] In the above explanations, the rate at which the packets can be accurately distributed is an important point. However, the quality of the video image is not uniform at a packet loss rate, depending on the kind of the video data encoding technique or other conditions. Therefore, the limit point at which degradation of the quality of the video image starts may be preferably tested for each load.
[0115] When only a single client is monitored as in the conventional test system, the number of frames of the video image, which were not reproduced by the video decoder, is detected by a client quality monitor which is connected to the client. However, the video decoder consumes substantial computer resources by (i) temporarily storing (i.e., buffering) one or a few video frames, each frame requiring a memory area of a few megabytes, (ii) processing an algorithm of a large-scale operation such as conversion of a coefficient in the two-dimensional spatial frequency region into a spatially-distributed value, or the like. Therefore, the video decoder cannot be assigned to each of a number of clients.
[0116] Accordingly, it is necessary to employ a method for evaluating the quality of the video image by using less computer resources. Such a method can be realized by the present embodiment.
[0117] Fourth Embodiment
[0118] [0118]FIG. 4 is a diagram showing the structure of the load test system for the video data distributing server, as the fourth embodiment of the present invention. The structure and function of the load test system 40 in the fourth embodiment will be explained below with reference to FIG. 4.
[0119] In the following explanations with respect to the fourth embodiment, parts identical to those which were explained by referring to FIGS. 1 to 3 are given identical or corresponding reference numerals, and explanations thereof are simplified or omitted.
[0120] As shown in FIG. 4, the load test system 40 in the present embodiment basically employs the structure shown in FIG. 1 and further employs a pseudo network 303 inserted between the clients 202 and the video data distributing server 201 . The present embodiment is provided for evaluating a video frame loss rate based on the packet loss rate.
[0121] Under the control of the manager 203 , the pseudo network 303 inserted between the clients 202 and the video data distributing server 201 can define any packet loss rate for video data which pass through the pseudo network 303 . Such a pseudo network 303 may be called a network simulator.
[0122] The operation of the fourth embodiment will be explained below.
[0123] First, the packet loss rate of video data which pass through the pseudo network 303 is set to a specific value, and video data distribution is performed from the video data distributing server 201 to the clients 202 . The client quality monitor 301 calculates the video frame loss rate for the video data distribution.
[0124] Similarly, under different packet loss rates which are defined in turn, the video frame loss rates are calculated, and the manager 203 collects data of the video frame loss rates. In this process, a number of distribution request packets are generated by the pseudo access generator 101 and are sent to the video data distributing server 201 , so that a number of video data distribution processes are simultaneously started.
[0125] The packet quality monitor 12 a extracts the packet loss rate included in each response packet, and the manager 203 collects the packet loss rates with respect to the pseudo clients 11 a.
[0126] A suitable video frame loss rate for the video data distribution is predetermined.
[0127] The manager 203 uses corresponding relationships between the different packet loss rates (which are assigned to the pseudo network 303 ) and the corresponding calculated video frame loss rates, as a conversion table. The manager 203 determines, for each number of simultaneous clients, the video frame loss rate with respect to each pseudo client, based on the packet loss rate of the pseudo client by using the conversion table.
[0128] If the determined video frame loss rate is inferior to the predetermined video frame loss rate, the load performance relating to the quality of video images of the video data distributing server 201 is insufficient at the relevant number of simultaneous clients.
[0129] Fifth Embodiment
[0130] [0130]FIG. 5 is a diagram showing the structure of the load test system for the video data distributing server, as the fifth embodiment of the present invention. The structure and function of the load test system 50 in the fifth embodiment will be explained below with reference to FIG. 5.
[0131] In the following explanations with respect to the fifth embodiment, parts identical to those which were explained by referring to FIGS. 1 to 4 are given identical or corresponding reference numerals, and explanations thereof are simplified or omitted.
[0132] As shown in FIG. 5, the load test system 50 in the present embodiment suitably uses the structures explained in the first to fourth embodiments, and further employs a video frame header detecting section 207 in the packet quality monitor 12 c.
[0133] The present embodiment is provided for calculating the video frame loss rate and evaluating the load performance of the video data distributing server based on the calculated results.
[0134] In the present embodiment, the packet quality monitor 12 c captures each video data packet, to which a sequence number is added. As for the video data packets, the packet quality monitor 12 c detects the absence of any sequence number so as to calculate the packet loss rate, and extracts a video frame header by using the video frame header detecting section 207 , so as to read out the video frame number included in the header.
[0135] The packet quality monitor 12 c further detects the absence of any image frame number. The video frame header corresponding to any absent video frame number is not received by the relevant pseudo client 11 a; thus, it is determined that no video frame is reproduced in this case. Accordingly, video frame loss is measured as an estimated value.
[0136] Here, the ratio of the number of lost video frames to the increment of the video frame number for a specific period indicates the video frame loss rate. The manager 203 collects the video frame loss rates and the packet loss rates of a number of pseudo clients 11 a.
[0137] In the above embodiments, the pseudo network 303 is used only on the fourth embodiment (refer to FIG. 4). However, the other embodiments may use a similar pseudo network 303 , so as to evaluate the performance with respect to the simultaneous clients by producing pseudo-variation of the distribution bandwidth by using the pseudo network 303 . That is, as for each of the different distribution bandwidths, the load test may be performed while changing the number of simultaneous clients.
[0138] Accordingly, it is possible to detect the limit point at which either one of the video data distributing server 201 and the distribution bandwidth indicates the load limit. That is, the so-called “bottle neck” can be determined, and it is possible to target portions which should be reinforced so as to improve the performance. Therefore, efficient system investment can be performed. | A load test system for the video data distributing server, by which the quality of distribution to all clients can be monitored without decreasing the number of simultaneous accesses. The load test system, inserted between real clients and a video data distributing server, comprises pseudo clients having a pseudo access generator for reproducing distribution request packets sent to the video data distributing server; a response section for sending response packets to the video data distributing server; and a manager for controlling each process of the load test and for collecting, analyzing, and displaying data. The system also has a packet quality monitor for monitoring a state of video data transmission by capturing packets communicated between the load test system and the video data distributing server. The monitored results are sent to the manager, and the quality of video images is evaluated based on the data analyzed by the manager. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of copending International Application No. PCT/DE00/02118, filed Jun.29, 2000, which designated the United States.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The invention pertains to a device and a method for exhaust-gas aftertreatment in an internal-combustion engine. The exhaust gas aftertreatment is effected by selective catalytic reduction of nitrogen oxides from the exhaust gas from an internal-combustion engine operating with excess air by introducing a liquid reducing agent.
[0003] The nitrogen oxide emissions from an internal-combustion engine, in particular a diesel internal-combustion engine, operating with excess air can be lowered with the aid of the selective catalytic reduction (SCR) technique, in order to form atmospheric nitrogen (N 2 ) and water vapor (H 2 O). The reducing agent that is used for the purpose is either gaseous ammonia (NH 3 ), ammonia in aqueous solution, or urea in aqueous solution. The urea serves as an ammonia carrier and is injected into the exhaust system with the aid of a metering system, upstream of a hydrolysis catalytic converter, where it is converted into ammonia by means of hydrolysis, and the ammonia in turn reduces the nitrogen oxides in the actual SCR or deNOx catalytic converter.
[0004] The important components of a metering system of this type are a reducing-agent vessel, a pump, a pressure regulator, a pressure sensor, and a metering valve. The pump delivers the reducing agent, which is stored in the reducing-agent vessel, to the metering valve, by means of which the reducing agent is injected into the exhaust-gas flow upstream of the hydrolysis catalytic converter. The metering valve is actuated by means of signals from a control device, in such a manner that a specific, currently required quantity of reducing agent is supplied as a function of operating parameters of the internal-combustion engine (see, German patent DE 197 43 337 C1).
[0005] It is an advantage of the ammonia-releasing substances which are present in aqueous solutions, such as for example urea, that storage, handling, delivery and metering are relatively simple in technical terms. A drawback of these aqueous solutions is that, depending on the concentration of the dissolved substance, there is a risk of freezing at certain temperatures.
[0006] 32% strength urea solution, as is typically used as reducing agent in SCR systems, has a freezing point of −110° C. Therefore, devices for heating the metering system have to be provided in order to ensure that all the components of the system are able to function within an acceptable time after the system has been started at ambient temperatures of below —11° C. and to prevent system components from freezing during operation.
[0007] One of the main components is the urea pressure sensor. Since this pressure sensor continuously monitors the urea pressure system, and in particular the pressure sensor can be used to detect freezing of the reducing-agent pump, of the connecting hoses or of the metering valve, this pressure sensor has to be reliably thawed and kept frost-free. The pressure sensor element is expediently fitted spatially in the vicinity of the control electronics for the metering system and in the vicinity of the pump outlet. Nevertheless, it is difficult if not impossible to thaw the pressure sensor only by means of the heating of reducing-agent line, reducing-agent pump and the inherent heating of the control electronics.
[0008] U.S. Pat. No. 5,884,475 (German published patent application DE 44 32 577 A1) discloses a device for avoiding frost damage to parts of an exhaust-gas cleaning installation which operates on the principle of selective catalytic reduction during stationary periods and for allowing such installations to operate below the freezing point of the reducing-agent solution used. For this purpose, the device has a thermally insulated reservoir for the reducing-agent solution and a feedline which is connected thereto and ends in an outlet opening for the liquid, a nonreturn valve, which can be acted on by a pressurized gas, being provided in the feed line. The reservoir and the feed line can be heated by means of an electrical heater which supplies a heat exchanger with heat.
[0009] Japanese patent application JP 61073382 describes a method for temperature compensation in a semiconductor pressure sensor, to the diaphragm surface of which a plurality of resistors are applied, which are used for pressure measurement. To eliminate changes in the ambient temperature from the pressure measurement, compensation resistors are provided. These heater elements are used for temperature compensation in the event of a change in ambient temperature and not to heat the pressure-sensor diaphragm. Therefore, these heater elements are applied outside the sensor diaphragm.
SUMMARY OF THE INVENTION
[0010] It is accordingly an object of the invention to provide a device and a method, which overcomes the above-mentioned disadvantages of the heretofore-known devices and methods of this general type and which avoids frost damage to components of an exhaust-gas aftertreatment installation, both during stationary periods and when an installation of this type is operating at temperatures below the freezing point, of the reducing-agent solution used.
[0011] With the foregoing and other objects in view there is provided, in accordance with the invention, a device for exhaust gas aftertreatment by selective catalytic reduction of nitrogen oxides in the exhaust gas of an internal-combustion engine operating with excess air, comprising:
[0012] a reduction catalytic converter for cleaning the exhaust gas;
[0013] a reducing agent vessel for storing a reducing agent to be injected into the exhaust gas, and a reducing agent pump communicating with the reducing agent vessel for delivering the reducing agent;
[0014] a metering valve communicating with the reducing-agent pump for introducing the reducing agent into the exhaust gas upstream of the reduction catalytic converter in a flow direction of the exhaust gas;
[0015] a metering control unit for controlling an introduction of the reducing agent according to demand; and
[0016] an electrically heatable pressure sensor for recording a pressure of the reducing agent connected to the metering control unit, the pressure sensor having a pressure-sensor diaphragm and electrical heating resistors for heating the pressure sensor disposed on the pressure sensor membrane.
[0017] In accordance with an added feature of the invention, there are provided electrical resistors for recording a temperature of the reducing agent disposed on the pressure sensor diaphragm of the pressure sensor.
[0018] In a preferred embodiment of the invention, the sensor membrane is formed of Al 2 O 3 (alumina).
[0019] In accordance with an additional feature of the invention, the pressure sensor is arranged in a feed line connecting the reducing agent pump to the metering valve.
[0020] In accordance with another feature of the invention, the pressure sensor and the reducing-agent pump are combined to form a structural unit within a common housing.
[0021] With the above and other objects in view there is also provided, in accordance with the invention, a method for exhaust-gas aftertreatment by selective catalytic reduction of nitrogen oxides in the exhaust gas of an internal-combustion engine operating with excess air, the method which comprises:
[0022] delivering a liquid reducing agent from a reducing-agent vessel with a reducing-agent pump and, under certain operating states of the internal-combustion engine, metering the reducing agent into the exhaust gas upstream of a reduction catalytic converter with a metering valve;
[0023] recording a pressure of the reducing agent with a pressure sensor having a pressure-sensor diaphragm; and
[0024] upon determining that a temperature of the pressure sensor lies close to or below a freezing point of the reducing agent, heating the pressure sensor with electrical heating resistors disposed on the pressure-sensor diaphragm of the pressure sensor.
[0025] In accordance with a further feature of the invention, the temperature of the pressure sensor is recorded with the electrical heating resistors on the pressure-sensor diaphragm. Alternatively, or in addition, the temperature of the pressure sensor is recorded with additional electrical resistors on the pressure-sensor diaphragm.
[0026] The idea on which the invention is based is that of using the pressure-sensor diaphragm as a support for heating resistors and for temperature measurement. The technology for production of the sensor resistor network is used to additionally apply heating and temperature-measuring resistors.
[0027] The use of the sensor-diaphragm surface for electrical heating of the aqueous urea solution avoids taking up additional space, sealing points and plugs for electrical power supply or control.
[0028] The electrical heating resistors enable the sensor diaphragm to be heated directly and therefore enable the availability of the pressure sensor to be ensured as quickly as possible and the pressure of the urea system to be monitored even during the thawing phase.
[0029] The additional costs for making the pressure sensor heatable are relatively low, since at most it is necessary to print an additional layer of resistors, and only one additional electrical connection on the sensor element is required.
[0030] Since the pressure sensor is in any case electrically connected to the control unit, there are only slight costs for electrical connection of the heating.
[0031] If the heating resistors are printed with a thick-film paste with a suitable temperature coefficient, they simultaneously serve as a temperature sensor. Since the pressure sensor is in any case, on account of the temperature compensation, calibrated by laser trimming under controlled temperatures, balancing the temperature sensor entails only insignificant additional costs. On the other hand, if the temperature profile of the pressure sensor is known through measuring of the sensor temperature, it is possible to dispense with temperature compensation, which considerably reduces the overall costs of the sensor. It is also possible for a separate temperature-measuring resistor to be applied for measuring the temperature, which results in higher accuracy of the temperature measurement, since the resistance can be optimized for this application.
[0032] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0033] Although the invention is illustrated and described herein as embodied in a device and method for exhaust-gas aftertreatment in an internal-combustion engine, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0034] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] [0035]FIG. 1 is a block diagram illustrating an internal-combustion engine with an associated exhaust-gas aftertreatment installation wherein the pressure sensor according to the invention is used;
[0036] [0036]FIG. 2A is a diagrammatic plan view of a pressure-sensor diaphragm;
[0037] [0037]FIG. 2B is a diagrammatic sectional view of the pressure-sensor diaphragm; and
[0038] [0038]FIG. 3 is a sectional view taken through part of a pump module housing with integrated pressure sensor.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown, in the form of a highly simplified circuit diagram, an internal-combustion engine which is operated with excess air and which has an associated exhaust-gas aftertreatment installation.
[0040] Only those parts that are required in order to gain an understanding of the invention are illustrated in the figure. In particular, the fuel circuit is not illustrated. In this exemplary embodiment, a diesel internal-combustion engine is shown as the internal-combustion engine, and aqueous urea solution is used as reducing agent for aftertreatment of the exhaust gas.
[0041] The air required for combustion is fed to the internal-combustion engine 1 via an intake line 2 . An injection assembly, which may be designed, for example, as a high-pressure storage injection assembly (i.e., common rail) with injection valves, which inject fuel KST directly into the cylinders of the internal-combustion engine 1 , is denoted by reference numeral 3 . The exhaust gas from the internal-combustion engine 1 flows via an exhaust pipe 4 to an exhaust-gas aftertreatment installation 5 and, from there it is exhausted, via a non-illustrated muffler, into the open air.
[0042] To control the internal-combustion engine 1 , an engine control unit 6 , which is known per se, is connected to the internal-combustion engine 1 via a data and control line 7 , which is only diagrammatically illustrated in the drawing. Signals from sensors (e.g. temperature sensors for intake air, charge air, coolant, load sensor, speed sensor) and signals for actuators (e.g. injection valves, control elements) are transmitted between the internal-combustion engine 1 and the engine control unit 6 via the data and control line 7 .
[0043] The exhaust-gas aftertreatment installation 5 has a reduction catalytic converter 8 , which includes a plurality of catalytic converter units that are connected in series and are not denoted in any further detail. In addition, there may be in each case an oxidation catalytic converter arranged downstream and/or upstream of the reduction catalytic converter 8 . Furthermore, there is a metering control unit 9 , which is assigned to a reducing-agent reservoir or storage vessel 10 with an electrically actuable reducing-agent pump 11 for delivering the reducing agent.
[0044] The reducing agent used in this exemplary embodiment is aqueous urea solution which is stored in the reducing-agent storage vessel 10 . The vessel has an electrical heater device 12 and sensors 13 , 14 which record the temperature of the urea solution and the filling level in the reducing-agent storage vessel 10 . Moreover, the signals from a temperature sensor, which is arranged upstream of the reduction catalytic converter 8 , and from an exhaust-gas measurement pick-up, e.g. an NOx sensor, which is arranged downstream of the reduction catalytic converter 8 , are transmitted to the metering control unit 9 .
[0045] The metering control unit 9 controls an electromagnetic metering valve 15 to which, if necessary, urea solution is fed, via a feed line 16 , from the reducing-agent storage vessel 10 with the aid of the reducing-agent pump 11 . A pressure sensor 18 , which records the pressure in the metering system and emits a corresponding signal to the metering control unit 9 , is fitted into the feed line 16 . The injection of the urea solution by means of the metering valve 15 takes place into the exhaust pipe 4 upstream of the reduction catalytic converter 8 .
[0046] When the internal-combustion engine 1 is operating, the exhaust gas flows through the exhaust pipe 4 in the direction indicated by the arrow.
[0047] The metering control unit 9 is connected to the engine control unit 6 for reciprocal data transfer via an electrical bus system 17 . The operating parameters which are relevant for calculation of the quantity of urea solution that is to be metered, such as for example engine speed, air mass flow, fuel mass flow, control travel of an injection pump, exhaust-gas mass flow, operating temperature, charge-air temperature, start of injection, etc., are transmitted to the metering control unit 9 via the bus system 17 .
[0048] Working on the basis of these parameters and the measured values for the exhaust-gas temperature and the NOx content, the metering control unit 9 calculates the quantity of urea solution that is to be injected and transmits a corresponding electrical signal to the metering valve 15 via an electrical connecting line 23 . The urea is hydrolyzed and mixed as a result of being injected into the exhaust pipe 4 . The catalytic reduction of the NOx in the exhaust gas to form N 2 and H 2 O takes place in the catalytic converter units.
[0049] The metering valve 15 for introducing the urea solution into the exhaust pipe 4 substantially corresponds to a standard low-pressure fuel injection valve which, for example, is secured releasably in a valve-holding device that is fixedly connected to a wall of the exhaust pipe 4 .
[0050] [0050]FIG. 2A shows a typical ceramic pressure-sensor diaphragm 181 , which is circular in cross section, belonging to the pressure sensor 18 , from the side which is remote from the pressurized medium (i.e., reducing agent). FIG. 2B shows this ceramic pressure-sensor diaphragm 181 in section. For reasons of chemical stability, sensor elements made from Al 2 O 3 ceramic are particularly suitable for pressure measurements carried out in aqueous urea solution. These sensor elements comprise a ceramic shaped part with integrated sensor diaphragm 181 . A resistor network 182 is applied to the sensor membrane 181 using thick-film technology. The network includes the sensor and calibration resistors. The measurement principle is based on the effect of the change in resistance when the sensor membrane is mechanically stressed (piezoresistivity). To compensate for temperature dependencies, additional temperature-dependent resistors may be provided.
[0051] Additional electrical resistors 183 are added for the purpose of heating the sensor diaphragm 181 . The same technique is used to apply the additional electrical resistors 183 . Sufficient free areas are available on the sensor diaphragm 181 for these electrical heating resistors 183 to be applied with a suitable geometry and output. In the case of applications with little demand for heating power (less than 1 watt), direct heating is also possible, by applying the on-board voltage (approx. 14 volts) instead of the reference voltage of usually 5 volts directly to the sensor resistor.
[0052] The sensor diaphragm 181 offers ideal conditions for this type of electrical heating, since Al 2 O 3 ceramic has a high thermal conductivity and, moreover, the sensor diaphragm 181 is in principle very thin. The sensor diaphragm 181 therefore represents the optimum electrical insulation of the electrical heating from the heated aqueous urea solution.
[0053] The electrical heating resistors 183 and the sensor resistor network 182 are connected via connection pins and connection lines 184 to evaluation electronics or a heating actuation means, which is preferably integrated in the metering control unit 9 . The sensor element can also be connected to the metering control unit 9 by means of bonding wires or by direct soldering.
[0054] [0054]FIG. 3 shows a section through a part of the pump module housing 19 with integrated pressure sensor 18 . The pressure sensor 18 is in this case sealed in the housing 19 by means of an O-ring seal 20 . Reducing agent passes from the reducing-agent pump 11 , via the inlet 21 , to the pressure-sensor diaphragm 181 of the pressure sensor 18 . The metering valve 15 is supplied with reducing agent via a hose connection 22 . The flow of the reducing agent is indicated by an arrow.
[0055] When the internal-combustion engine is started up, the metering control unit 9 checks that each individual component of the reducing-agent metering system is ready for use. To this end, the temperature is measured at the pressure sensor 18 . If the temperature of the pressure-sensor diaphragm 181 is sufficiently low for it to be likely that the pressure sensor will have frozen, the sensor heating is activated, i.e. a voltage is applied to the electrical heating resistors 183 .
[0056] Because of high temperature gradients in the pressure-sensor diaphragm during a heating phase, with conventional pressure sensors it is impossible to measure either the pressure or the temperature during this phase. After a fixed time, the heating is switched off and the temperature is measured again. From the change in temperature, it is then possible to unambiguously determine whether reducing agent has been in the frozen state or may even still be partially frozen. In the latter case, after a short waiting time, precisely the melting point of the reducing agent is established at the pressure sensor. This state can be used in order to calibrate the sensor very accurately to the melting point, in a self-teaching function, by storing a correction value in a nonvolatile memory of the metering control unit 9 . The heating operation is repeated until the volume of reducing agent in the pressure sensor has completely thawed. If the temperature measurement can be carried out continuously during the heating phase, it is also possible, by evaluating the temperature change per unit time, for both the melting point and the time of complete thawing of the volume of the reducing agent in the sensor to be determined.
[0057] If the temperature of the sensor diaphragm is definitely above the freezing point of the reducing agent, the pressure signal is checked for plausibility and the system is started up without sensor heating. The readiness of these components for operation at low temperatures can be monitored by evaluating the reaction of the pressure signal to pump and metering valve actuation.
[0058] Since the piezoresistive pressure sensor does not allow correct pressure measurement during and immediately after the heating phase, on account of excessively high temperature gradients, the sensor heating is only activated for the thawing phase. To prevent the sensor from freezing at low temperatures while the reducing-agent metering system is operating, the pressure sensor is constructed with sufficient thermal insulation and is kept above the freezing point of the reducing agent used by waste heat from reducing-agent pump, power electronics and any heating of the feed lines (e.g. hose heating).
[0059] In the exemplary embodiment described in accordance with FIG. 3, the reducing-agent pump 11 and the pressure sensor 18 form a common assembly, in order to reduce the costs for housing parts and lines and also to lower installation outlay. However, it is also possible for the reducing-agent pump 11 and the pressure sensor 18 to be designed as separate functional units.
[0060] It will be understood by those of skill in the pertinent art that it is also possible for the functions of the metering control unit 9 for the reducing-agent metering system to be integrated in the engine control unit 6 of the internal-combustion engine. | In order to prevent that a liquid reducing agent in a selective catalytic reduction system freezes, there are provided additional resistor heating elements on the pressure sensor diaphragm of the pressure sensor that is present in the reducing agent feed system. The same technique is applied in the production of the heating sensors as in the production of the sensor resistance network. The use of the sensor diaphragm surface for the electrical heating of the liquid reducing agent (e.g., aqueous urea solution) eliminates the need for additional installation space, sealed areas, and connectors for the electrical supply and triggering mechanism. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to jewelry storage devices and, more particularly, to jewelry boxes with sliding drawers.
Women in our society often possess a large quantity of jewelry such as rings, bracelets, earrings, necklaces, etc.. These items are usually kept in a dresser drawer or in a jewelry box that has one or two trays suspended above a bottom storage area.
When a piece of jewelry is required, a woman often has to sift through other jewelry to find the sought after piece. Or, in the case of a necklace, the necklace becomes intertwined with other pieces of jewelry and a time consuming separating process becomes necessary.
Relevant prior art to this type of jewelry box is shown in Pat. No. 4,058,356 to Michal and Pat. Des. No. 214,408 to Pintea.
Michal shows a jewelry box in which small pieces of jewelry such as rings, watches and bracelets may be hung from hooks. Longer pieces such as necklaces or chains may be hung from nail-like fingers that extend from a central rotatable tube. This box also acts as a coin bank with the central tube connecting a top slot to a storage area in the base. A pair of doors can be swung to a closed position to conceal the interior of the box. This prior art device lacks horizontal drawers for flat storage of jewelry. In this device, the hanging jewelry is located within the box at all times, thereby limiting the visibility of these pieces.
The Pintea jewelry box contains a plurality of horizontal drawers and an additional center storage area with swinging doors that includes movable jewelry trays. ? n this device, jewelry located on the back portion of the lead tray and on the following trays would be hard to see, since the doors and lead tray restrict the user's visibility.
SUMMARY OF THE INVENTION
The instant invention provides a unique storage unit for jewelry in which the different pieces of jewelry can be easily viewed. The invention also utilizes a unique storage system that eliminates tangling of the pieces of jewelry. It comprises a main box which contains a series of horizontal drawers in the center and a number of vertically oriented drawers on each side of the horizontal drawers.
The horizontal drawers provide flat storage for rings, barrettes, earrings, etc..
The vertically oriented drawers provide storage for long pieces of jewelry such as chains, necklaces or the like. This is accomplished by hanging these pieces from removable hooks. These drawers include a pulley and band system which allows rotation of the jewelry from the rear to the front of the drawer and from one side of the drawer to the other. The drawers, when fully withdrawn from the box, can be pivoted about a vertical axis to allow full and easy viewing of each side of the drawer.
The box also includes swinging doors which, when closed, conceal the vertically oriented drawers.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings accompanying and forming part of this application, and wherein like reference characters indicate like parts:
FIG. 1 is a perspective view of the jewelry box showing one of the swinging doors open and one of the vertically oriented drawers partially withdrawn.
FIG. 2 is a detailed elevation view of a rear portion of one of the vertically oriented drawers.
FIG. 3 is an elevation view showing a fixed divider mounted on the band, a divider hanging from a hook and the top of a necklace hanging from a hook.
FIG. 4 is an elevation view showing the hook mounted on the band.
FIG. 5 is a cross-sectional view of the band.
FIG. 6 is a perspective view of a vertically oriented drawer showing a guide for a chain.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, 1 indicates generally a jewelry box of the instant invention. The box is made up of an outer box structure 2, which slidably receives a plurality of horizontally oriented drawers 3. Swinging doors 4 and 5 are pivotally attached at 6 to the box and rotatably cover a plurality of vertically oriented sliding drawers 7. The drawers have notches 8, which facilitate a user's grasping of the drawer. The swinging doors each have a knob 9 which acts as a handle.
FIG. 1 also shows one of the vertically oriented drawers partially withdrawn. The drawer includes a top portion 10, middle portion 11 and bottom portion 12. The middle portion extends most of the drawer length, leaving a space to allow jewelry to travel from one side to the other, as will be subsequently described. As seen in the figure, the top portion includes a vertically disposed guide tab 13 which fits into a groove in the underside surface of the top of the box. The tab fitting within the groove maintains the drawer in a vertical orientation and, when the drawer is being withdrawn from the box, aligns and guides the drawer as it moves.
The figure also shows the band and pulley system for supporting long pieces of jewelry. A pair of pulleys 14 and 15 are rotatably mounted on the inner and outer ends of the drawer top and receive on their perimeter a band 16. Hooks 17 are removably attached to the band at mounts 18. For clarity, FIG. 1 only shows hooks on one side of the band. Preferentially, hooks would be evenly spaced on the entire band exterior. A chain may be used in place of the band.
The band may be moved by rotating one of the pulleys by hand. FIG. 1 shows a method for accomplishing this by the use of a knob 38 mounted to the forward pulley. The band may also be moved by other well known methods such as by an electrical motor (not shown) or by a wind-up mechanism (not shown).
The band is continuous and continued rotation of either pulley would cause a piece of jewelry hanging from one of the hooks to travel along both sides of the drawer and then back to its starting position.
The bottom portion of the drawer can be seen in FIGS. 1 and 2. The bottom portion comprises a catch tray 50 covered with a soft material 19. The top central portion of the catch tray connects to the drawer middle portion by a raised receiving portion 20. The bottom of the catch tray includes lower guide means 21 which fits into a complementary groove in the bottom of the box. The catch tray is used to catch any jewelry which falls from the hooks and also to support the lower portion of any jewelry which extends down to the tray.
FIG. 3 shows the band of the band and pulley system with optional dividers and the top portion of a necklace 60 hanging from a hook. The dividers comprise a rectangular sheet of plastic which is long enough to reach from the band to proximate the top of the catch tray. The divider 22 is fixedly mounted to the band by conventional means. A similar divider 40 is shown hanging from one of the hooks. A similar divider (not shown) can also be attached in place of one of the hooks. The dividers separate the jewelry and provide a convenient means to separate the jewelry by color or by type.
FIG. 2 also shows a rear portion of the guide used on the vertically oriented drawers. The drawer has a rear connector portion 51 that extends from the top of the drawer to the drawer bottom. The connector has top 23 and bottom 24. Vertically extending from the top and bottom are pivot pins 25. A U-shaped retaining member 26 is attached to the rear of the drawer by upper and lower channels 27 which receive the pivot pins 25. The top portion of the retaining member includes a tab 52 which contacts a stop 28 to prevent the drawer from becoming disengaged from the box. Upper and lower slots 29 and 30 are shown in the box inner surfaces for receiving the drawer guide tabs and the U-shaped retaining member.
In the instant invention, since a flexible band or chain is used, the mounting method shown in FIG. 5 is particularly advantageous. A rivet 31 passes through the band 16 and lockably engages a lug 32. As can be seen in FIG. 4, the top portion of each hook has an upside down key hole shaped channel 33. The large portion 34 of the hook channel is placed over the lug and then the hook is slid downwards and the small portion 35 of the hook channel securely engage the lug. The hook is prevented from falling off the lug by a lug flange portion 36. An alternative embodiment would have the channel in the band and the lug on the hook.
FIG. 5 also shows the centerline of a hook that is mounted on the band. The hook is designed and mounted so that the hook's vertical centerline 39 is in line with the belt. This minimizes twisting of the belt when the hook is loaded.
FIG. 6 shows an alternative embodiment in which a guide track 37 is mounted on the top of the drawer in the same plane as the pulleys 14 and 15. Each side of the guide track is "L" shaped in cross-section and the track is especially useful when the band 16 is replaced by a chain 45.
In use, when a necklace is required, the user would open one or both of the swinging doors to expose the vertically oriented drawers.
Then, the drawer could be partially withdrawn. If the needed jewelry was not in view, the knob would be rotated and the entire band of jewelry would rotate and any piece of hanging jewelry would soon be brought into view.
Alternatively, the drawer could be withdrawn from the box until the U-shaped member hits the stop. The entire drawer could then be pivoted from side to side so that the user would have full access to both sides of the drawer. The pivotal movement is enabled by the pivot pins 25 rotating within channels 27.
Another advantage of the instant invention results from the pivoting action of the drawers in combination with the belt and pulley system. When choosing a piece of jewelry, a woman will often place similar pieces of jewelry together by type, color or type of material so that she can compare them and then pick out the best piece for her outfit. The invention allows the jewelry to be hung in any manner seen fit by the user. Therefore, for example, a woman can hang all of her jewelry one adjacent the other in an order based on the jewelry color. When it was time for the woman to pick out a piece of jewelry, she could withdraw a particular vertically oriented drawer and pivot it to one side. At this point, she can easily view all the jewelry hung on one side of the drawer. She can then rotate knob 38 until all the jewelry of a particular range of colors was displayed on one side. She could then easily choose piece of jewelry of the right color to best match her outfit.
The embodiment and procedures disclosed herein have been discussed for the purpose of familiarizing the reader with the novel aspects of the invention. Although a preferred embodiment of the invention has been shown and described, many changes, modifications and substitutions may be made by one having ordinary skill in the art without necessarily departing from the spirit and scope of the invention. | A jewelry box is provided which is designed to store jewelry in an easily accessible manner. Horizontally oriented drawers are used for flat storage of smaller items and vertically oriented drawers are provided for hanging of longer pieces. The vertically oriented drawers include a belt and pulley system for movably mounting the hooks on which jewelry is hung. The vertically oriented drawers when fully withdrawn may be rotated to allow full viewing of each side. | 0 |
This application claims priority to Provisional Application No. 60/390,677 filed Jun. 21, 2002.
“This invention was made with government support under grant number 1 R43 CA83568-01 awarded by the National Institutes of Health (NIH). The government has certain rights in this invention.”
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to radionuclide generators, ion exchange materials for radionuclide generators and methods of making these materials.
2. Description of the Related Art
The use of alpha-emitting radionuclides in the treatment of specific forms of cancers has become increasingly of interest in recent years. Alpha particles are far more effective in the destruction of cancer cells than gamma or beta particles due to their greater linear energy transfer (LET) rates. Bismuth-213 ( 213 Bi) has been identified as an important radioisotope for use in this new field of radiomedicine.
In order for an isotope to be used in medical applications, the isotope should be of high purity to avoid introduction of undesirable radioactive isotopes into the body that would deliver an unnecessary dose to sensitive areas of the body such as the bone marrow. 213 Bi is produced as a daughter product in the decay of 229 Th, which is itself a daughter product of the decay of 233 U. 213 Bi has a short half-life of only about 45 minutes, which means that it rapidly decays away once introduced into the body. This also means that the isotope should be supplied in the form of a generator in which a suitable parent isotope is immobilized on an ion exchange material so that the 213 Bi can be eluted when required. 225 Ac is a parent isotope of choice that can be immobilized and shipped to medical facilities. The 229 Th decay series that includes 213 Bi is shown in FIG. 1 .
Alpha particles are extremely destructive towards conventional organic ion exchange resins, which leads to limited generator life, bleed of undesirable 225 Ac into the 213 Bi product and the possible release of pyrogens into the aqueous phase during 213 Bi elution.
Therefore, there is a need for a radionuclide generator, such as a 213 Bi generator, that has improved stability against alpha particles and other forms of ionizing radiation. It would be desirable if the generator provided high separation and high stability in order to yield a solution with substantially no parent isotope and no by products of generator decomposition.
SUMMARY OF THE INVENTION
The present invention provides a radionuclide generator comprising an organic zirconium phosphate or phosphonate composition. This composition is preferably prepared by reacting a source of zirconium with a mixture of phosphoric acid and a substituted phosphoric or phosphonic acid. Before use, cations of one or more radioisotopes are immobilized on the composition. The source of zirconium may be soluble and may be ZrOCl 2 .
A preferred embodiment provides a bismuth-213 generator comprising an insoluble composition having the general formula Zr(Phosponate) x (HPO 4 ) 2−x .nH 2 O, wherein x is between 0 and 2; and n is the number of waters of hydration, preferably between 0.5 and 2.5; and wherein cations of radioactive isotopes selected from radium, actinium and combinations thereof are immobilized on the composition. A preferred phosphonate is n-phosphonomethyl-miniodiacetic acid (PMIDA), wherein x is preferably between about 0.1 and about 1.9. The phosphonate may also be one or more phosphonate having the formula: H 2 O 3 P—(CH 2 ) a —N—((CH 2 ) b CO 2 H)—((CH 2 ) c CO 2 H), wherein a, b, and c are numbers from 1 to 3 that may or may not be equal. The value of x is preferably between about 0.1 and about 1.9. Optionally, the bismuth-213 generator comprises an elutable container defining an eluant flow path, the container containing a matrix comprising a substantially non-elutable inorganic layered zirconium phosphate and/or zirconium phosphonate compound containing actinium-225. The preferred ratios of phosphate to phosphonate are between about 0.1 and about 10. In one embodiment, the phosphonate is n-phosphonomethyl-miniodiacetic acid (PMIDA). In another embodiment, the phosphonate includes one or more phosphonate having the formula H 2 O 3 P—(CH 2 ) a —N—((CH 2 ) b CO 2 H)—((CH 2 ) c CO 2 H), wherein: a, b, and c are numbers from 1 to 3 that may or may not be equal. The bismuth-213 is produced by the decay of the actinium-225.
A further embodiment provides a radionuclide generator for producing bismuth-213 comprising an insoluble inorganic layered phosphate or phosphonate matrix including a compound containing actinium-225, the matrix being permeable to fluid passage and permitting diffusion of bismuth-213 through the matrix. The matrix is preferably prepared by reacting a mixture of phosphoric acid and a substituted phosphoric or phosphonic acid with a source of zirconium. Optionally, the source of zirconium is soluble. Furthermore, the source of zirconium is optionally ZrOCl2.
Yet another embodiment provides a method comprising immobilizing cations of radioactive isotopes selected from radium-225, actinium-225 and combinations thereof onto an insoluble zirconium phosphate/phosphonate cation exchange composition; and eluting bismuth-213 from the insoluble composition with an aqueous solution. Optionally, the aqueous solution may comprise a complexing agent, such as ethylenediaminetriacetic acid. Alternatively, the complexing agent may be selected from ethylenediaminetriacetic acid, nitrilotriacetic acid, citric acid, hydroxyethyl ethylenediaminetriacetic acid, and combinations thereof.
Preferably, the generator composition or matrix is characterized by an actinium/bismuth separation factor greater than 100. The composition or matrix is characterized by an actinium/bismuth separation factor greater than 1,000; greater than 2,000; or greater than 3,000. The bismuth-213 is produced from the decay of actinium-225. Optionally, the aqueous solution used to elute bismuth-213 may have a neutral pH. Further, the aqueous solution may, if desired, comprise a salt of a weak acid.
The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a chart showing the decay series that includes Bi-213.
FIG. 2 shows the chemical structure of N-Phosphonomethyliminodiacetic Acid.
FIG. 3 illustrates the structure of the Zirconium Phosphate/BPBPA Derivative Zr[(BPBPA)HPO 4 ].nH 2 O.
FIG. 4 is a chart showing the Lanthanum Absorption Kinetics.
DETAILED DESCRIPTION
This invention relates to the synthesis of novel zirconium phosphates and phosphonate materials that can be utilized for the production of pure 213 Bi from the decay of 225 Ac. These materials exhibit high selectivities towards mildly acidic solutions of lanthanum (a surrogate for Actinium) while exhibiting low selectivity towards bismuth ions under similar conditions. Consequently, lanthanum (and thus actinium) can be loaded onto the material and the decay product, 213 Bi, eluted as required.
The materials described in this disclosure are organic derivatives of zirconium phosphate, Zr(HPO 4 ) 2 .H 2 O. Details of the preferred syntheses of some of these materials are given below. However, in general terms, the materials are manufactured by mixing a soluble source of zirconium (e.g. ZrOCl 2 ) with a mixture of phosphoric acid and a substituted phosphonic or phosphoric acid. The mixture is then heated, refluxed or hydrothermally treated for a period of time ranging from a few minutes to a week or more. Preferably the white solid product is then filtered, washed and dried. Optionally, HF may also be used in the synthesis to improve the crystallinity of the product.
EXAMPLE 1
Synthesis of Zr (HPO 4 ) x PMIDA (2−x) .nH 2 O
Zirconium PMIDA derivatives have been shown to have a high affinity for polyvalent cations such as lanthanum, La 3+ , from weakly acidic media. Lanthanum ions will interact with the two carboxylic acid groups and may also interact with the lone pair of electrons associated with the nitrogen atom. The structure of PMIDA, N-Phosphonomethyliminodiacetic Acid, is shown in FIG. 2 .
A series of zirconium PMIDA/phosphate materials with the general formula Zr[(PMIDA) x (HPO 4 ) 2−x ].nH 2 O were synthesized where x varied from 0.2 to 1. A typical synthesis is described as follows. 1.33 g of PMIDA (10 mmol) and 0.48 mL of concentrated phosphoric acid (10 mmol) were dissolved in 10 mL of deionized water and 3.22 g of zirconyl chloride octahydrate (10 mmol) dissolved in 10 mL of deionized water was added drop wise with constant stirring. The resultant gel was then placed in a hydrothermal bomb with 2 mL of 48% HF and heated at 120° C. for 48 hours. The white product was then filtered, washed with water to remove residual HF and dried at 50° C.
EXAMPLE 2
Zirconium 4,4′-Phenyldiphosphonic Acid (PDPA) Derivatives
Zirconium PDPA derivatives were prepared in a similar manner to the PMIDA derivatives described in Example 1 to produce a series of materials with the general formula Zr[(PDPA) x (HPO 4 ) 2−2x ].nH 2 O, where x was varied from 0.1 to 0.5. These materials consisted of a layered structure permanently bridged by a phenyl group with HPO 4 groups attached to each layer. The structure is similar to the BPBPA derivative shown in FIG. 3 , except that the layers are separated by one phenyl group instead of two, thus limiting the access to the exchange sites on the phosphate groups to smaller ions. By varying the relative concentrations of phosphoric acid and PDPA in the starting mixture, it is possible to vary the density of the bridging PDPA moiety and thus vary the pore size and ion exchange properties of the final material. Since the PDPA is an inert bridging functionality, the ion exchange capacity of the material will be dependent upon the number of HPO 4 groups present. Consequently, as the percentage PDPA increases, the ion exchange capacity will decrease and will be zero for the pure Zr(PDPA) 2 material. Low ion exchange capacity is, however, not a problem due to the low masses of 225 Ac that will need to be absorbed onto the ion exchange column in the 213 Bi generator.
EXAMPLE 3
Zirconium 4,4′Biphenylbis(phosphonic) Acid (BPBPA) Derivatives
The idealized structure of the zirconium phosphate/BPBPA derivatives is shown in FIG. 3 . The BPBPA derivative serves to act as a rigid pillar, similar to the PDPA groups, separating the inorganic zirconium phosphate layers. Ion exchange reactions occur at the protons associated with the phosphate groups. As described previously for PDPA derivatives, varying the proportions of phosphoric acid and BPBPA in the reactant mixture will produce different ratios of pillars to phosphate groups in the final product leading to a range of pore sizes and ion exchange properties. The ion exchange capacity will also decrease as the BPBPA content increases. These materials were synthesized according to the procedure described in Example 2, using BPBPA in place of PDPA.
EXAMPLE 4
Other Zirconium Mixed Phosphate/Phosphonates
In addition to the materials outlined previously, a pure Zr(PMIDA) 2 .nH 2 O material and the mixed derivative Zr(PMIDA)(PDPA) were synthesized. The synthetic procedures were very similar to those described in the foregoing examples, except that the gels formed were heated at 160° C. instead of 120° C.
The ion exchange properties of synthesized materials were investigated using simple batch experiments. In order to promote safety, reduce costs, and allow a greater number of materials to be screened, the ion exchange experiments were mostly performed using inactive isotopes or appropriate surrogates. Bismuth distribution coefficients (K d s) were determined using bismuthyl perchlorate, BiOClO 4 , solutions in sodium chlorate media to ensure that no precipitation of bismuth occurred. Barium and lanthanum were used as surrogates for radium and actinium, respectively, and these experiments were performed in nitrate media. The solutions used to evaluate ion exchange selectivity were generally 0.1M in Na + in order to maintain a constant ionic strength during the experiments. The initial pH of the solutions was adjusted to approximately pH 3.5 using either dilute nitric or perchloric acid prior to contact with the ion exchangers. The concentrations of the ions in solution were analyzed using atomic absorption spectrometry (AAS).
Ion exchange material (0.05 g) was contacted with 20 mL of a 25 ppm solution of Bi, Ba or La, for 24 hours using a rotary shaker. The mixture was then filtered through a 0.2 μm syringe filter, the pH measured, and the aqueous phase analyzed by AAS. Prior to analysis, Bi samples were acidified with concentrated nitric acid to prevent any precipitation of bismuth salts on standing. Early experiments had indicated that there was limited stability of aqueous solutions of bismuthyl perchlorate. Consequently, all solutions were made up fresh immediately prior to use and blanks were run with each set of experiments to check for precipitation. K d s for bismuth, barium and lanthanum were then determined according to Equation 1:
K d =(( C i −C f )/ C f )· v/m (1)
Where: C i =initial concentration of ion in solution C f =final concentration of ion in solution v=volume of solution (ml) m=mass of exchanger (g)
A limited number of experiments were performed using radiotracers in support of work performed with inactive surrogates. This check of the K d determinations served to ensure that the results obtained using ppm levels of ions was relevant to generator conditions, where the actual concentrations of ions present in solution would be several orders of magnitude less. In the radiotracer experiments, 0.02 g of ion exchange material was equilibrated with 1 mL of a 0.1 M NaCl solution, spiked with 210 Bi (T 1/2 =5.01 days), for 3 hours. The mixture was then passed through a 0.2 μm filter and counted using liquid scintillation counting. K d s were then determined as described above.
Ion Exchange Selectivity of the PMIDA Derivatives
The ion exchange data for the zirconium phosphate/PMIDA derivatives is given in Table 1. Also included are ion exchange data for both amorphous and crystalline zirconium phosphate, Zr(HPO 4 ) 2 .H 2 O.
The PMIDA derivatives are an attractive series of materials having much lower affinities for bismuth than for lanthanum, apart from the 50% PMIDA derivative, and fairly low barium selectivity. The trend is for lanthanum K d s to increase with decreasing PMIDA content. Bi K d s also increase, but remain substantially less than the lanthanum K d . Barium K d s are generally low. The radiotracer work was in relatively good agreement with the data obtained using inactive surrogates, particularly with the lower PMIDA materials. This indicates the bismuth results using inactive bismuth salts are representative of the behavior of bismuth at radiotracer concentrations.
TABLE 1 La, Bi and Ba K d s for the Zirconium Phosphate/PMIDA Derivatives Phosphate: La/Bi Sample ID PMIDA La K d mL/g *Bi K d mL/g Ba K d mL/g Sep. Factor KS-40-1 50:50 791 821 51 0.96 KS-40-2 60:40 8,750 205 ( 1850 ) 2 43 KS-40-3 70:30 5,950 373 ( 901 ) 78 16 KS-40-4 80:20 4,900 1014 ( 1030 ) 118 4.8 KS-40-5 90:10 10,700 2940 ( 2700 ) 332 3.6 Amor. ZrP 100:0 3,400 >19,000 705 <0.18 Cryst ZrP 100:0 <1 303 5 <0.003 *Values in Italics and parenthesis determined independently at ANL using radioactive 210 Bi tracer
Ion Exchange Selectivity of the BPBPA Derivatives
The selectivity data for the zirconium phosphate/BPBPA derivatives is given in Table 2.
TABLE 2
La, Bi and K d s for the Zirconium Phosphate/BPBPA Derivatives
Phosphate:
La/Bi
Sample ID
BPBPA
La K d mL/g
Bi K d mL/g
Ba K d mL/g
Sep. Factor
KS-41-1
50:50
489
>19,900
62
<0.025
KS-41-2
60:40
916
>19,900
117
<0.046
KS-41-3
70:30
849
>19,900
86
<0.043
KS-41-4
80:20
2540
>19,900
48
<0.13
KS-41-5
90:10
>27,000
>19,900
92
1.35
The zirconium phosphate/BPBPA derivatives, other than the 10% BPBPA sample, exhibit lanthanum affinities that may be too low to warrant further study. The cross-linking BPBPA moiety consists of two aromatic rings and would be expected to be highly hydrophobic. The low lanthanum selectivities may be due to the polar, highly hydrated La 3+ ions being repelled by these hydrophobic centers. Consequently, the selectivity would be expected to increase as the percentage of the BPBPA decreases. This is seen in the analytical data with the maximum K d s being observed when the BPBPA component composed only 10%.
The bismuth affinities of all samples were very high. This may be because the bismuth species in solution is less polar with a much smaller hydration sphere and is thus able to access the available ion exchange sites. High bismuth selectivity is not too desirable because this indicates that the 213 Bi daughter would remain strongly bound to the ion exchange column. However, this affinity can be overcome by using chelating agents to form Bi complexes and reduce the affinity of the ion exchanger for bismuth.
Barium K d s are fairly low for all of these materials. This means that any 225 Ra in the 225Ac solution used to load the generator will only be weakly absorbed and thus can be readily removed by washing the column immediately after loading with 225 Ac has been completed.
Ion Exchange Selectivity of the PDPA Derivatives
The ion exchange selectivities of the zirconium phosphate/PDPA derivatives are given in Table 3.
TABLE 3
La, Bi and Ba K d s for the Zirconium Phosphate/PDPA Derivatives
Phosphate:
La/Bi
Sample ID
PDPA Ratio
La K d mL/g
Bi K d mL/g
Ba K d mL/g
Sep. Factor
KS-I-49(A)
50:50
2,850
>13,500
503
<0.22
KS-I-49(B)
60:40
11,400
>13,500
1,140
<0.84
KS-I-49(C)
70:30
2,980
>13,500
500
<0.22
KS-I-49(D)
80:20
ND
>13,500
1,270
?
ND - Not Determined
The data in Table 3 shows that the PDPA derivatives all show a high affinity for bismuth and relatively high selectivity towards lanthanum. However, the affinity for barium is high and, by analogy, the selectivity for radium would also be expected to be high. Consequently, this class of materials is less preferred than to the other materials investigated.
Other Zirconium Phosphate/Phosphonates
The ion exchange data for the pure Zr(PMIDA) 2 materials and the mixed Zr(PMIDA)(PDPA) mixed derivative are shown below in Table 4.
TABLE 4
Ion Exchange Data for the Pure Zirconium PMIDA Material and
the Mixed PMIDA/PDPA Derivative
Sample ID
Ligands
La K d mL/g
Bi K d mL/g
Ba K d mL/g
KS-I-54-1
100% PMIDA
4,610
>17,200
61
KS-I-54-3
50% PMIDA,
16,500
>17,200
78
50% PDPA
This data shows that it is still possible to obtain a high lanthanum selectivity with a pure zirconium PMIDA derivative. However, unlike the data in Table 2, the pure PMIDA material was also found to have a high selectivity for bismuth. This suggests that the selectivity for La over Bi achieved using the mixed phosphate/PMIDA derivative was dependent upon structural factors. Combining the PMIDA ligand with PDPA to produce a pillared layered material produced a higher La selectivity. However, this material also possessed a high bismuth K d . Repeat bismuth K d determinations and absorption blanks, coupled with acidic final pH values confirmed that the bismuth was removed from solution by ion exchange rather than precipitation.
Effect of pH on Lanthanum Absorption
The effect of pH on both the uptake of lanthanum (or actinium) and the elution of bismuth is an important factor. In high acid concentrations, protons will compete for the ion exchange sites on the materials and thus reduce uptake of other species and displace absorbed ions. To allow a material to be successfully used in a generator, it is therefore important to define a pH range where the generator can be loaded and eluted. The upper pH limit is defined by the precipitation of hydroxides of La, Ba and Bi which were found experimentally to occur at approximately pH 8.55, 11.58 and 6.65, respectively. The lower limit is defined by the level of acidity at which the selectivity of the material towards lanthanum (actinium) becomes too low. Experiments in acidic media showed that the lanthanum K d s decreased rapidly as the acidity of the solution was increased. At a pH<1, lanthanum K d s were negligible and, as a consequence, it is therefore desirable to load and elute a 213 Bi generator at a slightly acid pH in order to maximize lanthanum(actinium) K d s and to prevent any precipitation of bismuth, lanthanum(actinium) or barium(radium) salts.
Kinetic Studies
Ideally, the rate of absorption of ions by the ion exchange material needs to be rapid. This will allow quick, easy loading of the generator and the elution of 213 Bi in the minimum volume of liquid. Screening studies used a contact time of 24 hours, which was deemed to be sufficient for equilibrium to be obtained. Selected materials that exhibited a high selectivity for lanthanum ions were then investigated to determine the rate of reaction.
A 0.05 g quantity of KS-I-54-3 (a PMIDA/PMDP derivative) was contacted for a measured time with 20 mL of a 25 ppm solution of La 3+ in 0.1M NaNO 3 at pH 3.35. After the allotted time, the mixture was filtered and the residual lanthanum in solution measured by AAS. The final pH was also measured and found to have remained constant at pH 3.0+/−0.05. The results are shown below in FIG. 4 .
FIG. 4 indicates that the reaction rate is rapid with over 65% of the lanthanum present being absorbed within 5 minutes. Absorption of lanthanum continues to increase with time, with almost 85% of the available lanthanum ions being absorbed after 3 hours. This rapid reaction rate will ensure that the ion exchange materials can be quickly loaded with 225 Ac. In a generator situation, the uptake of 225 Ac would be expected to be considerably more rapid than lanthanum. The very low concentrations of actinium present means that diffusion through the ion exchanger will not be necessary because there are likely to be sufficient surface groups to absorb all of the actinium present in the loading solution. Thus, the uptake will not be limited by mass diffusion of the ions through the bulk of the ion exchanger.
Effect of Chelating Agents
Five common chelating agents were assessed in an attempt to improve the separation of bismuth from lanthanum using the available ion exchange materials.
These were:
1) Ethylenediaminetetraacetic acid, EDTA
2) Nitrilotriacetic Acid, NTA
3) Citric Acid
4) Iminodiacetic Acid (IDA)
5) N-(2-Hydroxyethyl)ethylenediaminetriacetic acid (HEDTA)
These complexants were then added to solutions of La 3+ and Bi 3+ and the ion exchange selectivities redetermined following the methods described previously. The stability constants for these complexants are given in Table 5. The stability constant (K stab ) is defined by Equation 2:
K stab =[MY z−x ]/[M z + ][Y x− ] (2)
where: M=metal cationz=cation charge
x=ligand chargeY=chelant
TABLE 5
Stability of Bi 3+ and La 3+ Complexes
Ligand
Log K, Bi 3+
Log K, La 3+
EDTA
27.8
15.5
Citric acid
10.78
6.65
NTA
17.5
10.47
IDA
Not Available
5.88
HEDTA
22.3
13.61
The stability data for Bi 3+ was incomplete, but it is clear that from the complexing agents for which data was available, that Bi 3+ forms complexes which are many orders of magnitude more stable than the corresponding La 3+ complexes. Thus, it is theoretically possible to use a chelating agent to selectively strip Bi from an ion exchange material and achieve the desired separation factor. This concept was then proven experimentally in the sections described below.
Stability of Bi Complexes in NaCl
The stability of Bi complexes with the ligands in Table 5 was evaluated in NaCl solutions. A 10 −3 M solution of ligand in 10 −3 , 10 −2 and 10 − M NaCl solutions (adjusted to pH 4) were spiked with a 250 ppm solution of BiOClO 4 to give a total bismuth concentration of approximately 25 ppm. The IDA solutions produced a white precipitate in 10 −2 M and 10 −1 M solutions of NaCl, suggesting the formation of insoluble BiOCl. The other solutions exhibited no evidence of precipitation but analysis of the Bi concentration in the filtered solutions by AAS suggested a small amount of Bi precipitation had occurred with the HEDTA solutions in 10 −1 M NaCl. This indicates that HEDTA and IDA formed relatively weak complexes with bismuth under the conditions studied and, consequently, EDTA, NTA and citric acid are the most preferred as potential stripping agents.
Effect of Citric Acid, EDTA and NTA on Bi and La K d s
The effect of citric acid, EDTA and NTA on La and Bi Kds was determined using a simple batch technique. Sample KS-I-49(B) was used to evaluate the effect of the complexants. 0.05 g of ion exchange material was contacted for 24 hours with 20 mL of a 25 ppm solution of either Bi or La in 0.1M NaCl, containing 0.001M solution of the complexants at a pH˜4. The mixture was shaken for 24 hours and the residual Bi and La in solution after filtration determined by AAS. Blank experiments showed no precipitation of Bi or La during the procedure. The results are shown in Table 6.
TABLE 6
Separation of La and Bi utilizing Complexants
Complexant
La K d mL/g
Bi K d mL/g
Separation Factor, α
None
11,400
>13,500*
<0.8
EDTA
3080
<1
>3,080
NTA
11,400
6
1,900
Citric Acid
14,000
3,610
3.9
*K d was determined in perchlorate media to maintain Bi solubility.
From the data in Table 6, it may be seen that the addition of NTA or EDTA greatly improved the separation of Bi and La. NTA and citric acid had a negligible affect on the La K d s, but reduced the Bi K d s to <10 mL/g. This may demonstrate how the La/Bi separation factor, α, can be improved by the addition of minor amounts of a complexant to the eluting solution. (α is the La K d divided by the Bi K d .) For medical applications, the amount of complexant required to complex the 213 Bi daughter will be negligible. Thus, the 213 Bi complex eluted from the generator can be destroyed in a matter of minutes using a safe oxidant such as ozone, UV irradiation or hydrogen peroxide, allowing rapid processing of the 213 Bi to be performed in order to synthesize the radiopharmaceutical. However, an alternative approach is to elute the bismuth using a solution of a complexant, such as derivatives of diethylenetriaminepentaacetic acid (DTPA), to produce a radiopharmaceutical (or radiopharmaceutical precursor) direct from the 213 Bi generator. This 213 Bi complex may then be rapidly processed further and attached to an antibody.
These experiments demonstrate that zirconium phosphate-based ion exchange materials may successfully separate bismuth from lanthanum and therefore can be used in a 213 Bi generator. It has also been shown that complexants may be used to enhance the La/Bi separation factors with separation factors in excess of 3,000 for La/Bi being obtained.
It will be understood from the foregoing description that various modifications and changes may be made in the preferred embodiment of the present invention without departing from its true spirit. It is intended that this description is for purposes of illustration only and should not be construed in a limiting sense. The scope of this invention should be limited only by the language of the following claims. | A bismuth-213 generator comprising an insoluble composition having the general formula Zr(Phosponate) x (HPO 4 ) 2−x .nH 2 O, wherein x is between 0 and 2; and n is the number of waters of hydration; and wherein cations of radioactive isotopes selected from radium, actinium and combinations thereof are immobilized on the composition. The value of x may be between about 0.2 and about 1. The phosphonate may be n-phosphonomethyl-miniodiacetic acid (PMIDA), wherein x may be between about 0.1 and about 1.9. The phosphonate may be one or more phosphonate having the formula:
H 2 O 3 P—(CH 2 ) a —N—((CH 2 ) b CO 2 H)—((CH 2 ) c CO 2 H),
wherein a, b, and c are numbers from 1 to 3 that may or may not be equal. The value of x may also be between about 0.1 and 1.9. | 8 |
This application is a continuation of PCT/JP2006/308778 filed on Apr. 26, 2006.
BACKGROUND OF THE INVENTION
1. Filed of the Invention
The present invention generally relates to a heating structure suitable for applying heat to a joint used for providing a connection between piping or to a joint used for providing a connection between a pipe and an associated device.
2. Description of the Related Art
In recent years, as an exhaust emission purifying apparatus for purifying nitrogen oxides (NO x ) contained in the exhaust gas of a diesel engine, there has been proposed a selective catalytic reduction (SCR) apparatus using a liquid reducing agent, such as the urea water or the like. In order to enhance the purifying efficiency of a nitrogen oxide reduction catalytic converter disposed in an exhaust passage, this apparatus adopts a configuration in which the liquid reducing agent is added into the exhaust gas during passing through a certain section of the exhaust passage that is arranged on the upstream side of the nitrogen oxide reduction catalytic converter,
In such an exhaust emission purifying apparatus using the liquid reducing agent, in the case where the urea water is used as the liquid reducing agent thereof, countermeasures against freezing of the liquid reducing agent must be made on piping through which the urea water is flown. This is because the urea water is frozen at a temperature below zero but at a relatively high predetermined temperature which might be met in rather cold weather regions.
Structures of keeping the piping warm by a heat-insulating material or heating the piping by a heater are widely adopted in fields of water supply lines, plant facilities and the like. In these known structures, a joint (including a connector and a flange) portion for connecting the pipe to the other side device or for connecting between different pipes is covered by the heat-insulating material or is wounded by a heater, separately from piping body, as disclosed in FIG. 5 and FIG. 6 of Japanese Unexamined Patent Publication No. 1992(H04)-102793.
However, the above conventional art relies on a technique on the premise of manual works, and therefore, involves an amount of efforts, and further, the stabilization of assembly quality is hard to be achieved due to individual differences in workers. Further, the entire joint portion is covered separately from the piping portion to thereby need much space, and therefore, such a conventional technology is not suitable for a pipe layout installed in an exhaust emission purifying apparatus having only a narrow disposing space.
On the other hand, in blow-by gas piping, there is also an example adopting, as a joint, a connector with a built-in heater. However, such a connector, that is, the joint with a built-in heater, is a specific component peculiarly designed for a specified engine, and accordingly, there is a problem in that the cost incurred for the molds for manufacturing the component must increase especially in the case of a small amount of production.
SUMMARY OF THE INVENTION
Therefore, in view of the above conventional problems, the present invention has an object to make a proposal of a heating component for a pipe joint which is able to be further easily attached compared with that in the conventional technique, and is further able to stabilize the assembly quality thereof.
Further, the present invention has an object to provide a heating component for a pipe joint which is able to be mounted on an existing joint afterwards and is able to reduce the cost such as the burden of the mold preparation cost and the like, so as to cancel any necessity for the peculiar design of the joint with a built-in heater as described above.
In order to achieve the above objects, a heating component for a pipe joint according to the present invention is characterized by comprising a configuration such that a heating wire is held in an inside of the heating component and also an internal shape is provided to have an inner surface capable of fitting on an outer shape of the pipe joint; the heating component being mounted on the joint due to fitting of the component from an exterior of the pipe joint; and the heating wire generating heat to be transmitted to the pipe joint upon being supplied with electric current.
The heating component for pipe joint as described above, is simply fitted with the joint from the exterior of the joint and therefore, may not need much space and is able to be very easily assembled with the joint. Further, since the heating component is able to be attached to the pipe joint only by a single predetermined working operation for fitting the heating component onto the pipe joint, differently from the conventional manual working operation, the quality of assembly can be stable irrespective of technical skills or experiences of operators. Furthermore, a specific joint with a built-in heater is not produced, but the heating component is able to be produced as a fitting unit with the existing joint. Therefore, the heating component is able to be attached to or mounted on an already assembled joint afterwards; and also, the mold preparation cost is able to be reduced significantly lower compared with the case of producing the exclusively used specific joint. The heating component for pipe joint of the present invention has the above-described advantages and therefore, is especially available as a heating component for a pipe joint applied to a pipe joining portion of a pipe layout in an exhaust emission purifying apparatus in which a nitrogen oxide reduction catalytic converter is disposed in an exhaust passage of an internal combustion engine and also a liquid reducing agent is added into a predetermined section of the exhaust passage located on the upstream side of the nitrogen oxide reduction catalytic converter.
With the above-described heating component for a pipe joint, a specific structural embodiment which is able to be easily produced may be structured such that the heating component for a pipe joint has partially thereon fitting portions each having an inner surface fit on a part of the outer shape of the joint, and also, a holding recess portion for holding therein the heating wire is formed on an inner surface portion other than the fitting portions, and the heating wire held in the holding recess portion comes in contact with the joint. To be more specific, in the heating component for a pipe joint according to the present invention, the fitting portions each having the inner surface fit on the part of the outer shape of the joint are partially formed thereon, and also, the holding recess portion holding therein the heating wire is formed on the inner surface portion other than the fitting portions; when the heating wire is held in the holding recess portion, and then, the heating component for a pipe joint is attached to the pipe joint by fitting the fitting portions to the parts of the outer shape of the joint, the heating wire held in the holding recess portion comes in contact with the joint; and as soon as the heating wire is supplied with electric current, heat generating in the heating wire is transmitted to the pipe joint.
According to the above structural embodiment, the heating wire is able to be removably accommodated in the holding recess portion afterwards, and a body portion of the heating component is able to be easily produced by the injection molding. Further, since the heating wire is in a direct contact with the joint, a heat transmission characteristic to the joint is enhanced,
In the described embodiment of the heating component for a pipe joint. It is preferable that the holding recess portion has a mounting pedestal on a bottom face thereof, and when the heating wire is held in the holding recess portion, the heating wire is mounted on the pedestal, so that the airspace is formed between the heating wire and the holding recess portion. This airspace functions as a heat-insulating layer to prevent heat dissipation to thereby enhance the thermal efficiency. Further, it is also possible to dispose a lid member for preventing the drop-off of the heating wire on a portion, in the holding recess portion which holds the heating wire, where the heating wire is not in contact with the joint. If this lid member is made of a heat-insulating material having good-heat-insulating properties, the thermal efficiency is further enhanced.
Further, in such a heating component for a pipe joint, it is preferable to form an inclined guide for conducting lead wire portions of the heating wire, which is to be extended to the outside, in an outward direction of piping diameter so as to curve or curl back against a plane in which the heating wire lies. Namely, in the case where the piping diameter is larger than that of the pipe joint as a result that the heat-insulating material is wound around the piping, by collecting up the heating-wire-lead portions extended from the heating component by the inclined guide to thereby guide them outwardly in the diameter direction, it is possible to make the handling of the heating-wire-lead portions easy and also to prevent the breaking thereof.
The heating component for a pipe joint of the present invention is able to be attached to the pipe joint by the simple working of only fitting the heating component to the existing joint and therefore, by omitting extra manual works, the quality of assembly can be stable without any influence of individual differences such as experiences and the like. Further, the heating component for a pipe joint of the present invention may not need much space compared with the conventional structure in which the heat-insulating material or the heater is wounded around the joint by the manual works, and therefore, is suitable especially for the pipe layout arranged in the exhaust emission purifying apparatus having a narrow disposing space. Furthermore, since the heating component for a pipe joint of the present invention can be attached to the existing joint afterwards, it is possible to reduce the cost, such as the mold preparation cost and the like compared with the case where the exclusively used specific joint with a built-in heater is produced.
Still further, according to the present invention, in a pipe layout structure for the exhaust emission purifying apparatus using the liquid reducing agent, the heating of a joint portion as well as the heating of piping portion, can be reliably performed, so that over the total piping length, the heating is able to be uniformly accomplished without causing appearance of any defective portions in heat retainment and defrosting.
In the conventional piping structure for the exhaust emission purifying apparatus, there has been also taken a method in which, without disposing the heater to the joint portion, the heater wattage of the piping portion is increased, to thereby help the heating of the joint portion without provided with the heater. However, according to the present invention, compared with such a conventional method in which the total wattage is increased at the heat-retaining or defrosting time, the power consumption can be surely reduced to be lower, and if the wattage in the present invention is same as that in the conventional method, a time for heat-retaining or defrosting can be shortened. Namely, for the limit generator capacity, the unnecessary power consumption is able to be appreciably suppressed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing an embodiment of the present invention;
FIG. 2 is a plan view of a heating component for a pipe joint in FIG. 1 ;
FIG. 3 is a cross section view of the heating component for a pipe joint in FIG. 2 ;
FIG. 4 is a plan view showing the heating component for a pipe joint in FIG. 1 except for a heating wire;
FIG. 5 is a cross section view of the heating component for a pipe joint in FIG. 4 ; and
FIG. 6 is a plan view showing the whole heating wire.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereunder, there will be described embodiments of the present invention based on FIG. 1 through FIG. 6 .
FIG. 1 is an exploded perspective view showing heating component for a pipe joint 1 and a joint 10 , FIG. 2 is a plan view of the heating component for a pipe joint 1 which holds therein a heating wire H, and FIG. 3 is a cross section view of the heating component for a pipe joint 1 shown in FIG. 2 . FIG. 4 is a plan view showing the heating component for a pipe joint 1 from which the heating wire H is removed, FIG. 5 is a cross section view of the heating component for a pipe joint 1 shown in FIG. 4 , and FIG. 6 is an overall diagram of the heating wire H.
The heating component for a pipe joint 1 in the present embodiment, being a resin molded product having a unitary body, is to be mounted on and attached to an elbow type joint 10 which connects between two pipes K 1 and K 2 at 90°, and has, at two sites thereof, fitting portions 2 each having an inner surface suitable for being fit on a part (a claw portion 11 in the present embodiment) of an outer shape of the joint 10 . Further, on an inner surface portion of the heating component for a pipe joint 1 other than the fitting portions 2 a holding recess portion 3 is formed. The holding recess portion 3 has a pedestal 5 formed on a bottom face 4 thereof, and a heating wire H is put on the pedestal 5 so that a space is formed between the heating wire H and the bottom face 4 , thereby the airspace being formed.
The heating wire H is held so as to be laid in a U-shape in the holding recess portion 3 . Further, lead portions L of both end portions of the heating wire H are extended to the outside of the heating component 1 , to be connected via a resistor R to electric wiring E which is connected to a coupler C. This heating wire H is appropriately controlled by, for example, a control unit (ECU) of an exhaust emission purifying apparatus, in accordance with the outside air temperature, the tank internal temperature of a liquid reducing agent or the like.
The joint 10 is attached to the first pipe K 1 , and the second pipe K 2 disposed at 90° relative to the first pipe K 1 is connected to the joint 10 . On a periphery of an opening portion of the second pipe K 2 , a flange F is formed, and on an outer periphery of the joint 10 , the claw portions 11 for latching the flange F are disposed at two sites at 180° intervals. Accordingly, when the second pipe K 2 is inserted into the joint 10 , the flange F is latched by the claw portions 11 at two sites, so that the second pipe K 2 is prevented from being extracted, and then, the second pipe K 2 is fixed to the joint 10 . Further, in the present embodiment, since a latch release button 12 is disposed on the joint 10 , when the latch release button 12 is pushed inwardly, the claw portions 11 are expanded, so that the latch between the claw portions 11 and the flange F is released, and consequently, the second pipe K 2 is able to be extracted from the joint 10 .
These pipe K 1 and K 2 are, as one example, those for transporting the liquid reducing agent from a tank preserving the liquid reducing agent, in an exhaust emission purifying apparatus in which a nitrogen oxide reduction catalytic converter is disposed in an exhaust passage of an internal combustion engine and also the liquid reducing agent is added into the exhaust passage on the upstream side of the nitrogen oxide reduction catalytic converter. As the liquid reducing agent, for example, the urea water for the selective catalytic reduction (SCR) as described in the above is used.
Each of the fitting portions 2 at two sites in the heater component for a pipe joint 1 is formed to have the inner surface fitted with the claw portion 11 disposed on the outer periphery of the joint 10 . Accordingly, the heater component for a pipe joint 1 holding the heating wire H in the holding recess portion 3 thereof is able to be easily attached to the joint 10 , only by allowing the heater component for pipe joint 1 to be placed on the joint 10 covering the latter, until the fitting portions 2 are fitted with the claw portions 11 . After the attaching, when a clip 6 is inserted into insertion holes 7 to pass through the insertion holes 7 to an opposite side, the clip 6 enters into the claw portions 11 of the joint 10 to be latched. As a result, it is possible to achieve the further reliable drop-off prevention so that the heating component for a pipe joint 1 would not be dropped off from the joint 10 .
In the present embodiment, a stainless-steel lid member 8 is attached to cover a part of the holding recess 3 , so that the heater wire H held in the holding recess 3 can be further reliably prevented from being dropped off. Namely, two mounting pieces 8 a protruding from side portions of the lid member 8 are latched onto two latch holes 9 bored on the side wall which forms the holding recess 3 , of the heater component 1 , so that the lid member 8 is fixed to cover the holding recess 3 . The lid member 8 has a role of covering the U-shaped folded portion (the portion which is not in contact with the joint 10 ) of the heater wire H to prevent the drop-off of the heater wire H, and at the same time, has a role of reducing the heat dissipation from the covered portion to the outside to enhance the thermal efficiency. In order to play these roles, a material having a further heat-insulating effect, for example, glass or ceramic, may be used as the material of the lid member 8 .
Further, in the heater component for a pipe joint 1 in the present embodiment, an inclined guide 1 G is formed on the site at which the lead portions L of the heater wire H are extracted from the holding recess 3 . This inclined guide 1 G is disposed for laying thereon the lead portions L so that the lead portions L face outwardly in a diameter direction of the first pipe K 1 . Namely, in the case where a heat-insulating material (not shown in the figures) is wound around the first pipe K 1 and accordingly, a diameter of the first pipe K 1 inclusive of the heat-insulating material is larger than that of the pipe joint 10 , the inclined guide 1 G guides to collect up the lead portions L so that the lead portions L of the heater wire H is diverged outwardly from the first pipe K 1 in the direction of diameter of that first pipe. As a result, there are provided such advantageous effects that the handling of the lead portions L is made easier and also that the lead portions L are prevented from being folded steeply at an edge of the heater component 1 . On an inner face portion of such an inclined guide 1 G, there is formed a semicircular guide groove m for holding therein the lead portions L, so that the holding performance for the lead portions L is further improved.
Explaining the assembling procedure of the pipe joint heater component 1 having the above configuration, firstly, the heater wire H is run in U-shaped to be held in the holding recess 3 of the pipe joint heater component 1 . The heater wire H held in the holding recess 3 is put on the pedestal 5 so that the airspace is formed between the heater wire H and the bottom face 4 . Subsequently, the latch pieces 8 a are latched onto the latch holes 9 to thereby mount the lid member 8 to the heater component for a pipe joint 1 , thereby preventing the drop-off of the heater wire H. Then, the heater component for a pipe joint 1 is placed on the joint 10 to be mounted to the joint 10 , by fitting the fitting portions 2 of the heater component for a pipe joint 1 with the claw portions 11 of the joint 10 . Next, the clip 6 is inserted into the insertion holes 7 to be fixed so that the pipe joint heater component 1 is not dropped off from the joint 10 .
When the heater component for a pipe joint 1 is mounted on the joint 10 , the portion of the heater wire H, which is supported by the pedestal 5 in the holding recess 3 surely comes in contact with the joint 10 . Accordingly, when the electric power is supplied to the heater wire H, the heat of the heater wire H which generates the heat with the electric power supply, is transmitted to the joint 10 .
In this mounding work, even in the cases where the heat-insulating material is wound around the first pipe K 1 and the diameter of the first pipe K 1 is large, since the lead portions L of the heater wire H are guided by the inclined guide 1 G to be collected up without being cluttered and also the steeply folding thereof is prevented, the handling thereof is made easy and also a possibility of the breaking thereof is reduced.
In the above description, there has been described the example of the pipe joint heater component for the joint which connects the two pipes at 90°. However, the present invention is not limited thereto, and can be surely applicable to a joint connecting two pipes at 180° or other angles, or to a joint connecting three or four pipes. | The present invention makes a proposal of a heating component for a pipe joint which can be easily mounted on a pipe joint and also can stabilize the assembly quality to the pipe joint. The heating component for a pipe joint is characterized in that the heating component for a pipe joint has partially thereon fitting portions each having an inner face shape fitted with a part of an outer shape of the pipe joint, and also, a holding recess portion for holding therein a heating wire is formed on an inner face portion other than the fitting portions; when the heating wire is held in the holding recess portion, and then, the heating component for piping joint is mounted to the joint by fitting the fitting portions with the parts of the outer shape of the joint, the heating wire held in the holding recess portion comes in contact with the pipe joint. | 5 |
BACKGROUND OF THE INVENTION
[0001] This invention concerns a padding product whereof the basic material consists of feather; it also concerns the method of preparation of such product and the installation for the implementation of the method.
DESCRIPTION OF THE RELATED ART
[0002] Feather-based padding products find their application in numerous industries because of their properties and qualities.
[0003] They can be found in the bedding industry, furniture, clothing, but they can also be used for padding and/or thermal insulation in other fields.
[0004] This material consists of feathers, but it consists generally of feathers, feather quality items, small feathers and/or downs according to the usages. It is normally available in bulk and its implementation is rather awkward. It has indeed characteristics close to those of light pulverulent materials, i.e. it is formless and it is quite volatile.
[0005] It has already been suggested, as described in the documents WO-92 06916 and WO-00 56971, to master this raw material in order to improve the conditions of its implementation.
[0006] In these documents, it is contemplated to confer it cohesion while profiling said material in the form of panels or laps by means of a method consisting in gluing the downs either by a chemical reaction or by means of an agent sprayed on the material.
[0007] Another document, JP-61-213087, suggests a structure in the form of a leaf wherein downs, small feathers or feathers are interwoven with animal fibre and are made integral by melting an integral synthetic fibre into the mixture.
[0008] In the latter document, the low melting point synthetic fibre is mixed to the padding product to enable fastening by gluing the downs, small feathers and/or feathers, on the animal fibre which is longer.
[0009] This invention propose a padding product, based on feather, small feathers and/or downs which also exhibits a certain coherence, available for instance in the form of plates or rolls.
[0010] But this product, with respect to the products described in the documents mentioned above, has the advantage of preserving the properties inherent to feathers and to downs, i.e. their thermal power, their inflating property and their feel generally speaking.
SUMMARY OF THE INVENTION
[0011] The invention promotes this product and makes it useable in domains where high thermal insulation and comfort quality is sought as in furniture, bedding, car seats for instance.
[0012] This product according to the invention is notably recognisable by the means which enable to confer to said product a form and a volume, better suited to its destination and especially to its implementation in the different industries for which it is intended.
[0013] According to the invention, this padding product consists essentially of feathers and of a supple structure, coherent, in a three-dimensional network, which retains and traps said feathers, which structure consists of appropriate thermoplastic fibres which are interwoven and bound together, and this product is derived from a preparation method detailed below which consists, in a first step, in preparing the fibres by processing forming then in realising this intimate mixture, by mechanical processing of said fibres and feathers i.e. of both these products of so different natures, which mixture is then worked into the form of a web then processed thermally before bonding and/or gluing the fibres together.
[0014] According to a preferred arrangement, the fibres forming this structure consist of two-component fibres: the component forming the core is a synthetic fibre made of material such as a polymer stable at high temperature, i.e. having a high softening point, above the temperature of the thermal treatment of the mixture, i.e. 200° C. for instance, the other component at the surface of the fibre, forming a sheath, is made of a material such as a polymer whereof the softening temperature is lower than that of the core, ranging for instance between 70 and 180° C., enabling to provide thanks to said thermal treatment, a true bonding at a contact point of two of these structural fibres.
[0015] Still according to the invention, the length of the structural fibres ranges between 20 and 100 mm with a titration of 1 to 25 dtex for instance.
[0016] The properties of this basic padding product, i.e. comprising simply a mixture of feathers and of structural fibres, can also be modified by the adjunction of complementary fibres. Thus, according to the invention the product may comprise in addition, so-called volume fibres, which exhibit for instance a curling, preferably a substantially helical shape, which fibres are either natural, artificial or synthetic whereof the temperature at which the state may change by degradation or by softening is higher than the temperature of the bonding of the structural fibres, i.e. a temperature close to or greater than that of the core of the structural fibres.
[0017] The adjunction of volume fibres, i.e. of curled fibres, improves the inflating character of the product, i.e. its propension to occupy and to keep a certain volume. Their presence also exhibits the advantage of improving the cohesion of the product since they may also be glued to the structural fibres.
[0018] The product according to the invention may still contain other constituents with one or several particular functionalities of the anti-bacterial, anti-acarian, flame retardant type. These constituents may be the volume fibres especially processed or any other complementary fibre or still feathers or added particles.
[0019] Still according to the invention, the padding product consists of feathers, i.e. feathers, small feathers, downs, in a proportion ranging between 10 and 80% in weight, preferably of the order of 30 to 60% and the complement consists of structural fibres and/or of mixture of structural fibres and of complementary fibres, volume fibres or other constituents, in which complement the structural fibres have a proportion which is for instance of the order of 10 to 100% in weight.
[0020] The padding product according to the invention is preferably worked into the form of web and this web may possibly be covered over one of its faces or be completely enveloped, by means of a coating made of the material of non-woven type or a sprayed-on film, which coating may also be of thermomeltable type and it is preferably applied before the thermal treatment operation of the web in order to be bonded and/or glued to the structural fibres, notably.
[0021] This coating promotes the retention of the feathers and reduces leaks, during the-cutting operations of the web, in the vicinity of the cutting zone.
[0022] The invention also concerns the general preparation method of the padding product detailed above. This method consists—in preparing an intimate and homogeneous mixture comprising feathers, i.e. feathers, small feathers, downs and free fibres made of at least so-called structural fibres,—in conforming this mixture in the form of a web and,—in performing a thermal treatment with hot air, at appropriate temperature, sufficient to web said structural fibres wherever they are in contact to one another and,—in cooling down the web and its structure gradually, before conditioning.
[0023] Still according to the invention, the preparation of the mixture of feathers and of fibres consists, in a first step, in applying successively on an endless conveyor belt, a suitable quantity of fibres then of feathers, and in subjecting this sandwich, to at least one processing forming operation which enables intimate and homogeneous mixing of the feathers and fibres before making the lap.
[0024] Still according to the invention, before mixing with the feathers, the fibres are subject to a prior processing forming operation, regardless whether structural fibres on their own or an assembly formed of said structural fibres, of complementary fibres, such as the volume fibres or other constituents having particular functionality, which fibres and constituents, as the case may be, are distributed by superimposed layers, on an endless conveyor belt, in the form of a sandwich, before being subject to at least one processing forming operation.
[0025] The method may also consist, before thermal treatment of the web, in protecting and enveloping said web by means of a coating in the form of non-woven fabric or in the form of spayed-on film or thin layer which coating made for instance of a material such as a thermoplastic polymer, may also be capable of binding by thermal softening with the structural fibres.
[0026] The invention concerns also the installation for the implementation of the method detailed previously. This installation comprises a storage cell for the padding material, i.e. feathers, small feathers and downs and, at least a supply or storage cell for pre-processed fibres, which cells are provided to deposit on a endless conveyor belt, a layer of fibres then a layer of feathers, which conveyor belt is arranged upstream of a so-called pre-processing forming machine which realises intimate and homogeneous mixture composed of feathers and of free fibres, which installation comprises, after said pre-processing forming machine, a napper and, behind this napper, a facility for thermal treatment which enables to realise the welding operation of the structural fibres at each of their contact points.
[0027] The installation may contain between the pre-processing forming machine and the napper, one or several so-called pre-processing forming machines, which improve still the quality of the feathers-fibres mixture, which mixture is then sent to a hopper connected to said napper.
[0028] The installation comprises also, to suit the requirements, at least one so-called pre-processing forming machine for the fibres and other possible constituents, which pre-processing forming machine is fed by an endless conveyor belt, which conveyor belt circulates beneath one or several cells wherein are stored the fibres i.e. the structural fibres and, possibly, the complementary fibres i.e. the volume fibres and the other constituents or fibres having for instance particular functionality, which fibres are arranged in layers on said endless conveyor belt and the sandwich thus prepared is subject to pre-processing forming before being mixed with the feathers.
[0029] The installation contains a napper of volumetric chimney type and may possibly be followed with a second napper of pneumatic type for instance, which pneumatic napper comforts and reinforces the random distribution of the structural fibres and multiplies the contact points of said fibres between one another, while disturbing their arrangement in the mass of the mixture in the form of lap, which provides said lap with identical resistance to deformation in all directions.
[0030] The installation also contains means which enable to associate a superficial coating with the lap, before the thermal treatment, on one or on both faces.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The invention will still be detailed using the following description and appended drawings given for exemplification purposes and wherein:
[0032] FIG. 1 represents schematically a portion of the padding product according to the invention;
[0033] FIG. 2 represents a structural fibre;
[0034] FIG. 3 represents a so-called volume fibre;
[0035] FIG. 4 represents schematically a pre-processing forming machine for the fibres;
[0036] FIG. 5 represents schematically the pre-processing forming machine of the fibres-feathers mixture;
[0037] FIG. 6 represents globally and schematically the different processing and profiling steps of the fibres-feathers mixture;
[0038] FIG. 7 represents in a more detailed fashion and schematically a napper comprising a vertical napper and a pneumatic napper;
[0039] FIG. 8 represents in a more detailed fashion than FIG. 6 , the thermal treatment facility of the web, followed by the conditioning station.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0040] FIG. 1 shows a portion of the padding product according to the invention. This product consists mainly of feathers 1 which are trapped in a structure formed of fibres 2 .
[0041] As detailed thereafter, the fibres 2 are first of all mixed with the feathers 1 and the assembly is then subject to a thermal treatment operation which will bind the structural fibres 2 together.
[0042] The word ‘feathers’ designates indifferently feathers, small feathers or downs or even a mixture of these different products. The proportion of feathers in the padding product ranges between 10 and 80% in weight, preferably of the order of 30 to 60%. The remainder, as detailed below consists notably of the structural fibres 2 .
[0043] A structural fibre 2 is represented on FIG. 2 . This fibre is of the two-component type. The central component or core 3 consists of a fibre made of the material of the polymer type with high softening point, above the temperature of the thermal treatment of the feathers-fibres mixtures, i.e. above 200° C. for instance. The other component, at the surface, forms for instance a sheath 4 made of the material of the polymer type also but whereof the softening temperature is smaller, for instance ranging between 70 and 180° C.; this temperature corresponds to the temperature of the thermal treatment of the feathers-fibres mixture which will be discussed below.
[0044] This particularity of the structural fibres 2 , as they consist of two polymer components, enables to obtain fibre to fibre welding using one of the components while the other preserves its integrity and confers its technical characteristics to the product.
[0045] The configuration of the structural fibres 2 is preferably a core 3-sheath 4 configuration, whereas said sheath is manufactured using a (polymer) material whereof the melting temperature is lower than that of the core 3 .
[0046] During thermal treatment of the fibres-feathers mixture, this core-sheath configuration of the structural fibres 2 enables said sheaths 4 to merge together at each of their contact point(s) and thus, when cooling down said mixture, as many bonding points 5 are formed and a contention structure of feathers is obtained.
[0047] The length of the structural fibres 2 is of the order of 2 to 10 cm for instance with a titration ranging between 1 and 25 dtex.
[0048] These structural fibres 2 are mixed intimately with the feathers and are distributed at random in the product, as represented on FIG. 1 . Throughout the preparation phase of the feathers-fibres mixture in the form of a web, i.e. before the thermal treatment of said mixture, the structural fibres are free and taking their number into account, they are occasionally in contact with one another. They are also pressed against one another and the bonds take place during the thermal treatment. The temperature of the treatment is such that it causes, as indicated previously, a real bonding at each contact point 5 of these fibres 2 between one another, thanks first of all to their sheath 4 softening and melting, then to a hardening during the cooling phase as detailed below in connection with FIG. 8 .
[0049] These multiples bonds between the structural fibres 2 form intrinsically, in the product represented on FIG. 1 , a three-dimensional network which retains and traps the feathers or the mixture of feathers, forming thus a coherent product, that can be handled and profiled easily to suit the requirements.
[0050] Heating the web, then cooling it down, may cause a compacting phenomenon of the feathers and of the product obtained. The product only gains in volume after several hours, let alone several days.
[0051] This retraction during the thermal treatment, may be disturbed or reduced, let alone suppressed, by the adjunction of complementary fibres in the fibres 2 -feathers 1 mixture, as represented on FIG. 1 ; these complementary fibres form the volume fibres 6 .
[0052] These fibres 6 are for instance curled and are preferably in the form of a helicoid as illustrated on FIG. 3 . Their length and titration is of the same order as the structural fibres.
[0053] These volume fibres 6 are either natural fibres or artificial or synthetic fibres. The state change temperature by degradation or by softening is above the welding temperature of the structural fibres 2 .
[0054] The complementary natural fibres may be of animal origin (wool, rabbit hairs . . . ) or of vegetal origin (kapok . . . ).
[0055] The distribution of the complementary fibres in the padding product is, as for the structural fibres 2 , as homogeneous as possible. They contribute to the cohesion of the product. They may wherever they are in contact with structural fibres 2 and according to their nature, be glued to said fibres when the sheath 4 of these structural fibres 2 softens.
[0056] Other constituents, non represented, may also be integrated to the padding product in relation to its destination, as for instance fibres or particles with particular functionality deriving from a flame retardant, anti-bacterial, anti-acarian treatment etc.
[0057] These treatments may also be applied to the complementary fibres, to the volume fibres 6 or to feathers or other particles.
[0058] As indicated previously, the feathers occupy 10 to 80% in weight, preferably 30 to 60%, of the padding product. The complement consists of the structural fibres 2 and, possibly, the complementary volume fibres 6 or other. In this complement, the proportion of structural fibres is of the order of 10 to 100% in weight as the case may be and the other fibres of 0 to 90%.
[0059] FIGS. 4 and 5 show schematically the sequence of the so-called pre-processing forming machines in the mixing installation of the fibres and feathers.
[0060] This installation comprises first of all, as represented on FIG. 4 , a preparation station of the fibres and when using a mixture, of different sorts of fibres, then it comprises, as represented on FIG. 5 , a mechanical station for mixing the fibres and the feathers.
[0061] The preparation machine of the fibres, then so-called pre-processing forming machine 9 , is a conventional machine of the type of those used in the domain of preparation of fibres for non-woven fabric.
[0062] The fibres, generally speaking, are delivered compacted. The pre-processing forming machine 9 enables to decompact the structural fibres 2 and, as the case may be, the volume fibres 6 and, possibly, other fibres or complementary constituents, while performing a suitable mixture.
[0063] The pre-processing forming machine 9 is fed by an endless conveyor belt 10 provided beneath one or several cells or hoppers. A first cell 12 contains structural fibres 2 . This cell 12 is preceded by a cell 13 which contains the volume fibres 6 and one may find other complementary cells 14 wherein are stored fibres or other constituents with various functionalities as indicated previously.
[0064] Each type of fibres as the case may be, is deposited on the conveyor belt 10 and the layer(s) forming a sandwich, are introduced in the pre-processing forming machine while passing first of all beneath a compacting drum 15 , then beneath a driving roll 16 situated above the end of the conveyor belt 10 . Then the sandwich is driven by a pair of rolls 17 and it is shown to a spiked pulling roller 18 which sends the fibres through the output 19 towards the pre-processing forming machine 20 of the following station.
[0065] It is also possible to connect a conduit 21 on the output 19 to introduce in the circuit materials to be recycled such as for instance of the raw material or waste collected from the production line or even to introduce waste returned from customers.
[0066] This prior separate preparation of the fibres is an important step of the method; it provides a better result as regards the mixture then performed between the feathers and said fibres.
[0067] The pre-processing forming machine 20 , FIG. 5 , is similar to that of FIG. 4 . It is also fed by a conveyor belt 22 which receives on the one hand the fibres coming from the output 19 of the pre-processing forming machine 9 , and, on the other hand, the feathers or mixtures of feathers provided in a cell 23 situated downstream of said output 19 .
[0068] The fibres and feathers are dosed and are deposited on the conveyor belt 22 . The conveyor belt 22 receives first of all a layer of fibres which form a thickness of 5 to 15 cm for instance, then a layer of feathers whereof the thickness may reach 50 to 60 cm. This sandwich is introduced by the conveyor belt 22 in the pre-processing forming machine 20 . A drum 15 situated at the input, performs first compacting of the layers. It is followed with a roll 16 which also presses the sandwich, which roll 16 is arranged above the end of the conveyor belt 22 . Then the layers pass between a pair of feeding rolls 17 which present the sandwich to the spiked pulling roller 18 .
[0069] The feathers and fibres are mixed intimately in a homogeneous fashion and sent through the output 24 either another pre-processing forming machine, non-represented, or towards the napper.
[0070] The fibres and feathers transit from one machine to the other by suction effect and the suction waste is re-injected into the circuit and recycled through the conduit 21 .
[0071] FIG. 6 illustrates, in the form of a simple functional diagram, the treatment and the profiling of the fibres-feathers mixture, to lead to the product suggested by the invention i.e. a lap which may be handled and for instance be conditioned in the form of a roll.
[0072] The fibres-feathers mixture arrives from the output 24 of the pre-processing forming machine 20 and it is placed in a buffer cell 25 . This cell 25 is arranged above a conveyor belt 26 , which conveyor belt receives a layer of the mixture consisting of fibres and feathers. This layer is deposited in the form of a web 27 . A continuous weighing system, by means of scales 28 arranged under the upper side of the conveyor belt 26 , enables to adjust the thickness of the web 27 . The cell 25 may contain a mobile wall 29 in the form of an adjustable batten, to modify the flow rate of the mixture, i.e. the quantity of fibres and feathers deposited on the conveyor belt 26 .
[0073] The cell 25 acts as a napper on the diagram of FIG. 6 . The actual napper will be detailed below, on FIG. 7 .
[0074] After the cell 25 which acts as a napper, one finds the thermal treatment installation of the feathers-fibres mixture, deposited in the form of a web on the conveyor belt 26 .
[0075] The thermal treatment installation comprises first of all a casing 30 for heating then a casing 31 for cooling.
[0076] The casing 30 for heating the mixture enables to raise the core temperature to a sufficient value to soften, melt and weld the structural fibres 2 , at all their contact points between one another.
[0077] Heating is performed for instance by circulating hot air through the casing 30 . The fibres-feathers mixture circulates through the casing 30 at a speed suitable for the result expected.
[0078] The casing 31 for cooling enables to consolidate the bonding points of the structural fibres 2 and possibly the gluing points between said fibres and the complementary fibres such as the volume fibres 6 .
[0079] Cooling is performed for instance by circulating fresh air.
[0080] Still on FIG. 6 , means enable to apply a simple coating on the web 27 freshly formed, or to envelope said lap before thermal treatment.
[0081] A spray nozzle 32 enables for instance to apply on the surface a product which forms a superficial coating in the form of a film or of a thin gluing film.
[0082] This coating may also consist of a material of non-woven type or of a film stored on a roll 33 to be deposited on the web 27 downstream of the cell 25 . Another roll 34 situated upstream of said cell may place this coating under the web, between said web and the conveyor belt 26 .
[0083] By using a thermomeltable coating, this said coating may be glued or welded to the structural fibres 2 during the thermal treatment.
[0084] At the output of the casing 32 , the web 27 forms an actual manufactured product that can be conditioned in the form of a roll, capable of being worked more easily than bulk feathers.
[0085] FIG. 7 represents, still schematically, but in a more detailed fashion, a napper 35 which receives, from the output 24 of the pre-processing forming machine 20 , the fibres and feathers mixture.
[0086] This fibres-feathers mixture is transported and sent by a suction effect to a hopper 36 which is part of the napper. This hopper 36 carries, at its lower end, a couple of rotors 37 acting as extractors, followed by an rotor 38 which sprays the mixture onto a conveyor belt 39 situated at the lower section of the napper.
[0087] This conveyor belt 39 , which is horizontal, feeds a second conveyor belt 40 which forms a kind of lift conveyor belt fitted with hooking members to drive the fibres and feathers towards the napper properly speaking, detailed thereafter.
[0088] This lift conveyor belt 40 is connected at its upper section to a rotor 41 which equalises the layer brought by said conveyor belt and recycles the fibres and feathers towards the inside of the caisson 42 of the napper, i.e. in the section situated above the supply conveyor belt 39 .
[0089] The lift conveyor belt 40 sends the feathers and fibres to the napper properly speaking, which comprises a volumetric chimney 44 consisting of two vertical and parallel plates 45 , 46 arranged opposite one another; one of the walls is vibrating and the other is situated at an adjustable distance from the first. The fibres and feathers are packed in the chimney 44 and this mixture takes the form of a web.
[0090] This mixture in the form of web progresses by simple gravity and reaches a driving and compacting assembly consisting of two couples of rolls 47 and 48 . These rolls 47 and 48 propel the mixture towards a conveyor belt 49 , which conveyor belt 49 feeds a second napper, so-called pneumatic napper 50 .
[0091] This pneumatic napper 50 comprises, at the end of the conveyor belt 49 , a presser drum 51 followed by a pair of couples of driving rolls 52 and 53 which feed a roller 54 . This roller 54 enables to re-calibrate the web which comes from the first napper. It evolves at a speed which is adjusted in relation to the forward speed of the transport conveyor belt 49 .
[0092] The roller 54 drives the web on a punched conveyor belt 55 which is in the form of an endless band rotating round a suction system 56 . The web is thus pressed against the active side 57 of the punched conveyor belt 55 and it is additionally calibrated by means of a roller 58 situated downstream of the suction zone, above the active side 57 .
[0093] The suction device 56 enables to shake the mixture and to promote disorientation of the fibres, notably structural fibres 2 , in the thickness of the web.
[0094] This random distribution of the structural fibres confers to the finished product a resistance to elongation which is comparable regardless of the direction of the load that is applied to said product.
[0095] At the output of the pneumatic napper 50 , the web is inserted by means of a conveyor belt 59 , into the thermal treatment station 60 .
[0096] This station 60 comprises two conveyor belts which extend from the input to the output:—a lower endless conveyor belt 61 and—an upper endless conveyor belt 62 . The web is guided between both these conveyor belts which enable to compress the mixture and to drive said mixture throughout the whole treatment which takes place first of all with hot air to raise the lap to a suitable temperature, then with cold air.
[0097] The station comprises therefore two zones: a zone 63 which extends from the input for raising the temperature of the web, followed by a zone 64 for cooling the web.
[0098] The speed of the web in the furnace may be two m/mn for instance and the total duration of the treatment is of the order of two to three minutes approximately.
[0099] The duration of the thermal treatment is established in relation to the thickness of the web to obtain homogeneous and sufficient temperature at the core of the mixture, in order to soften the sheaths 4 of the structural fibres 2 , then to melt and bound each contact point between the fibres 2 , with consolidation of these contact points as the cooling progresses.
[0100] The temperature in the zone 63 is selected in relation to the characteristics of the structural fibres 2 ; it is for instance of the order of 140° C.
[0101] At the output of the station 60 , the web is conditioned in the form of a roll 65 or it is cut off by means of a knife 66 and stored in the form of a plate 67 on a cart 68 . The width of the web, according to the installation, may be of the order of 2 m or more to suit the requirements.
[0102] Before insertion into the furnace, the lap may also be subject to a dressing operation, i.e. receive a coating of non-woven type or in the form of a sprayed-on film, as detailed above with FIG. 6 .
[0103] This coating, for instance of a thermoplastic material, may also have a softening point close to that of the envelope 3 of the structural fibres 2 and, in this case, be welded or glued to said structural fibres during the thermal treatment of the web.
[0104] To obtain good calibration of the web, as shown on FIG. 8 , disks 69 may be positioned on the conveyor belt 59 at the input of the thermal treatment station 60 , in order to cut the selvedges at the input. Similarly, disk knives 70 may be arranged at the output of the thermal treatment station to cut the selvedges of the lap once more in order to calibrate its width.
[0105] Still on FIG. 8 , brushes enable to clean the endless conveyor belts 61 and 62 .
[0106] A brush 71 is provided at the end of the lower conveyor belt 61 and a brush 72 is provided similarly at the end of the upper conveyor belt 62 .
[0107] The waste from the cutting disks 69 , 70 of the selvedges and that coming from the brushes 71 and 72 , are re-injected into the circuit, upstream of the pre-processing forming machine 20 by means of the conduit 21 as indicated previously. | The feather-based padding product has a coherent form due to the presence of a structure in the form of a three-dimensional network; this network consists of thermoplastic fibres ( 2 ) mutually bound, which trap the feathers. These fibres ( 2 ) are first mixed with the feathers, then, with appropriate thermal treatment, these fibres are bonded at their contact points ( 5 ). The padding product is thus in the form of a web and it is conditioned as a roll or in the form of slabs. | 3 |
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